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Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
C5288
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Tender Document Part
Part 1 – Particulars of Work and Special
Requirements
Contract Number
C5288
Description
680/690 11kV Feeder Repowering
Location
Vales Point Power Station
Advertise Date
9 December 2016
Pre Tender Date
15 December 2016
Closing Date
31 January 2017
NOTE TO TENDERER
The Tenderer shall attend a (mandatory) pre tender site meeting on:
Date
Time
Location
15 December 2016
9:00 – 12:00
Vales Point Power Station
And carry out site inspections to make it-self familiar with conditions thereon and rules and
procedures applying to the Site. Personnel attending the pre-tender site meeting will be signed
in as a Visitor to site and should present themselves to the Security gate house. The Annexure
1 shall be completed and forwarded to The Principal representative named below 24 hours prior
to the meeting. Proof of identity will be required prior to entry.
NB: If details as required above are not supplied personnel will be denied entry to Vales
Point Power Station.
Visitors to the Site must provide and wear their own safety hats, safety footwear, protective
safety eyewear, long sleeved shirts and long trousers or combination overalls. As some of the
sites for the proposed works require four wheel drive access, prospective tenderers are
requested, if possible, to bring a four wheel drive vehicle to the inspection as The Principal has
a limited number of vehicles that can be used for the inspection.
Accredited representatives of firms proposing to attend the pre tender site meeting and
inspection can contact:
The Principal Contract Representative:
Simon Nawrot
Asset Management Specialist
Vales Point Power Station
Vales Road
PO Box 7285
Mannering Park NSW 2259
Phone (02) 4352 6084
Mobile 0417 202 680
Email [email protected]
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
C5288
2 of 116
TABLE OF CONTENTS
1.0
Introduction ................................................................................................................................... 5
2.0
Interpretations and Definitions ................................................................................................ 5
2.1
Site Specific ............................................................................................................................ 5
2.2
Pricing ..................................................................................................................................... 5
2.3
Quality Assurance ................................................................................................................. 6
2.4
Technical................................................................................................................................. 6
3.0
Description of Plant ................................................................................................................... 7
3.1
Plant Details............................................................................................................................ 7
3.2
Risks and Hazards ................................................................................................................. 7
3.3
Asbestos ................................................................................................................................. 8
4.0
Particulars of Work .................................................................................................................... 9
4.1
Negotiation Clause - Not Used ............................................................................................. 9
4.2
Experience and Qualifications.............................................................................................. 9
4.3
Regulations/Standards ........................................................................................................ 10
4.4
Resources ............................................................................................................................. 10
4.5
Pricing Schedule Details ..................................................................................................... 10
4.6
Drawings ............................................................................................................................... 11
4.7
Country of Manufacture ...................................................................................................... 11
4.8
Work Scope Main Objectives .............................................................................................. 11
4.9
Work Scope .......................................................................................................................... 12
4.10 690 Feeder 6.6/11kV Substation ......................................................................................... 13
4.11 6.6kV Circuit Changeover Link Boxes. .............................................................................. 27
4.12 6.6kV Cable from the 6.6kV Station Service Switchboard 5 ........................................... 29
4.13 6.6kV Cable from the 6.6kV Station Service Switchboard 3 ........................................... 30
4.14 6.6kV Cable from the 6.6kV Circuit Changeover link boxes to the 6.6/11kV 690 ......... 32
4.15 11kV Cable from the 690 11kV Substation to 690 Feeder Pole 110 ................................ 33
4.16 Pole Mounted 11kV Auto-Recloser. ................................................................................... 37
4.17 11kV Feeder Connections and Disconnections ................................................................ 39
4.18 Electrical Protection ............................................................................................................ 41
4.19 Additional surge protection. ............................................................................................... 49
4.20 Additional on-site commissioning and testing requirements for Transformers. .......... 50
4.21 Testing requirements for factory FRA test and on-site FRA test. .................................. 50
4.22 Specific Safety Requirements for Construction and Maintenance Works ................... 51
4.23 Programming of Works – In addition to the requirements of Clause 8.5 h) . ................ 53
4.24 Control and instrumentation cables available for free issue. ......................................... 54
4.25 Spare 6.6/11kV Transformer. .............................................................................................. 55
4.26 Control Wiring Numbering and Colours ............................................................................ 55
4.27 Drawings to be amended by The Contractor .................................................................... 55
4.28 Design Review. ..................................................................................................................... 56
4.29 Construction General Requirements. ................................................................................ 56
5.0
Pricing Particulars ................................................................................................................... 56
5.1
General .................................................................................................................................. 57
5.2
Firm Lump Sum Price .......................................................................................................... 58
5.3
Schedule of Firm Rates ....................................................................................................... 58
5.4
Quantities.............................................................................................................................. 59
6.0
Requirements .............................................................................................................................. 59
6.1
6.2
6.3
6.4
6.5
6.6
7.0
Responsibilities.................................................................................................................... 59
Access and Protection ........................................................................................................ 60
Completion ........................................................................................................................... 60
Programing of Works .......................................................................................................... 61
Training ................................................................................................................................. 62
Risk and Property ................................................................................................................ 63
Performance ............................................................................................................................. 63
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
C5288
3 of 116
8.0
Contractor Plans and Information ......................................................................................... 63
8.1
Safety Management Plans ................................................................................................... 63
8.2
Guidelines for Preparing Site Specific Safety Management Plan Documentation ....... 65
8.3
Quality Management Plan ................................................................................................... 69
8.4
Environmental and Waste Management Plans ................................................................. 70
8.5
Documentation and Drawings ............................................................................................ 73
8.6
Records ................................................................................................................................. 76
8.7
Inspection and Test Plans ................................................................................................... 77
8.8
Verification ............................................................................................................................ 77
8.9
Inspection and Test Plan Schedule ................................................................................... 78
8.10 Design Review ...................................................................................................................... 78
9.0
Works or Services Provided By The Principal ..................................................................... 79
9.1
Site ......................................................................................................................................... 79
9.2
Site allocation ....................................................................................................................... 79
9.3
“Free Issue” .......................................................................................................................... 79
10.0
Terminal Points .................................................................................................................... 80
11.0
The Principal’s Representative........................................................................................... 80
12.0
Contact Officers ................................................................................................................... 80
13.0
13.1
13.2
13.3
13.4
13.5
13.6
13.7
Contractor’s Management and Staffing ............................................................................. 80
Contractor's Representative ............................................................................................... 80
Contractor’s Site Manager .................................................................................................. 81
Contractor’s Staff and Employees ..................................................................................... 81
Industrial Relations .............................................................................................................. 82
Outage Safety Management and Co-ordination Meeting ................................................. 82
Contractor Personnel Screening ........................................................................................ 83
Working Hours ..................................................................................................................... 83
14.0
14.1
14.2
14.3
Site Conditions ..................................................................................................................... 83
Contractor Acknowledgments Regarding the Conditions Existing on Site .................. 83
Risk of Conditions Existing on Site ................................................................................... 84
Acknowledgement and Site Information ........................................................................... 84
15.0
15.1
15.2
15.3
15.4
15.5
15.6
15.7
15.8
15.9
15.10
15.11
15.12
15.13
15.14
15.15
15.16
15.17
15.18
15.19
15.20
Site Safety ............................................................................................................................. 84
Legal Obligations ................................................................................................................. 85
Safety Training and Competency Requirements .............................................................. 85
Consultation ......................................................................................................................... 86
Risk Management and Process Control ............................................................................ 86
Emergency Response and Incident Notifications ............................................................ 87
Site Rules .............................................................................................................................. 88
Commissioning .................................................................................................................... 89
Plant and Equipment ........................................................................................................... 89
Confined Spaces .................................................................................................................. 91
Control of Radiographic Sources and Radiography ........................................................ 91
Fire Protection ...................................................................................................................... 91
Chemicals ............................................................................................................................. 91
Hot Work ............................................................................................................................... 92
Access to Apparatus Rules ................................................................................................ 93
Scaffolding and Rigging ...................................................................................................... 93
Underwater Diving ............................................................................................................... 93
Work Method Statements .................................................................................................... 93
Workplace Inspections ........................................................................................................ 94
Impairment Testing .............................................................................................................. 94
Asbestos ............................................................................................................................... 94
16.0
16.1
16.2
16.3
Site Security, Access and Removals from Site ................................................................ 94
Site Security ......................................................................................................................... 94
Site Access ........................................................................................................................... 94
Removal from site ................................................................................................................ 95
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
C5288
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17.0
17.1
17.2
17.3
17.4
17.5
17.6
17.7
17.8
17.9
17.10
17.11
17.12
17.13
Environment ......................................................................................................................... 95
Environment Management .................................................................................................. 95
Environment training and competency requirements ..................................................... 96
Contractor Environment Responsibilities ......................................................................... 96
Environmental Incident Report ........................................................................................... 96
Environmental Emergency Response ............................................................................... 96
The Principal Environment Protection Licence ................................................................ 97
Water Protection .................................................................................................................. 97
Hazardous Substances ....................................................................................................... 97
Hazardous Waste ................................................................................................................. 98
Flora and Fauna ................................................................................................................... 99
Noise and Air Pollution ....................................................................................................... 99
Environment Risk Assessments ........................................................................................ 99
Finding of Minerals, Fossils and Relics .......................................................................... 100
18.0
18.1
18.2
18.3
Site Establishment ............................................................................................................. 100
Contractor to supply .......................................................................................................... 100
Site accommodation standards and rules ...................................................................... 100
Costs ................................................................................................................................... 101
19.0
19.1
19.2
19.3
Spares, Disposal and Return of Plant .............................................................................. 101
Disposal and Return of Plant ............................................................................................ 101
Supply of Spare Parts ........................................................................................................ 101
Items of equipment to be delivered to The Principal's Store ....................................... 101
TABLES ................................................................................................................................................. 103
TABLE A – TABLE OF KEY DATES ................................................................................................ 103
TABLE B - DRAWINGS AND DOCUMENTS FOR TENDERING PURPOSES ............................... 105
TABLE C - DRAWINGS TO BE PROVIDED BY THE CONTRACTOR ............................................ 106
TABLE D - FIRE FIGHTING EQUIPMENT ........................................................................................ 106
TABLE E - QA DOCUMENT SUBMISSION MATRIX ....................................................................... 107
ANNEXURE 1 - REQUEST TO ATTEND PRE TENDER MEETING .................................................... 108
ANNEXURE 2 – GENERAL CONSTRUCTION REQUIREMENTS ...................................................... 109
A2.1
A2.2
A2.3
A2.4
A2.5
A2.6
A2.7
A2.8
A2.9
A2.10
A2.11
A2.12
A2.13
A2.14
A2.15
A2.16
A2.17
A2.18
A2.19
A2.20
Labels and Nameplates ..................................................................................................... 109
Earthing ............................................................................................................................... 109
Fasteners ............................................................................................................................ 110
Cabling (General) ............................................................................................................... 110
Cabling (Crimping) ............................................................................................................. 111
Terminations of Cables ..................................................................................................... 111
Plugs and Sockets ............................................................................................................. 112
Ferruling .............................................................................................................................. 112
Ferruling .............................................................................................................................. 112
Extent of Cable Supply ...................................................................................................... 112
Setting out of Cabling ........................................................................................................ 112
Cable Trays and Racking .................................................................................................. 113
Conduits.............................................................................................................................. 113
Cable Selection .................................................................................................................. 113
Fault and Impedance Rating ............................................................................................. 113
Setting Out of Terminal Strips .......................................................................................... 113
Enclosures for Electrical and Control Equipment .......................................................... 114
Power Supply Systems ..................................................................................................... 114
Voltage and Frequency Limits .......................................................................................... 114
Current Transformers ........................................................................................................ 115
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
C5288
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1.0
Introduction
The Particulars of Work and Special Requirements part 1 is the Part that sets out what is
required by The Contractor, and information specific to working with The Principal.
2.0
Interpretations and Definitions
2.1
Site Specific
a)
Location of Site
The Vales Point Power Station is located on the southern shore of Lake Macquarie,
approximately 130 km north of Sydney, New South Wales, and approximately 3 km off
the Pacific Highway North of Doyalson.
b)
Access to Apparatus Rules
Rules adopted by The Principal for managing work safety by controlling access to plant
and evaluating safety risks. The Contractor shall complete the Works, supply and install
equipment in accordance with the Access to Apparatus Rules.
c)
Site Access Induction
The Principal has a responsibility under WHS legislation for the safety, health and
welfare of all persons on the Site. Vales Point Power Station Site Access Induction
(SAI) is The Principal’s requirement for issuing personal or Contractor identification
security card access to the requested site areas.
d)
Principal Contractor
Has the meaning given to that term in the WHS Regulation.
e)
Principal
Sunset International t/as Delta Electricity is the Principal.
f)
The Principal Site Representative
Person appointed by The Principal to deal with all Contract Site issues.
and like words have a corresponding meaning.
2.2
Pricing
a)
Lump Sum
The quoted Firm Lump Sum Prices contained in Part 3 – Returnable Schedules for
the workscope detailed in Clause 4.0.
b)
Schedule of Rates
The quoted Firm Rates contained in Part 3 – Returnable Schedules for work carried
out under the Schedule of Rates provisions of the Contract.
c)
Work Direction
Is The Principal's written direction to The Contractor for work to be carried out under the
Schedule of Firm Rates provisions of the Contract or for the purchase of specialist
labour, equipment or materials in accordance with Clause 5.3.
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
C5288
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2.3
Quality Assurance
a)
Preliminary Visit
(i)
b)
A visit by The Principal of short duration (generally half a day) paid by The
Principal to a potential Contractor's/Supplier's premises for the purpose of:
A)
Familiarisation with The Contractor's/Supplier's Organisation and
facilities;
B)
Evaluation of The Contractor's commitment to quality; and
C)
Assessing the effectiveness of The Contractor's quality system in
selected areas of their operation.
Audit (Quality Audit)
A systematic and independent examination to determine whether quality activities and
related results comply with planned arrangements and whether these arrangements are
implemented effectively and are suitable to achieve objectives.
c)
Surveillance
The continuous monitoring and verification of the status of an entity and analysis of
records to ensure that specific requirements are fulfilled.
d)
Corrective Action Request (CAR)
A formal notification detailing an observed deficiency in the quality system.
e)
Non Conformance Report (NCR)
A formal notification of the departure or absence of one or more quality characteristics
or quality system elements from specific requirements.
f)
Hold Points
A hold point is defined as a position in the design, manufacture, construction and
commissioning phases of the Contract beyond which work will not proceed without
mandatory verification and acceptance by The Principal.
g)
Witness Points
A position in the design, manufacture, construction and commissioning phases of the
Contract where the option of attendance may be exercised by The Principal.
2.4
Technical
a)
Preventive Maintenance
Maintenance carried out to ensure that the equipment remains in good working order.
This includes rectification of defects found during Scheduled inspections.
b)
Remedial Maintenance
Maintenance carried out at the request of The Principal in order to rectify a malfunction.
c)
Parent Plant Spares
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
C5288
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Parent Plant Spares are spares unique or specific to the plant, equipment and are not in
common use. They exclude any parts or items that have a general industrial usage, or
are consumable, even if the items or parts are associated with parent plant equipment.
3.0
Description of Plant
3.1
Plant Details
a)
b)
c)
3.2
The Principal owns two 11kV feeders (680 Feeder and 690 Feeder) that are used to
supply infrastructure typically outside the general perimeter of the power station. Some
of the main loads include:
(i)
The Wyee Rail Unloader;
(ii)
The RV Conveyer system for the delivery of coal from the Wyee Rail Unloader
and Mandalong Colliery;
(iii)
The Wyee Conveyer System for the delivery of coal from the Mannering LDO;
(iv)
Morgan Ash dust reclamation plant;
(v)
Ash Dam Return Water System; and
(vi)
Proposed Ash & Dust Pumping Station.
For reference refer to the following drawings:
(i)
VX807320 - Power Supplies 11kV Transmission Lines 680, 690 Route Plans;
(ii)
VX807320 – With Legend and Explanatory Notes; and
(iii)
VX827544 - 11kV Network Single Line Diagram.
The two feeders are currently supplied by separate circuit breakers from the Ausgrid
133 Zone Substation.
Risks and Hazards
a)
The following list is provided to assist The Contractor in preparing risk assessments and
safe work method statements when undertaking work at The Principal’s site. The list is
indicative only and does not include risks and hazards associated with the individual
tasks associated with the contract work which must be independently assessed by The
Contractor.
b)
Risks and hazards associated with work at Vales Point Power Station consist of but are
not limited to the following:
(i)
High Voltage Electricity;
(ii)
Asbestos/galbestos material;
(iii)
High Pressure Vessels and Pipe Work;
(iv)
Hazardous Substances and Bulk Chemical Storage;
(v)
Dangerous Goods;
(vi)
Confined Space;
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
C5288
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(vii)
Hazardous Areas;
(viii)
Hydrogen filled generators;
(ix)
Oil filled transformers;
(x)
Steam turbines, high pressure and super-heated steam;
(xi)
High pressure lubricating oil lines;
(xii)
High speed rotating machinery;
(xiii)
Tripping, Trip hazards uneven floor and work surfaces;
(xiv) Working in cramped, confined and constricted areas;
(xv)
Working on a construction site;
(xvi) Working in remote areas of the power station;
(xvii) Illumination levels;
(xviii) Being struck by falling objects;
(xix) Mobile plant operating;
(xx)
Fire from hot work;
(xxi) Electrocution, high voltage and low voltage high energy sources and extra low
voltage;
(xxii) Working with HV test equipment;
(xxiii) Use of hand tools;
(xxiv) Heavy lifting and manual handling;
(xxv) Noise;
(xxvi) Air borne dust;
(xxvii) Deep fast flowing water, inlet and outlet canals;
(xxviii)Lightning strikes;
(xxix) Electric Magnetic Fields;
(xxx) Bushfire;
(xxxi) Exposure to the elements, wind, rain and sun;and
(xxxii) Wildlife and vermin including snakes, spiders, birds, rats, possums.
3.3
Asbestos
The Contractor acknowledges that:
a)
The Principal has an asbestos register ("register");
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
C5288
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b)
It or its representative have been provided with a copy of the register and will ensure
that the register is reviewed by The Contractor before the commencement of work
under the Contract;
c)
Its personnel may encounter asbestos or asbestos containing material (ACM);
NOTE: Gaskets on flanges not previously accessed can be of asbestos type. All staff
shall be made aware of this fact and informed that gaskets are to be treated as
asbestos if there is any doubt to the composition and the Contract Administrator
informed. Gaskets are never to be removed by any means other than scrapping.
4.0
d)
It must ensure that, at all times, its personnel will take proper precautions and have in
place safety plans and procedures to deal with the possible presence of asbestos and
ACM when carrying out work under the Contract;
e)
If asbestos or ACM is encountered by The Contractor when carrying out work under the
Contract, The Contractor will immediately contact the relevant Principal’s
Representative. The Principal Asbestos Identification Risk Assessment process will be
implemented by The Principal Representative;
f)
Material that is encountered which resembles or could be identified as asbestos or ACM
must be treated as asbestos until proven otherwise and the procedures outlined in subclause (e) above must be undertaken by The Contractor; and
g)
No equipment or materials are to be accepted that have asbestos bearing materials.
Equipment that is procured from overseas is to have asbestos free consignment note
attached to the goods delivered.
Particulars of Work
The Contractor will be responsible for the repowering of the 680 and 690 11kV Feeders.
Practical completion is required before 30 June 2017.
4.1
Negotiation Clause - Not Used
4.2
Experience and Qualifications
a)
The Contractor’s engineering design staff must have proven demonstrable experience
and competence in the works required. Evidence is to be provided at the time of tender
for review.
b)
All work crews shall hold appropriate qualifications and statutory accreditation to
perform the assigned work. Refer also to Clause 4.22 for specific requirements for
working on 11kV systems at Vales Point.
c)
For works on the site, The Contractor’s staff will require the following The Principal
Training:
(i)
Site induction (conducted every weekday at 7:30am; duration of approximately
40 minutes)
(ii)
ATAR High Voltage Awareness certification for all staff working on high voltage
equipment (duration of approximately 1 hour)
(iii)
ATAR safety rules certification including High Voltage Permit Holder and Hot
Work certification for supervising staff (duration of approximately one day).
Note that The Principal will require at least two of The Contractor’s staff trained
Objective ID No. D1385418
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Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
C5288
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to this requirement and that the holder of a High Voltage Permit must be
present at the immediate worksite at all times whilst works are underway
4.3
Regulations/Standards
All work is to be completed in accordance with The Principal’s Policies and Standards and all
applicable Australian Standards.
4.4
Resources
The Contractor shall provide all necessary resources to perform the works including but not
limited to:
4.5
a)
All site services including offices, meal rooms and wash rooms;
b)
All computing, IT and communications equipment;
c)
All engineering design and documentation (where applicable);
d)
All training and supervision to perform the works;
e)
All documentation including job modules, drawings and instruction manuals;
f)
All safety, PPE and consumables;
g)
All general and specialised tooling;
h)
Scaffolding and associated equipment for safe access;
i)
Removal and re-instatement of all lagging and refractory; and
j)
All Mobile plant and equipment required survey, testing and verification instrumentation.
Note:
these shall be incorporated into pricing schedules.
Pricing Schedule Details
a)
All prices shall include but not be limited to :
(i)
Staff on-costs, overhead and profit;
(ii)
Administration, travel and accommodation if required;
(iii)
All safety, PPE, consumables, general and specialised tooling;
(iv)
Current certification and licencing to execute the work required;
(v)
The Principal ATAR certification to execute the work required;
(vi)
Staff trained with Confined Space;
(vii)
Scaffolding for safe access;
(viii)
Removal and re-instatement of all lagging;
(ix)
Mobile plant and equipment;
(x)
Spare parts unless specified as “free issue” by The Principal;
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
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b)
4.6
(xi)
Required management and engineering staff;
(xii)
Required supervisory and support staff;
(xiii)
Required safety and QA staff;
(xiv)
Required survey, testing and verification; and
(xv)
Required trades and non-trades staff.
The Contractor in completing Part 3 Returnable Schedules warrants that it has
undertaken its own investigation as noted on each pricing schedule.
Drawings
This specification shall be read in association with the drawings listed in Table B – Drawings for
Tendering Purposes.
4.7
a)
Where information in this specification contradicts information in a drawing, then the
information in this specification shall take precedence.
b)
Where information in two drawings is contradictory, then the information in the most
recent drawing shall take precedence.
c)
Notwithstanding the above, The Contractor shall regularly carry out site surveys and
dimensional checks to ensure the manufacture or repair of any component shall be fit
for purpose and duty. Drawing dimensions and details are not guaranteed, The
Contractor shall rely on his own investigations to ensure parts and material is fit for
purpose.
c)
If The Contractor finds any discrepancies with The Principal’s drawings they are
required to mark them up in red pen and provide to the Contract Administrator, who will
organise for them to be amended.
d)
All drawings to be provided by The Contractor shall be in AutoCAD format and comply
with drawing requirements clause 8.5.
Country of Manufacture
The Country of Manufacture of any materials or other things which are to be incorporated in the
Works shall not be changed from that stated in the Contract without the approval in writing of
The Principal.
4.8
Work Scope Main Objectives
a)
The main objectives of workscope under this Contract include:
(i)
Disconnection of the two 11kV Ausgrid supplies for alternate connection to the
Power Station’s 6.6kV Station Services Switchboards;
(ii)
Connection of the 680 and 690 feeders together;
(iii)
The feeder is to be supplied via a 6.6/11kV substation that can be fed from
either 6.6kV Station Switchboard 3 or 6.6kV Station Switchboard 5;
(iv)
Maintaining the existing requirement for earth fault level limiting through the
use of a neutral earthing resistor (maximum earth fault level is approximately
10A);
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
C5288
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4.9
(v)
Segregation of the downstream portion of the feeder (mostly 680 feeder) from
the upstream portion by an 11kV auto-recloser;
(vi)
A considerable portion of the 680 feeder is located in the Ash Dam. This area
is prone to lightning strikes and is struck at least once per year. The 690
feeder which will form most of the upstream portion of the feeder is rarely
affected by lightning. The proposed auto-recloser is required to shed the
downstream portion of the feeder during a lightning strike event detected by
fast acting protection. The protection at the auto-recloser is to be effectively
graded against upstream protection to ensure that the upstream portion
remains in-service after a lighting strike event
(vii)
To facilitate fault clearing after a lightning strike event and subsequent
successful reclosing of the faulted section the work scope provides for the
improvement of lightning protection at locations on the feeder that have been
previously damaged by lightning strikes in the past.
Work Scope
a)
Supply and construct the 6.6/11kV 690 Feeder Substation at the site of the existing
Construction Substation B including removal and disposal of the redundant elements of
the Construction Substation B. Refer to drawing VX807320 – With Legend and
Explanatory Notes for the proposed location of the substation relative to the feeders.
b)
Supply and install 6.6kV cabling between the 6.6kV station switchboards 3 and 5 and
the 690 Feeder 6.6/11kV Substation. Separate supplies from station switchboards 3
and 5 are to be cabled to changeover link boxes located in the cable tunnel close to the
Station Switchboard 5. The link boxes must be cabled via the cable tunnel and
underground conduits to the 6.6/11kV 690 Feeder Substation. Refer to drawing
VX306408 – Proposed 6.6kV Cable Routes.pdf and Const Sub B Conduits.pdf
c)
Modification to and augmentation of circuit connections and protection systems at the
6.6kV station switchboards 3 and 5
d)
Supply and install a 690 Feeder protection panel in the 6.6kV Station Switchboard 5
switch room
e)
Connect the 690 Feeder 6.6/11kV Substation to the 690 Feeder by one of the following
options:
(i)
Utilising the existing cable between the existing Construction Substation B
and Pole 110
(ii)
Supplying and installing an underground cable between Construction
Substation B and Pole 110
(iii)
Supplying and installing wooden poles and overhead conductors between
Construction Substation B and Pole 110 with an under-road cable
f)
Joining of the 680 Feeder to the 690 Feeder as well as various other 11kV overhead
connections and disconnections
g)
Install an 11kV auto-recloser at 680 Feeder Pole 224 complete with electrical
protection.
h)
Additional lightning surge protection is to be supplied and /or modified and installed at
the following locations:
(i)
Objective ID No. D1385418
Rev: 7 December 2016
680 Feeder Pole 276 (at the junction of the Ash Dam return water spur);
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4.10
(ii)
RV 2-3 Substation;
(iii)
RV 3-4 Substation;
(iv)
RV 4-5 Substation;
(v)
Return Water System Substation; and
(vi)
Ash Dam Substation.
i)
Refer to Single Line Diagram of Proposed Power and Protection Circuits.pdf for the
proposed arrangement of the power system and protection schemes.
j)
Data on existing and proposed plant is provided in Proposed 11kV Feeder
Parameters.pdf. The Contractor must conduct its own assessment of relevant factors
including, current carrying capacity, voltage drop, motor starting, fault levels, earthing
requirements, lightning protection, electrical protection and commissioning to satisfy
itself that the requirements of this specification will provide for a satisfactory outcome.
The cost of implementing additional requirements critical to the satisfactory operation of
the plant after contract award will be borne by The Contractor.
690 Feeder 6.6/11kV Substation
a)
The site of the existing Construction Substation B is to be used for the 690 Feeder
Substation.
b)
Existing infrastructure in the substation may be reused as required. All unused
equipment is to be removed and disposed of by The Contractor with the exception of
the existing 11kV/415V transformer which is to be relocated to the Vales Point Oil
Handling Facility bund for storage.
c)
The substation must meet the requirements of AS2067 at the completion of
construction. This standard must also apply to any elements of the existing
Construction Substation B that have been reused.
d)
The minimum insulation levels for all equipment in the substation must be:
e)
(i)
11kV: 95kV Impulse (1.2/50us) / 28kV power frequency; and
(ii)
6.6kV: 75kV Impulse (1.2/50us) / 22kV power frequency.
Generally the substation must include but not necessarily be limited to :
(i)
11/6.6kV Star/Delta 3.5MVA ONAN power transformer;
(ii)
Three-phase voltage transformer for 11kV voltage measurement. This may be
integral to the power transformer or a separate unit;
(iii)
Minimum of two 11kV line CTs for overcurrent protection. These may be
integral to the transformer or separate units;
(iv)
Neutral earthing resistor for the impedance earthing of the11kV star point;
(v)
Two neutral earthing CTs for 11kV Definite Time Earth Fault Protection;
(vi)
All ancillary marshalling cabinet for signalling, control and protection;
Objective ID No. D1385418
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f)
(vii)
11kV air break circuit disconnector;
(viii)
High voltage overheads, cables and connections;
(ix)
Substation earth mat and earthing system;
(x)
Earthing stirrups on 11kV overheads for attachment of portable earths;
(xi)
Lightning protection;
(xii)
Equipment foundations and structures;
(xiii)
Miscellaneous power and lighting;
(xiv)
Transformer bund;
(xv)
Substation fencing;
(xvi)
Substation surfacing; and
(xvii)
Conduits.
The requirements for the power transformer are as follows:
(i)
The supplied transformer must meet or exceed the requirements of AS60076.
Where a requirement listed in Clause 4.10 f) exceeds a requirement of
AS60076 the requirement of Clause 4.10 f) takes precedence;
(ii)
Rating: 3.5MVA;
(iii)
Phases: 3;
(iv)
Rated frequency: 50Hz;
(v)
The transformer must be a separate winding transformer;
(vi)
The transformer must be an outdoor type;
(vii)
Method of cooling: ONAN;
(viii)
Impedance voltage: Not to exceed 5% on 3.5MVA base on all taps;
(ix)
Required vector group: YNd1 or YNd11; and
(x)
Insulation levels:
(xi)
A)
HV: Um = 12kV, Lightning impulse withstand voltage: 95kV peak, AC
withstand voltage: 28kV r.m.s.;
B)
LV: Um = 7.2kV, Lightning impulse withstand voltage: 60kV peak, AC
withstand voltage: 20kV r.m.s.; and
C)
All windings must be uniformly insulated.
Rated voltages (no load):
(A)
Objective ID No. D1385418
Rev: 7 December 2016
HV: 11000V (nominal);
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(xii)
(B)
LV: 6600V (nominal); and
(C)
Exact final ratio is subject to final agreement between The Principal and
The Contractor.
Temperature rise limits at rated load:
(A)
Maximum oil temperature rise: 50°C;
(B)
Maximum average winding temperature rise by resistance: 60°C;
(C)
Maximum winding hot spot temperature rise: 70°C; and
(D)
Max hot spot temperature in core surface, tank and turrets: 70°C.
(xiii)
In addition to the requirement of Clause 5.4.3 of AS60076.1 the transformer
must be capable of continuous operation at a V/Hz of 110% when operating at
rated current.
(xiv)
Offload tap changer (for de-energised tap changing) with a tapping range of at
least - 5%/+7.5% from nominal ratio in maximum increments of 2.5%. Tapping
is to be done on the high voltage winding such that the transformer will be
tapped in a Constant Flux Voltage Variation (CFVV) arrangement. Taps must
be settable via an external adjustment not requiring the removal of any cover
plate and the tap position is to be lockable with a padlock.
(xv)
Method of earthing:
(A)
11kV neutral will be impedance earthed with 600 ohms resistive; and
(B)
Transformer tank directly earthed.
(xvi)
The transformer’s active part must be of solid insulation comprising of
thermally upgraded paper immersed in a naphthenic mineral insulating oil.
Only new oil is to be used. Reclaimed or recycled oil may only be used
subject to the approval of The Principal.
(xvii)
Insulating oil must be processed to the following minimum specification prior
to filling the transformer with oil:
(A)
Electric strength to AS1767: >60kV;
(B)
Residual water content: <10ppm; and
(C)
Residual particulate size: <3μm.
(xviii)
The residual paper moisture content of the transformer’s solid insulation must
not exceed 1% by weight upon delivery of the transformer to site.
(xix)
The oil preservation system must consist of a conservator and a moistureremoving silica gel breather fitted in the connection to the atmosphere. The
silica gel breather must be located at ground level to allow for the in-service
exchange of the silica gel desiccant. The conservator’s internal surface must
be treated internally as well as externally to prevent corrosion.
(xx)
A topping up pipe must be fitted to the conservator and brought to ground
level in order to permit the in-service topping up of oil.
(xxi)
Allowable tank vacuum: Full vacuum.
Objective ID No. D1385418
Rev: 7 December 2016
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(xxii)
The transformer must have a Buchholz relay with gas accumulation and surge
functions that can be independently wired to separate alarm and trip circuits.
(A)
The low oil level trip function on the Buchholz must be configurable; the
required configuration is: No trip on low oil.
(B)
The Buchholz relay must not be adversely affected by reverse flow of
oil, e.g. during oil filling or filtering operations.
(C)
The Buchholz relay must incorporate a ground level gas receiver to
permit the in-service bleeding of oil and sampling of fault gases at
ground level.
(D)
The Buchholz relay must have a facility for testing the operation of the
contacts, e.g. mechanical plunger.
(xxiii)
Sight glass and oil level gauge on conservator with low oil level alarm contact.
(xxiv)
Top oil temperature measurement with PT100 RTD. A PT100 to 4-20mA loop
powered signal converter is to be installed at the substation for signalling back
to the power station’s DCS.
(A)
(xxv)
To facilitate The Principal’s implementation of an inferred winding
temperature calculation on the DCS, The Contractor must provide data
to The Principal required for a basic thermal model. This should include
as a minimum:
(i)
HV winding temperature gradient at rated load
(ii)
LV winding temperature gradient at rated load
(iii)
Winding hot spot factor(s)
(iv)
Thermal time constants associated with the above i.e. the time
taken for the temperature step response to reach 63.2% of its
final value
Terminals
The LV and HV terminals of the transformer may be either air bushings, cable
box type or a combination of the two subject to the following limitations. The
air bushings may be used for connection to an overhead structure or for direct
connection to a cable mounted on a suspended cable tray.
Objective ID No. D1385418
Rev: 7 December 2016
(A)
Air bushings must be located after final installation in the substation at
sufficient height to provide the safety clearance requirements of
AS2067. The Contractor must also consider the effect that the
increased final height of the transformer may have on the transformer
bund wall requirements of AS2067 and Clause 5.8 and Appendix H of
AS1940-2004
(B)
Connection via air bushings of the low voltage side (6.6kV) to
conductors an overhead structure will require the employment of surge
arresters on the low voltage side to protect the low voltage winding
(C)
Where a cable box is employed, the transformer must provide for a set
of removable links so that the transformer can be disconnected for
testing without disturbing the cable terminations. Alternatively the cable
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terminations shall be easily disconnectable from the transformer
terminals (by nut and bolt arrangement) and the cables ends of
adequate flexibility to allow them to be pushed to one side and secured
when disconnected to achieve a clearance between the cable end and
transformer bushing and between cable end and cable box of at least
140mm.
(D)
Cable boxes must be of a weatherproof design incorporating as a
minimum the following features.
(1)
All seals on cover plates must be continuous having no joints.
The use of adhesive rubber or foam rubber strip or similar will not
be accepted.
(2)
The box cover shall employ a lip / gutter arrangement that drains
water away from the cover plate seal and prevents water from
pooling against the seal. Alternatively the flange for the cover
plate seal shall protrude outwards from the edge of the cable box
to prevent water from pooling against the seal.
(3)
Minimum IP rating: IP 56.
(E)
The high voltage side (11kV) of the transformer will require surge
arrestors installed on the 11kV conductors in the 6.6/11kV substation in
addition to those installed at the cable end on 690 Feeder Pole 110.
The Contractor must consider how the appropriate level of lightning
protection will be afforded (as outlined in Clause 4.10 p)) if using a
cable box on the high voltage terminals of the transformer.
(F)
As required by Clause 4.10 p) The Contractor must assess the
requirement for backflash protection on the low voltage (6.6kV) side of
the transformer. Where such surge protection is required The
Contractor must consider how this will be accommodated if using a
cable box on the low voltage terminals of the transformer.
(xxvi)
All ancillary cabling must be enclosed by ‘Anaconda’ armoured flexible
conduit or equivalent. PVC cabling may be used in lieu of the above
requirement provided that it is of an appropriately UV stabilised material.
Particular attention is required to ensure that all terminal lids and cable entry
locations are sealed to a minimum IP rating of IP55 to prevent water entry.
(xxvii)
The transformer tank must be constructed in such a way that water does not
pool on any external surfaces.
(xxviii)
In addition to any other valves specified elsewhere the transformer must have:
(xxix)
Objective ID No. D1385418
Rev: 7 December 2016
(A)
Valves located at opposite sides of the transformer with one located at
the top of the tank and the other located at the bottom of the tank for oil
filtering purposes;
(B)
A separate valve located at the bottom of the tank dedicated for the
purposes of oil sampling; and
(C)
Bleed valves (or plugs) at the top of the tank or on oil filled link boxes
as applicable.
A factory test report is to be provided detailing as a minimum the following
routine transformer tests in accordance with AS60076:
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(A)
(xxx)
Objective ID No. D1385418
Rev: 7 December 2016
Routine tests in accordance with Clause 11.1.2.1 of AS60076.1
including:
(1)
Measurement of winding resistance;
(2)
Measurement of voltage ratio and check of phase
displacement;
(3)
Measurement of short circuit impedance and load loss;
(4)
Measurement of no-load loss and current;
(5)
Dielectric routine tests in AS60076.3: Induced Short Duration
AC (ACSD) and Separate Source AC tests;
(6)
Leak testing with pressure;
(7)
Check of ratio and polarity of built in current transformers and
voltage transformers where applicable; and
(8)
Check of core and frame insulation where applicable.
(B)
Frequency Response Analysis (FRA) test. Refer to Clause 4.21 for
requirements.
(C)
The following tests are to be performed unless a type test certificate
can be provided demonstrating that the tests have previously been
performed on a representative transformer with satisfactory outcome
subject to the requirements in Clause 3.11.2 of AS60076.1. In this case
the supplier must provide the results of the type tests:
(1)
Lightning impulse test in accordance with AS60076.3;
(2)
Temperature rise test in accordance with AS60076.2. The
results must meet the temperature rise limits outlined in this
specification; and
(3)
Sound level test in accordance with AS60076.10.
After installation of the transformer on site, The Contractor must arrange and
conduct the following high voltage tests on site. The Contractor must employ
The Principal’s High Voltage Test Contractor to conduct these tests:
(A)
Insulation resistance to the same standard as AS60076.1;
(B)
Separate source withstand test at 22kV 50Hz AC for the HV winding
and 16kV for the LV winding;
(C)
Induced test (1 phase at a time) to 1.1 x rated voltage at the HV
winding for 1 minute;
(D)
Winding resistance of each phase and tap setting (as applicable) of the
LV and HV windings; and
(E)
Frequency Response Analysis (FRA) test. Refer to Clause 4.21 for
requirements. The results of this test must be compared with the
previous tests undertaken in the factory and must demonstrate that
there has been no winding movement during transport, delivery and
installation.
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The Contractor is responsible to make good, at The Contractor’s expense, any
failure of the transformer to pass tests on site.
g)
Voltage transformer for 11kV voltage measurement
(i)
The voltage transformer (VT) may be integral to the power transformer or a
separate unit.
(ii)
The VT must meet the requirements of AS60044.2. Where a requirement
listed in Clause 4.10 g) exceeds a requirement of AS60044.2, Clause 4.10 g)
takes precedence.
(iii)
The VT must be star-star connected, 3 phase and is required with the
secondary neutral terminal brought out.
(iv)
Ratio: 11kV/110V.
(v)
Accuracy class designation: 0.5.
(vi)
The rated output must be at least 50VA.
(vii)
Maximum winding temperature rise must not exceed 60 degrees C.
(viii)
Insulation level Um = 12kV, Lightning impulse withstand voltage: 95kV peak,
AC withstand voltage: 28kV r.m.s.
(ix)
The white phase secondary terminal must be connected to earth at the
Ancillary Marshalling Cubicle via a removable earth link.
(x)
The VT must have HV fuses protecting the HV side of the VT.
(xi)
Requirements for secondary fuses and links:
Objective ID No. D1385418
Rev: 7 December 2016
(A)
The secondary fuses and links must be located in the Ancillary
Marshalling Cubicle;
(B)
The earth link shall be connected to the white phase VT terminal
upstream of any fuses or other links;
(C)
An IPD Red Spot white fuse base and fuse holder containing a link
must be connected to the white phase VT secondary terminal;
(D)
IPD Red Spot black fuse bases and fuse holders containing fuses must
be connected to the other phases and neutral terminal;
(E)
On the load side of the abovementioned fuses and link a set of 4mm
“banana plug” style sockets must be connected for each phase and
neutral (if applicable). An additional 4mm socket must be provided
connected to earth. These sockets are required for temporary earthing
of the VT secondary circuit as required under The Principal’s Safety
Rules;
(F)
Downstream of the abovementioned 4mm sockets, The Contractor
must install for each phase and the neutral an IPD Red Spot white fuse
base and fuse holder containing a link; and
(G)
Fuses shall be appropriate to clear any short circuit fault on the VT
secondary wiring without causing damage to the VT.
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(xii)
After installation, The Contractor will arrange and conduct the following high
voltage tests on site. The Contractor must employ The Principal’s High
Voltage Test Contractor to conduct these tests:
(A)
Insulation resistance of the HV winding at 2.5kV DC after 1 minute;
(B)
Insulation resistance of the LV winding at 1kV DC after 1 minute;
(C)
Separate source withstand test at 22kV AC for the HV winding; and
(D)
Insulation resistance of the connected LV secondary wiring at 1kV DC
after 1 minute.
The Contractor is responsible to make good, at The Contractor’s expense, any
failure of the VT to pass tests on site.
h) 11kV Line Current Transformers.
i)
(i)
The current transformers (CTs) are for current measurement at the 11kV lines
for the implementation of the required overcurrent protection schemes.
(ii)
A minimum of two line CTs are required.
(iii)
The CTs must meet the requirements of AS60044.1. Where a requirement
listed in Clause 4.10 h) exceeds a requirement of AS60044.1, Clause 4.10h)
must take precedence.
(iv)
The CTs may be either integral to the transformer or mounted externally.
(v)
External CTs must be of an outdoor type of suitable construction to resist the
degrading effects of weather and sunlight.
(vi)
Maximum winding temperature rise must not exceed 60 degrees C.
(vii)
If the CT has a primary winding then its required insulation level is Um =
12kV, Lightning impulse withstand voltage: 95kV peak, AC withstand voltage:
28kV r.m.s.
(viii)
The CT must be of protection class 5P. The Contractor must nominate the
required ratio, accuracy limit factor, rated output, secondary winding
resistance and rated thermal current limits that are appropriate to the fault
levels and protection schemes to which they are connected and submit these
to The Principal for review and final approval.
Neutral earthing resistor.
(i)
The 11kV neutral of the power transformer is to be earthed through a neutral
earthing resistor.
(ii)
The neutral earthing resistor must be enclosed in a suitably vented outdoor
cabinet.
(iii)
Resistance: 600 ohms at 20 degrees C.
(iv)
Test Voltage: 25kV RMS / 1 minute.
(v)
Short Time Rating: 10.6 Amps / 6 seconds.
Objective ID No. D1385418
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(vi)
Type of cooling: Air natural.
(vii)
After installation, The Contractor will arrange and conduct the following high
voltage tests on site. The Contractor must employ The Principal’s High
Voltage Test Contractor to conduct these tests.
(A)
Insulation resistance at 2.5kV DC after 1 minute.
(B)
Separate source withstand test at 22kV AC for 1 minute.
(C)
Measurement of resistance at ambient temperature.
The Contractor is responsible to make good at The Contractor’s expense, any
failure of the resistor to pass tests on site.
j)
11kV Neutral earthing CTs
(i)
The Contractor must provide two CTs for current measurement at the 11kV
Neutral for the implementation of a Number 1 and Number 2 Neutral Earth
Fault protection scheme.
(ii)
The CTs must meet the requirements of AS60044.1. Where a requirement
listed in Clause 4.10 j) exceeds a requirement of AS60044.1, Clause 4.10 j)
takes precedence.
(iii)
The CTs may be either integral to the transformer or mounted externally.
(iv)
External CTs must be an outdoor type of suitable construction to resist the
degrading effects of weather and sunlight.
(v)
Maximum winding temperature rise must not exceed 60 degrees C.
(vi)
If the CTs have a primary winding then its required insulation level is Um =
12kV, Lightning impulse withstand voltage: 95kV peak, AC withstand voltage:
28kV r.m.s.
(vii)
The CTs must be of protection class P. The Contractor must nominate the
required ratio, accuracy class, accuracy limit factor, rated output, secondary
winding resistance, rated thermal current limits that are appropriate to the fault
levels and protection schemes to which they are connected and submit these
to The Principal for review and final approval.
k) Ancillary cabling and marshalling cubicle for signalling, control and protection.
(i)
The marshalling cubicle should be an outdoor type with minimum IP rating:
IP55
(ii)
The marshalling cubicle must include:
Objective ID No. D1385418
Rev: 7 December 2016
(A)
Terminals for the marshalling of the transformer Buchholz alarm and
trip contacts;
(B)
Terminals for the marshalling of the 11kV VT secondary wiring and
required fuses and links;
(C)
A loop powered 4-20mA PT100 RTD signal converter connected to the
transformer’s top oil temperature RTD;
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(D)
Terminals for the marshalling of the neutral and line CT secondaries;
and
(E)
Terminals for the marshalling of the transformer low oil level contact.
(iii)
All terminations are to be via heavy duty pre insulated ring type or lip type
crimp lugs. Only screw type spring loaded (such as Weidmueller SAK type) or
stud terminals are allowed.
(iv)
All ancillary cabling in the substation must be marshalled within the
marshalling cubicle.
(v)
All cable runs and terminations of ancillary cabling within the substation,
between the substation and DCS, between the substation and the 11kV
Feeder Protection Panel must be done by The Contractor.
(vi)
All ancillary cabling with the exception of DCS cabling must have a minimum
cross section of 2.5mm^2. The Contractor must assess if a larger conductor
size is required for the protection CT wiring.
(vii)
Alarm signalling, DC protection wiring and AC protection wiring shall be run in
separate cables between the substation and the various destinations such
that:
(A)
Buchholz trip to the 11kV 690 Feeder Protection Panel must have its
own cable. The cable is to be 4C+E 2.5mm2 0.6/1kV Control Cable
(Delta part number: DE30358);
(B)
The protection CT secondary wiring and 11kV VT secondary wiring to
the 11kV 690 Feeder Protection Panel must have their own cable. The
cable must be a 25C+E 2.5mm2 0.6/1kV Control Cable (Delta part
number: DE30362). All CT wiring must be of two paralleled cores of the
cable for each connection. The VT secondary wiring need not be
paralleled; and
(C)
Buchholz alarm, transformer top oil temperature and low oil level
contact signals to the DCS must have their own cable. The cable is to
be 8 Pair + Drain 0.5mm2 twisted and screened PVC/PVC Dekoron
instrumentation cable (Delta part number: CC67008). The Contractor
must run the cable and terminate to the Station Electrical DCS Cubicle
1T20-01. DCS configuration work will be done by The Principal.
This cabling for which part numbers are listed will be provided to The
Contractor free-issue. Refer to available cables in the Cable Stock line table in
Clause 4.24
l)
11kV Air Break Disconnector.
(i)
Must be of air break type and mechanically operable from ground level.
(ii)
The mechanism must be lockable (with a padlock) from ground level in the
open and closed positions.
(iii)
Must be compliant with AS 62271.102.
(iv)
As the disconnector will not be interlocked with the circuit breakers at the
6.6kV station switchboards, the disconnector must be rated for the full load
feeder and downstream transformer magnetising switching capacity in case of
inadvertent operation of the disconnector with a live supply.
Objective ID No. D1385418
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(v)
m)
n)
o)
After installation, The Contractor must arrange and conduct the following high
voltage tests on site. The Contractor must employ The Principal’s High
Voltage Test Contractor to conduct these tests.
(A)
Insulation resistance at 2.5kV DC after 1 minute between all live
elements and earth.
(B)
Separate source withstand test at 22kV AC for 1 minute between all
live elements and earth.
(C)
Separate source withstand test at 22kV AC for 1 minute between open
contacts.
D)
Contact resistance of each phase with contacts closed.
HV overheads, cables and connections.
(i)
All exposed transformer bushing terminals, surge arrestor terminals or any
other terminals in close proximity to earthed conductors or structures must
have protective bird covers installed over them.
(ii)
All 11kV down leads connected to exposed transformer bushing terminals,
surge arrestor terminals or any other terminals in close proximity to earthed
conductors or structures must be of an insulated type designed for use on
11kV systems.
(iii)
High voltage cable terminations must be made with Raychem termination kits
applicable to the insulation level of the cable.
(iv)
High voltage cable screens are required to be earthed at both ends.
Substation earth mat and earthing system.
(i)
The substation earth mat and earthing system must be designed in
accordance with the requirements of AS2067 and IEEE Std 80 to ensure
personnel safety with respect to touch, step and transferred voltages.
(ii)
As part of the design process, The Contractor must gather all information and
conduct all measurements necessary (including those for soil resistivity
analysis) and conduct an engineering study to ensure the safety of the
system.
(iii)
The Contractor will be required to provide an engineering report prior to
construction detailing the design of the earthing system and the analysis and
modelling that has taken place to demonstrate the safety of the system.
(iv)
The Contractor must test the earth system once constructed to confirm
personnel safety with respect to touch, step and transferred voltages.
(v)
This specification includes options for the connection of the 690 Substation to
the 690 Feeder via an underground cable terminated at 690 Feeder Pole 110.
The analysis and report must also include an investigation of any touch, step
and transferred voltages at Pole 110 that result from the earthed cable
screen.
11kV Earth stirrups for portable earthing equipment.
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
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p)
q)
r)
(i)
The Contractor must provide 11kV overhead earthing stirrups on each phase
in the substation located on the supply side of the 11kV disconnector i.e.
between disconnector and transformer.
(ii)
The stirrups must be suitable for the attachment of CATU MT815S screw
action clamps and (refer DES 647175) and CATU MT701 snap action line
clamps (refer to drawing DES917006).
(iii)
The Contractor must also provide The Principal’s standard earthing stub
attached to the substation earth bar at ground level for connection of portable
earths. Refer to drawing DES647067 and Substation Earth Stub.pdf.
Lightning Surge Protection.
(i)
For the 11kV conductors, The Contractor must connect lightning arrestors to
either the cable end, to the transformer terminals or both depending on The
Contractor’s design and other requirements of Clause 4.10 p).
(ii)
The Contractor must assess if the potential for backflash on the 6.6kV side of
the transformer exists and if so, connect lightning arrestors to the 6.6kV
terminals also.
(iii)
Regardless of mounting location, The Contractor shall employ the shortest
possible lead lengths for surge arrestor connections.
(iv)
The surge arrestors must be of Metal Oxide Varistor (MOV) technology to IEC
60099-4.
(v)
The surge protection must be designed with a minimum 20 percent protection
margin for an insulation lightning impulse level not exceeding 95 kV and
assume a typical discharge current of no less than 20kA when taking into
account the distance effects of any connecting leads.
(vi)
The surge arrester Uc shall be selected for an impedance earthed 11kV
nominal voltage system with a minimum safety margin of 16%.
(vii)
Protective bird covers are to be installed on all live and exposed surge
arrester terminals.
(viii)
All live 11kV down leads to surge arrestors and transformer terminals are to
be of an insulated type designed for use on 11kV systems.
Metal structures.
(i)
All metal structures in the substation are to be earthed.
(ii)
All metal structures must be hot dipped galvanised.
(iii)
All fasteners must be galvanised or 316 stainless steel.
Miscellaneous Power and Lighting (MP&L)
(i)
MP&L must be installed to the requirements of AS3000.
(ii)
MP&L is to be supplied from the spare switch in the adjacent Contractors’
Amenities Distribution Board.
(iii)
MP&L requirements are:
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
C5288
25 of 116
s)
t)
(A)
Sufficient lighting for night-time substation inspection, operating,
isolation and earthing activities;
(B)
A minimum of two 240V socket outlets; and
(C)
A 100A three-phase outlet with neutral.
(iv)
Lighting must be controlled by a photocell to ensure operation of lights only at
night.
(v)
Lighting fittings must be Stahl 2 x 18W fluoro or 2x 36W fluoro energy efficient
fitting with electronic ballast (Delta part numbers: DE58271, DE58272). This
can be provided free-issue to The Contractor.
(vi)
The required 100A three phase outlet is Clipsal WCFSP5100-EC switched
socket outlet, Fuse/Switched, 500V, 100A, 5 Round Pin, 3 Pole and Neutral,
Corrosion Resistant.
Transformer bund.
(i)
The transformer bund is to be constructed according to the requirements of
AS2067 and Clause 5.8 and Appendix H of AS1940-2004.
(ii)
The capacity of the bund must be at least 133% of the total oil volume of the
transformer.
(iii)
The Contractor must install the transformer on a concrete plinth so that the
transformer’s steel base / mountings are kept above typical levels of
accumulated rainwater.
Substation security fence and gate.
(i)
The substation security fence must contain a single pedestrian gate.
(ii)
The substation fence must be constructed in accordance with The Principal’s
Standard DES324847. Refer to drawing DES324847.
(iii)
The substation gate must be constructed in accordance with Pedestrian Gate
Type G5 of The Principal’s Standard DES324846. Refer to drawing
DES324846.
(iv)
A pad bolt may be used to secure the gate.
(A)
The padbolt must be welded to a mounting plate.
(B)
The mounting plate must be welded to the gate frame.
(C)
The padbolt must locate inside a hole in the fence post.
(D)
A padlock will be provided free-issue by The Principal.
(v)
Finished fences will be true to line and grades and will not follow the lesser
irregularities of the surface in ungraded areas.
(vi)
A three (3) metre clearance of trees shrubs and undergrowth from the centre
line as depicted will be maintained where directed.
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
C5288
26 of 116
(vii)
Small surface irregularities along the route will be evened out by levelling and
filling and any obstacles such as large rocks and tree stumps will be removed
and disposed of in a manner approved by The Principal.
(viii)
Tree stumps that are within the stated line will be ground below the surface if
they are deemed to interfere with the works.
(ix)
Posts will be set vertically in concrete and will be uniformly spaced (at
intervals not exceeding three (3) metres) unless shown otherwise.
(x)
Concrete work will generally be in accordance with AS1480, and the concrete
will meet the strength requirements stated on the relevant layout drawings.
(xi)
Horizontal concrete surfaces will be struck off and finished with sponge float
class U2 finish.
(xii)
All corner posts and strainer posts will have double bracing stays.
(xiii)
Posts will have backstays only when indicated on the layout drawings or as
advised by The Principal.
(xiv)
All wires will be taut and standard chain link stretching equipment must be
used.
(xv)
Chain wire will be fastened to cable wires and posts in a continuous length
and will be spliced only at posts, except where minor repairs are required.
(xvi)
Ties will be spaced approximately 250mm centres and will consist of three (3)
complete turns of tie wire with ends fully twitched and laid flat.
(xvii)
Barbed wire will be fastened to posts with two (2) turns of wire through each
hole or indent.
(xviii)
Fences shall generally be in accordance with AS1725 “Galvanised rail less
chain wire security fence and gates with components to AS1074, AS1450 and
AS2423.
(xix)
Components
(A)
Posts must be galvanised mild steel plain end tubes and caps will be
fitted to all posts.
(B)
50 mm nominal size (60.3mm OD, 3.6mm wall thickness) for corner,
end, strainer posts and intermediate posts.
(C)
32 mm nominal size (42.4mm OD, 3.6mm wall thickness) for top and
bottom rails, diagonal braces and stays.
(xx)
All fittings including nuts and bolts must be galvanised.
(xxi)
Support Cables must comprise of 2 strands of 3.15mm diameter heavily
galvanised wire to form a uniform 50mm mesh with top selvedge twisted and
barbed. UPVC coated chain wire must only be used where specified (3.15mm
Galvanised core).
(xxii)
Tie Wire must be 2mm diameter heavily galvanised, UPVC where specified.
(xxiii)
Barbed Wire must be 2.5mm heavily galvanised 4 point barbs at nominal
90mm centres.
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
C5288
27 of 116
u)
4.11
(xxiv)
Fabrication - Members must be saw cut, bent to shape, welded if required and
the welds fully sealed and ground smooth. Fillet welds must not be less than
6mm and all welding must be in accordance with AS1554 part 1.
(xxv)
Where the galvanised coating has been broken due to fabrication,
modification or site welding, drilling or damage, the exposed surface must be
treated as soon as possible with epoxy paint.
Phase out.
(i)
Prior to final connection of the 6.6/11kV substation to the feeder and
energisation The Contractor, to the satisfaction of The Principal must identify
the phases of the feeder and confirm that the phase rotation has not been
changed by connecting to the new supply.
(ii)
The Contractor must also confirm that correct phase rotation is maintained
between the 680 and 690 Feeders when they are connected together.
(iii)
The Contractor may be required to take phase measurements with the feeder
connected to the Ausgrid supply prior to disconnection for future comparison.
(iv)
The Contractor must not allow connected loads on the feeder to be subject to
incorrect phase rotation which could be damaging to those connected loads.
6.6kV Circuit Changeover Link Boxes.
a)
The link boxes shall be affixed to the wall in the cable tunnel and located between the
6.6kV Station Switchboard 5 cable penetrations and the conduit openings to the
6.6/11kV 690 Feeder Substation.
b)
The link boxes must consist of three removable links that allow for the changeover of
supply to the 6.6/11kV 690 Feeder Substation between the supply from the 6.6kV
Station Switchboard 3 and the supply from the 6.6kV Station Switchboard 5.
c)
The link boxes must be built to the applicable requirements of AS 62271.
d)
The link boxes must be type tested to the requirements in Clause 6 of AS62271.200.
Note that an IAC classification is not required although the link boxes should employ
suitable venting through a sealed rupture disc type arrangement suitable for the
expected phase-phase fault level.
e)
The link boxes must be mounted as close as possible to the cable tunnel ceiling.
f)
The links must provide electrical clearance of any disconnected portion sufficient for
safety isolation.
g)
The link for each phase must be enclosed in its own link box. The three link boxes must
mounted separately on the cable tunnel wall.
h)
All conductors comprising the link boxes must be made of tinned copper.
i)
The copper links must be of solid tinned copper. Laminated copper will not be accepted.
j)
Copper links must be installed by bolting. Copper links must have closed bolt holes
requiring the affixing nut to be completely removed from the bolt before the link can be
removed.
k)
Requirements for bolting at links:
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
C5288
28 of 116
(i)
Bolts or studs must be of 304 or 316 grade stainless steel;
(ii)
The threads of bolts or studs must be lubricated prior to bolting of the links;
(iii)
Bolts or must be of standard metric sizes;
(iv)
Design torque must be in accordance with Table B1 of AS62271.301;
(v)
The joints must be of the general form shown in drawing VX837912;
(vi)
The Belleville washer must be an HDS type load washer applicable to the bolt
size according to DIN 6796. Belleville washers for sizes M10, M12 and M16
can be made available as free-issue to The Contractor on request;
(vii)
Mudguard washers of appropriate thickness and diameter are to be
employed. Mudguard washers for sizes M10, M12 and M16 can be made
available as free-issue to The Contractor on request; and
(viii)
The bolting must allow for easy disconnection from the front of the link box
when the cover is removed. Sufficient clearance must be afforded to allow for
the use of a standard spanner to hold the bolt whilst the nut is being removed.
l)
The link boxes must be earthed to a local earth bar in the cable tunnel. The Contractor
must extend the earth bar as required. Earthing conductor size and the securing of
conductors must be adequate to withstand all prospective fault current levels at the
location including phase to phase faults.
m)
A portable earth attachment shall be attached to each of the conductors on the 690
Substation side of the links (three in total). The portable earth attachments must be a
CATU MT 3952/1 or CATU 3950/35 earth ball attachment (refer to CATU Earth
Ball.pdf). These attachments shall reside inside each of the link boxes.
(i)
n)
The link boxes must have removable covers to allow for the changeover of link position.
(i)
o)
The same type earth ball attachment shall be located outside the three link
boxes and connected to earth to allow for the earthing of each outgoing phase
of the cable to the 6.6/11kV 690 Feeder Substation.
Each cover must have a viewing window through which the position of each
link can be easily seen without ambiguity.
The Link boxes must have Trafolite labels identifying the following:
(i)
Circuit description;
(ii)
The phase designation of each link box; and
(iii)
The identification of each cable entry and link terminal.
Trafolite labels shall be attached with mounting screws and not rely entirely on
adhesive for their attachment. The labels must not be placed on removable covers.
p)
Required ingress protection rating: IP56.
q)
The link boxes must not be made from cast metal.
r)
As the cable tunnels are subject to salt water ingress from time to time the link boxes
must be constructed of either stainless steel or galvanised mild steel.
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
C5288
29 of 116
4.12
6.6kV Cable from the 6.6kV Station Service Switchboard 5 to the 6.6kV Circuit Changeover link
boxes.
a)
The Contractor is required to supply and install a three phase 6.6kV cable from the
6.6kV Station Services Switchboard 5 on existing and new cable tray (as required) in
the cable tunnel to the new 6.6kV Circuit Changeover Link Boxes.
b)
The cable must consist of three single cables (one per phase.)
c)
The cable must employ a wire screen and be able to carry the required fault rating of
the installation.
d)
The Contractor must carry out all installation, termination, slab penetration, switchboard
augmentation works, restoration of firestopping and all other necessary works
associated with the cable
e)
The supplied cable shall meet the requirements of AS/NZS 1429.1 2006
f)
The minimum required rated voltage of the cable is Category C voltage designation
6.35 /11 (12)kV of AS/NZS1429.1 2006
g)
Following installation and with terminations applied, the cable shall be tested as follows
and The Contractor must employ The Principal’s High Voltage Test Contractor to
conduct these tests.
(i)
Insulation resistance at 1kV DC at 1 minute. The measurement shall be
conducted between each phase and the earthed cable screens one phase at
a time.
(ii)
50Hz AC applied withstand test of 7.2 kV r.m.s for 15 minutes between each
phase conductor and the earthed screens.
The Contractor is responsible to make good, at The Contractor’s expense, any failure
of the cable to pass tests on site.
h)
Where a termination requires an aluminium to copper joint, the appropriate bi-metal
lugs must be used
i)
At the 6.6kV Station Switchboard 5 end, the cable must be connected to the Oil and Grit
Standby Circuit. Refer to VX837356 for the single line diagram of the 6.6kV Station
Switchboard 5, VX837371/1/2 for the schematic diagram of the existing Oil and Grit
Standby Circuit and VX801300 for the Power Station single line diagram. Requirements
include but are not necessarily limited to:
(i)
The Contractor must penetrate the concrete floor under the terminal chamber
as required;
(ii)
Cable screens are to remain in place up to the inside of the terminal chamber.
The screen wires near the termination are to be twisted together and crimped
to an earth cable which must be earthed at the earth bar within the circuit
chamber;
(iii)
Raychem terminations rated to the same insulation level as the cable must be
applied following the manufacturer’s approved method;
(iv)
The cables must connect to the same busbars as the outgoing cables for the
Oil and Grit Standby circuit. The Contractor must attach suitable connecting
flanges to the busbar as required;
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
C5288
30 of 116
(v)
A portable earth attachment must be attached to each phase of the
connecting busbars (three in total). The portable earth attachments must be
CATU MT 3952/1 or CATU 3950/35 earth ball attachment. The earth ball
attachments must be located as close as possible to the rear cover of circuit
chamber;
(vi)
Another earth ball attachment must be located on the earth bar inside the
circuit chamber to allow for the earthing of the each outgoing phase of the
circuit. The earth ball attachment must be located as close as possible to the
rear cover of circuit chamber;
(vii)
Removal and replacement of the existing combined protection and metering
resin cast CTs with ones of rating appropriate to the increased load
contributed by the feeder circuit. Refer to drawing VX837362/2 for the 6.6kV
Station Switchboard 5 general arrangement showing CT locations and
VX837371/1 for the schematic diagram of the protection circuit. General
information for the existing resin cast CT are provided in GIS 12 resin cast
CT.pdf;
(A)
(viii)
j)
4.13
The metering CT is 200/1A 15VA 0.5M. Icth for the CT has been
confirmed to be 200A which will not be sufficient for the increased load
contributed by the feeder.
Fire stopping must be installed and reinstated as required.
At the link box end the requirements include but are not necessarily limited to:
(i)
Cable screens are to remain in place up to the inside of the link box. The
screen wires near the termination are to be twisted together and crimped to
an earth cable which must be earthed inside the link box; and
(ii)
Raychem terminations rated to the same insulation level as the cable must be
applied following the manufacturer’s approved method.
6.6kV Cable from the 6.6kV Station Service Switchboard 3 to the 6.6kV Circuit Changeover link
boxes.
a)
An existing 240mm2 aluminium XLPE cable consisting of three individual cables has
been run between station switchboards 3 and 5. The cable ends are located in the
cable tunnel under each switchboard.
b)
The Contractor is required to join additional lengths to each end as required to
terminate to the specified locations.
c)
The cable must be made to connect the 6.6kV Station Services Switchboard 3 to the
new 6.6kV Circuit changeover link boxes. New and existing cable tray is to be used as
required.
d)
Although the cable has already been run, The Contractor is responsible for
appropriately laying and securing the cable to the cable tray along its entire length.
e)
The cable must consist of three single cables along its entire length.
f)
The cable must employ a wire screen and able to carry the required fault rating of the
installation.
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
C5288
31 of 116
g)
The Contractor must carry out all installation, termination, slab penetration, switchboard
augmentation works, restoration of fire stopping and all other necessary works
associated with the cable.
h)
The supplied cable shall meet the requirements of AS/NZS 1429.1 2006.
i)
The minimum required rated voltage of the cable is Category C voltage designation
6.35 /11 (12)kV of AS/NZS1429.1 2006.
j)
Following installation and with terminations applied the cable shall be tested as follows.
The Contractor must employ The Principal’s High Voltage Test Contractor to conduct
these tests.
(i)
Insulation resistance at 1kV DC at 1 minute. The measurement shall be
conducted between each phase and the earthed cable screens one phase at
a time.
(ii)
50Hz AC applied withstand test of 7.2 kV r.m.s for 15 minutes between each
phase conductor and the earthed screens.
The Contractor is responsible to make good, at The Contractor’s expense, any failure
of the cable to pass tests on site.
k)
Where a termination requires an aluminium to copper joint, the appropriate bi-metal
lugs must be used.
l)
At the 6.6kV Station Switchboard 3 end, the cable must be connected to the Coal
Bunkering Substation Duty Supply Circuit. Refer to VX837357 for the single line
diagram of the 6.6kV Station Switchboard 3, VX837382/1/2 for the schematic diagram
of the Coal Bunkering Standby Supply Circuit and VX801300 for the Power Station
single line diagram Requirements include but are not necessarily limited to:
(i)
The Contractor shall penetrate the concrete floor under the terminal chamber
as required
(ii)
Cable screens are to remain in place up to the inside of the terminal chamber.
The screen wires near the termination are to be twisted together and crimped
to an earth cable which can be earthed at the earth bar within the circuit
chamber.
(iii)
Raychem terminations rated to the same insulation level as the cable must be
applied following the manufacturer’s approved method
(iv)
The cables must connect to the same busbars as the outgoing cables for the
Coal Bunkering Substation Duty Supply Circuit. The Contractor must attach
suitable connecting flanges to the busbar as required
(v)
A portable earth attachment must be attached to each phase of the
connecting busbars (three in total). The portable earth attachments shall be
CATU MT 3952/1 or CATU 3950/35 earth ball attachment. The earth ball
attachments must be located as close as possible to the rear cover of circuit
chamber
(vi)
Another earth ball attachment shall be located on the earth bar inside the
circuit chamber to allow for the earthing of the each outgoing phase of the
circuit. The earth ball attachment must be located as close as possible to the
rear cover of circuit chamber
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
C5288
32 of 116
(vii)
Removal and replacement of the existing combined protection and metering
resin cast CTs with ones of rating appropriate to the increased load
contributed by the feeder circuit. Refer to drawing VX837395/2 for the 6.6kV
Station Switchboard 3 general arrangement showing CT locations and
VX837382/1 for the schematic diagram of the protection circuit. General
information for the existing resin cast CT are provided in GIS 12 resin cast
CT.pdf
(A)
(viii)
m)
4.14
The metering CT is 400/1A 15VA 0.5M. Icth for the CT has been
confirmed to be 400A which will not be sufficient for the increased load
contributed by the feeder
Fire stopping must be installed and reinstated as required
At the link box end the requirements include but are not necessarily limited to:
(i)
Cable screens are to remain in place up to the inside of the link box. The
screen wires near the termination are to be twisted together and crimped to
an earth cable which must be earthed inside the link box; and
(ii)
Raychem terminations rated to the same insulation level as the cable must be
applied following the manufacturer’s approved method.
6.6kV Cable from the 6.6kV Circuit Changeover link boxes to the 6.6/11kV 690 Feeder
Substation.
a)
The Contractor is required to supply and install a three phase 6.6kV cable from the new
6.6kV Circuit Changeover Link Boxes to the 6.6/11kV 690 Feeder Substation on
existing and new cable tray in the cable tunnel and via new and existing conduits. Refer
to VX306408 – Proposed 6.6kV Cable Routes.pdf and Const Sub B Conduits.pdf.
b)
The cable must consist of three single cables (one per phase).
c)
The cable must employ a wire screen and be able to carry the required fault rating of
the installation.
d)
The Contractor must carry out all installation, termination, excavation, installation of
cable trays, laying of conduit, ground survey (for other buried services) and all other
necessary works associated with the cable.
e)
The supplied cable must meet the requirements of AS/NZS 1429.1 2006.
f)
The minimum required rated voltage of the cable is Category C voltage designation
6.35 /11 (12)kV of AS/NZS1429.1 2006.
g)
Following installation and with terminations applied the cable shall be tested as follows.
The Contractor must employ The Principal’s High Voltage Test contractor to conduct
these tests.
(i)
Insulation resistance at 1kV DC at 1 minute. The measurement shall be
conducted between each phase and the earthed cable screens one phase at
a time.
(ii)
50Hz AC applied withstand test of 7.2 kV r.m.s for 15 minutes between each
phase conductor and the earthed screens.
The Contractor is responsible to make good, at The Contractor’s expense, any failure
of the cable to pass tests on site.
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
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33 of 116
4.15
h)
Where a termination requires an aluminium to copper joint, the appropriate bi-metal
lugs must be used.
i)
At the link box end the requirements include but are not necessarily limited to:
(i)
Cable screens are to remain in place up to the inside of the link box. The
screen wires near the termination are to be twisted together and crimped to
an earth cable which must be earthed inside the link box; and
(ii)
Raychem terminations rated to the same insulation level as the cable must be
applied following the manufacturer’s approved method.
11kV Cable from the 690 11kV Substation to 690 Feeder Pole 110
a)
b)
The Contractor must connect the 690 Feeder 6.6/11kV Substation to the 690 Feeder by
one of the following options. The Option employed will be at the discretion of The
Principal.
(i)
Option 1 - Utilising the existing cable between the existing Construction
Substation B and Pole 110.
(ii)
Option 2 - Supplying and installing a new underground cable between the 690
Feeder Substation and Pole 110.
(iii)
Option 3 - Supplying and installing wooden poles and overhead conductors
between the 690 Feeder Substation and Pole 110 with an under-road cable.
Option 1 - Utilising the existing cable between the existing Construction Substation B
and Pole 110.
(i)
Previous insulation resistance and conductor resistance measurements taken
by The Principal indicate that the cable may be serviceable as the supply
cable for the 690 feeder.
(A)
Phase conductor resistance between the Construction Substation B
and 690 Feeder Pole 110: 11.4 milliohm per phase.
(B)
Screen resistance between the Construction Substation B and 690
Feeder Pole 110: 50.6 milliohm.
(C)
Armour resistance between the Construction Substation B and 690
Feeder Pole 110: 76.6 milliohm.
(D)
Screen to Armour resistance between the Construction Substation B
and 690 Feeder Pole 110: 49 milliohm.
(E)
All measurements were made from Construction B substation.
(ii)
Reuse of the cable will be ultimately at the discretion of The Principal.
(iii)
The cable leaves the Construction Substation B as a PILC triplex cable and
emerges at Pole 110 as three separate cables of another material indicating
that there is a buried cable joint somewhere along the cable’s length. The
location of the cable joint is unknown.
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
Vales Point Power Station
C5288
34 of 116
(iv)
Prior to any work being undertaken to utilise this cable The Contractor must
conduct the following tests on the cable. The Contractor must employ The
Principal’s High Voltage Test Contractor to conduct these tests.
(A)
Insulation resistance at 1kV DC at 1 minute between all phases and the
earthed cable screens.
(B)
50Hz AC applied withstand test of 12 kV r.m.s for 15 minutes between
each phase conductor and the earthed screens.
(C)
Confirmation of the conductor resistances outlined in Clause 4.15 b) (i).
(D)
Note that the HV tests will require the earths on the cable at Pole 110 to
be temporarily disconnected and the 690 Feeder to be isolated; note
restrictions in Clause 4.23 a).
If the test results from the above tests are to the satisfaction of The
Principal then The Contractor may proceed to use the cable and conduct
the works listed below.
(v)
(vi)
Objective ID No. D1385418
Rev: 7 December 2016
Refurbishment works:
(A)
The Contractor must disassemble, refurbish and remake and protect
from further corrosion the cable armour to pothead connection at the
substation end
(B)
The missing cable serving at the Substation end shall be replaced by
the following method:
(1)
Cable saddles on the pole are to be removed.
(2)
The cable is to be excavated until the intact portion of the
serving can be found or at least 500mm below the ground
level. Note that this ground level refers to the final ground level
of soil at the base of the pole and does not include the depth of
any surfacing materials that may be ultimately applied such as
crushed rock or concrete.
(3)
Raychem CRSM cable wraparound repair sleeve heatshrink
with hot melt adhesive is to be used to cover and protect the
exposed cable armour from the depth of the excavation to the
pothead connection.
(4)
The armour to pothead connection is to be suitably protected
from further corrosion.
(5)
New saddles are to be installed and the cable backfilled.
The Contractor is required to earth the cable screens and armour at both ends
of the cable.
(A)
At the substation end the earth down lead from the pothead is to be
replaced with a new earth wire for connection to the substation earth.
(B)
At Pole 110 the existing route of the earth down lead is to be
straightened so as to provide a direct path to earth. The down lead
must be covered with a timber batten or polymeric cover to a height of
2.44m above ground. The existing one may be used if serviceable.
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(vii)
c)
Cable surge protection must be provided at both ends of the cable.
(A)
At Pole 110 connections between the surge arrestors and the cable
phases and screen must be of the shortest possible conductor length.
(B)
At the substation The Contractor may either connect the surge
arrestors close to the cable termination or close to the transformer as
required by The Contractor’s design and other requirements of this
specification. The Contractor shall employ the shortest possible lead
length in either case.
(C)
The surge arrestors must be of Metal Oxide Varistor (MOV) technology
to IEC 60099-4.
(D)
The surge protection must be designed with a minimum 20 percent
protection margin for an insulation lightning impulse level not exceeding
95 kV and assume a typical discharge current of no less than 20kA
when taking into account the distance effects of any connecting leads.
(E)
The surge arrester Uc shall be selected for an impedance earthed 11kV
nominal voltage system with a minimum safety margin of 16%.
(F)
The existing silicon carbide arrestors are to be removed and disposed
of by The Contractor.
(G)
Protective bird covers are to be installed on all live and exposed surge
arrester terminals.
(H)
All live 11kV down leads to surge arrestors and transformer terminals
are to be of an insulated type designed for use on 11kV systems.
Option 2 - Supplying and installing a new underground cable between Construction
Substation B and Pole 110.
(i)
The Contractor is required to supply and install an underground three phase
11kV cable from the 690 Feeder Substation to 690 Feeder Pole 110.
(ii)
The cable may consist of a single multicore cable or multiple runs of single
core cable.
(iii)
The cable must employ a wire screen and able to carry the required fault
rating of the installation.
(iv)
The Contractor must carry out all installation, termination and excavation and
ground survey (for other buried services) works associated with the cable.
(v)
The supplied cable shall meet the requirements of AS/NZS 1429.1 2006.
(vi)
The minimum required rated voltage of the cable is Category C voltage
designation 12.7 /22 (24)kV of AS/NZS1429.1 2006.
(vii)
Following installation with terminations applied the cable shall be tested as
follows. The Contractor must employ The Principal’s High Voltage Test
Contractor to conduct these tests.
(A)
Objective ID No. D1385418
Rev: 7 December 2016
Insulation resistance at 1kV DC at 1 minute. For single core cable the
measurement shall be conducted between each phase and the earthed
cable screens one phase at a time. For a multicore cable the insulation
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resistance measurement shall be conducted between all phases and
the earthed cable screens in one measurement.
(B)
50Hz AC applied withstand test of 12 kV r.m.s for 15 minutes between
each phase conductor and the earthed screens.
The Contractor is responsible to make good, at The Contractor’s expense, any
failure of the cable to pass tests on site.
(viii)
d)
The underground cable must be installed to the requirements of 3.11 of
AS3000 subject to the following:
(A)
The installation must be a Category A classification according to
Clause 3.11 of AS3000;
(B)
A direct buried cable must not be installed unless it is sheathed
armoured and served;
(C)
The section of the cable under the roadway must not be direct buried;
and
(D)
Minimum installation depth below finished ground level must be
750mm.
(ix)
The Contractor is required to earth the cable screens and armour at both ends
of the cable.
(x)
Cable surge protection must be provided at both ends of the cable with the
shortest possible conductor length between phase connections and screen.
(A)
The surge protection must be of Metal Oxide Varistor (MOV)
technology to IEC 60099-4.
(B)
The surge protection must be designed for a lightning impulse level not
exceeding 95 kV and assume a typical discharge current of no less
than 20kA when taking into account the distance effects of any
connecting leads.
(C)
The surge arrester Uc shall be selected for an impedance earthed 11kV
nominal voltage system with a minimum safety margin of 16%.
(D)
The existing silicon carbide arrestors are to be removed and disposed
of by The Contractor.
(E)
Protective bird caps are to be installed on all live surge arrester
terminals.
Option 3 - Supplying and installing wooden poles and overhead conductors between
the 690 Feeder Substation and Pole 110.
(i)
The Contractor must provide and install all poles and accessories for the
installation including the stringing of conductors.
(ii)
The Contractor must install stay poles and stay wires wherever there is a
change of direction at a pole. This also applies to existing poles that are
reused Cover-guards must be installed on all stay wires.
(iii)
The overheads must not be run over the roadway.
Objective ID No. D1385418
Rev: 7 December 2016
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(iv)
4.16
The requirements for the under-road cable are the same as those for Option
2.
Pole Mounted 11kV Auto-Recloser.
a)
Option 1 – Electronic auto-recloser with core balance CT for earth fault protection.
(i)
The feeder is to be segregated by a pole mounted auto-recloser located at
680 Feeder Pole 224. Refer to Pole disc 680 Feeder Pole 224.jpeg for a
photograph of the pole disc for Pole 224.
(ii)
The auto-recloser must be of the vacuum operated type.
(iii)
The auto-recloser must provide for indication of its open/closed status from
ground level.
(iv)
The auto-recloser must be electronically controlled with an electronic
protection system capable of implementing the protection scheme outlined in
Clause 4.18 d).
(v)
The auto-recloser must have configurable reclose settings and shall be
configured for one reclose attempt following a fault before locking out if the
fault has failed to clear.
(vi)
The auto-recloser protection and controls must be housed in a lockable
weatherproof enclosure located at ground level for easy in-service access. A
pole mounted cabinet is acceptable.
(vii)
All auxiliary power requirements for the protection and control are to be
provided for. Auxiliary power must be sourced from the 11kV supply side of
the auto-recloser.
(viii)
The auto-recloser panel must include a 10A 240V socket outlet for the
purpose of future protection relay testing. Supply to the socket outlet must be
sourced from the 11kV supply side of the auto-recloser.
(ix)
The auto-recloser protection must have a backup battery supply that allows
for the protection relay to be interrogated for tripping information in the case
where a fault event has caused loss of supply.
(x)
The auto-recloser protection relay must provide the following trip information
in stored values as a minimum:
(A)
Current date and time;
(B)
Logged time of events;
(C)
Protection operation events (i.e. tripping); and
(D)
Protection pick up events.
(xi)
As a minimum the auto-recloser system must include a set of two line CTs for
overcurrent protection and a low ratio core balance CT for sensitive earth fault
protection.
(xii)
11kV Isolating switch. The Contractor has the option to supply either:
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
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b)
(A)
An auto-recloser with integral air break isolating switch operable from
ground level with an operating stick or from ground level with a lockable
operating handle; or
(B)
Maintenance to the currently unserviceable air break switch 45032
located downstream of the proposed auto-recloser location. The
Contractor must restore the switch to a working condition and
demonstrate its satisfactory function to The Principal.
(xiii)
The required insulation level for the auto-recloser and any associated 11kV
ancillary equipment is: Um = 12kV, Lightning impulse withstand voltage: 95kV
peak, AC withstand voltage: 28kV r.m.s.
(xiv)
Surge arrestors must be installed on both supply side and load side of the
auto-recloser.
(A)
The surge protection must employ the shortest possible lead length
between the surge arrestor and the earthed auto-recloser frame.
(B)
The surge protection must be of Metal Oxide Varistor (MOV)
technology to IEC 60099-4.
(C)
The surge protection must be designed with a minimum 20 percent
protection margin for an insulation lightning impulse level not exceeding
95 kV and assume a typical discharge current of no less than 20kA
when taking into account the distance effects of any connecting leads.
(D)
The surge arrester Uc shall be selected for an impedance earthed 11kV
nominal voltage system with a minimum safety margin of 16%.
(E)
Protective bird covers are to be installed on all live and exposed surge
arrester terminals. Where applicable bird covers must also be installed
on the auto-recloser bushings.
(xv)
All live 11kV down leads to surge arrestors and recloser bushings are to be of
an insulated type designed for use on 11kV systems.
(xvi)
The auto-recloser must be earthed at the base of the pole. The earth down
lead must be covered with a timber batten or polymeric cover to a height of
2.44m above ground.
(xvii)
All requirements of Clause 4.18 d) apply.
Option 2 – Auto-recloser without core balance CT for earth fault protection.
(i)
The feeder is to be segregated by a pole mounted auto-recloser located at
680 Feeder Pole 224. Refer to Pole disc 680 Feeder Pole 224.jpeg for a
photograph of the pole disc for Pole 224.
(ii)
The auto-recloser must be of the vacuum operated type.
(iii)
The auto-recloser must provide for indication of its open/closed status from
ground level.
(iv)
The auto-recloser must be capable of implementing the overcurrent protection
scheme outlined in Clause 4.18 d) (i).
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
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4.17
(v)
The auto-recloser must have configurable reclose settings and shall be
configured for one reclose attempt following a fault before locking out if the
fault has failed to clear.
(vi)
If any auxiliary power requirements are applicable, auxiliary power must be
sourced from the 11kV supply side of the auto-recloser.
(vii)
As a minimum the auto-recloser system must include a set of two line CTs for
overcurrent protection.
(viii)
11kV Isolating switch. The Contractor has the option to supply either:
(A)
An auto-recloser with integral air break isolating switch operable from
ground level with an operating stick or from ground level with a lockable
operating handle; or
(B)
Maintenance to the currently unserviceable air break switch 45032
located downstream of the proposed auto-recloser location. The
Contractor must restore the switch to a working condition and
demonstrate its satisfactory function to The Principal.
(ix)
The required insulation level for the auto-recloser and any associated 11kV
ancillary equipment is: Um = 12kV, Lightning impulse withstand voltage: 95kV
peak, AC withstand voltage: 28kV r.m.s.
(x)
Surge arrestors must be installed on both supply side and load side of the
auto-recloser.
(A)
The surge protection must employ the shortest possible lead length
between the surge arrestor and the earthed auto-recloser frame.
(B)
The surge protection must be of Metal Oxide Varistor (MOV)
technology to IEC 60099-4.
(C)
The surge protection must be designed with a minimum 20 percent
protection margin for an insulation lightning impulse level not exceeding
95 kV and assume a typical discharge current of no less than 20kA
when taking into account the distance effects of any connecting leads.
(D)
The surge arrester Uc shall be selected for an impedance earthed 11kV
nominal voltage system with a minimum safety margin of 16%.
(E)
Protective bird covers are to be installed on all live and exposed surge
arrester terminals. Where applicable bird covers must also be installed
on the auto-recloser bushings.
(xi)
All live 11kV down leads to surge arrestors and recloser bushings are to be of
an insulated type designed for use on 11kV systems.
(xii)
The auto-recloser must be earthed at the base of the pole. The earth down
lead must be covered with a timber batten or polymeric cover to a height of
2.44m above ground.
(xiii)
The applicable requirements of Clause 4.18 d) apply.
11kV Feeder Connections and Disconnections
The Contractor must provide the following options. The Options employed will be at the
discretion of The Principal.
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
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a)
b)
Option 1 – Refer also to VX807320 – 680 and 690 Feeder Connection Options.pdf.
(i)
Join 680 Feeder Pole 10 to 690 Feeder Pole 23.
(ii)
Disconnect and remove the section of conductor between 680 Feeder poles 7
and 9. The Contractor must provide a stay for Pole 9.
(iii)
Disconnect and remove the section of conductor between 680 Feeder Poles 2
and 3.
(iv)
Disconnect and remove the section of conductor between the 680 Metering
Pole 1 and 680 Feeder Pole 2.
(v)
Disconnect and remove the section of conductor between the 690 Feeder
Pole 14 and the Ausgrid Zone Substation.
(vi)
Join 680 and 690 Feeders together between 690 Feeder Pole 14 and 680
Feeder Pole 2.
(vii)
Remove and dispose of the metering equipment from pole 690 Feeder Pole
15 and apply bridges across the metering connections.
(viii)
Disconnect and remove the droppers on Pole 234 that connect the 680
Feeder to the Ausgrid Backup Supply Metering Pole 82613.
Option 2 - Refer also to VX807320 – 680 and 690 Feeder Connection Options.pdf.
(i)
Join 680 Feeder Pole 10 to 690 Feeder Pole 23.
(ii)
Disconnect and remove the section of conductor between 680 Feeder poles 7
and 9. The Contractor must provide a stay for Pole 9.
(iii)
Join 680 Feeder Pole 3 to either 690 Feeder Pole 15 or 16. The Contractor
must provide stays to these poles as required.
(iv)
Join 680 Feeder Pole 4 to 680 Feeder Pole 223. The Contractor must provide
additional stay(s) to Pole 223. The Contractor must provide a stay at Pole 4 if
required.
(A)
When making this connection The Contractor must consider the future
connection of a supply for the proposed ash and dust pumping station
at 680 Feeder Pole 223. This will be either an underground cable
connection or overhead connection.
(B)
The Contractor must clear any vegetation required to facilitate the
connection between Pole 4 and Pole 223.
(v)
Disconnect and remove the section of conductor between 680 Pole 3 and 680
Metering Pole 1.
(vi)
Disconnect and remove the section of conductor between 680 Metering Pole
1 and 680 Pole 223.
(vii)
Disconnect and remove the section of conductor between the 680 to 690
connection at either 690 pole 15 or 16 and the Ausgrid substation.
(viii)
Remove pole 222.
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
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(ix)
c)
Option 3 – Option 3 may be undertaken if Option 1 or Option 2 is exercised.
(i)
d)
f)
(i)
Remove 680 Feeder Pole 2.
(ii)
Remove 690 Feeder Pole 14.
Option 6 – Install stays at Wyee Conveyer Substation Poles.
Install stays at the Wyee Conveyer Substation poles 11 and 24 and tension to
prevent further leaning of the poles.
Option 7 – Option 7 may be undertaken if Option 1 is exercised.
(i)
4.18
Remove the conductors on the redundant section of the 680 Feeder between
poles 3 and 7. The Contractor may take possession of the removed
conductors.
Option 5 – Option 5 may be undertaken if Option 2 is exercised.
(i)
g)
Disconnect from the Ausgrid substation 680 Feeder metering Pole 1 and
remove and dispose of Pole 1 and the metering equipment.
Option 4 – Option 4 may be undertaken if Option 1 or Option 2 is exercised.
(i)
e)
Disconnect and remove the droppers on Pole 234 that connect the 680
Feeder to the Ausgrid Backup Supply Metering Pole 82613.
Straighten 680 Feeder Pole 222.
Electrical Protection
Requirements for the protection schemes are provided below. Protection schemes must be fit
for purpose and follow good design practice. The proposed arrangement of the protection
schemes is outlined in Single Line Diagram of Proposed Power and Protection Circuits.pdf.
a)
Protection for Oil and Grit Standby / 690 Feeder Substation Combined Circuit
requirements:
(i)
At 6.6kV Station Switchboard 5, modification to the settings of the existing
SEL 751 A overcurrent and earth fault relay to suit the additional feeder load
on the circuit. For existing settings refer to Station Board 5 Oil and Grit
Standby Transformer Protection Settings.pdf. Refer also to schematic
diagram for the existing protection in VX837371/1.
(ii)
Reconfigure the SEL 751 A relay to accept the second 11kV Neutral CT input
and provide a second definite time neutral earth fault scheme. The scheme
must be capable of being set low enough to pick up at a 1A primary fault level.
The existing earth fault scheme for the 6.6kV system may be implemented
through the relay’s “calculated residual facility” or a replacement card
obtained with the additional IG input. The Neutral CT input must be wired
through slide links in the same panel as the relay.
(iii)
The existing CT and relay combination has a nominal secondary current of
5A. It is unlikely that a 5A nominal secondary current will allow for sufficient
sensitivity of the 11kV definite time neutral earth fault scheme as minimum
pickup is 0.5A. For example, if using a 10/1 neutral CT, a 5A card will not
allow for pickup levels below 5A primary fault current. To overcome this the
tender may consider the following:
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
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(A)
Change the CT input card on the relay to one with a 1A nominal input
card for the IN element.
(B)
Change the CT input card on the relay to one with the sensitive IN
option (e.g. Inom = 50mA) and use a neutral CT at the transformer with
a larger turns ratio.
(C)
Retain a 5A nominal input and use an interposing CT to increase the
current available at the relay from the neutral earthing CT.
(iv)
Tripping and CBF intertripping shall be the same as that already installed on
the relay.
(v)
Configure an additional alarm contact on the relay for the following:
(A)
11kV Feeder Earth Fault (Protection 2).
(vi)
The Contractor must run the cable for the above alarm and terminate to the
Station Electrical DCS Cubicle 1T20-01. The required cable is a 2 Pair + Drain
0.5mm2 twisted and screened PVC/PVC Dekoron instrumentation cable
(Delta part number: CC67002). DCS configuration work will be done by The
Principal. This cable can be provided free-issue to The Contractor (refer to
Clause 4.24).
(vii)
Commissioning must include but may not necessarily be limited to:
Objective ID No. D1385418
Rev: 7 December 2016
(A)
By secondary current injection at the CT links local to the panel or the
existing Siemens test blocks test for correct relay operation of the 6.6kV
overcurrent and residual earth fault schemes;
(B)
By secondary injection at the CT links local to the panel test for the
correct operation of the 11kV Protection 2 Neutral Earth Fault scheme;
(C)
By primary current injection into the No. 2 Protection 11kV neutral CT at
the 6.6/11kV 690 Feeder Substation, confirm expected current
measurement on the protection relay display. The primary injection may
be carried out as follows:
(1)
If the neutral earthing CT is an external CT, by connecting the
primary injection leads on either side of the CT’s primary
conductor or by running a loop of wire through the CT’s
aperture;
(2)
If the neutral CT is internal to the 6.6/11kV transformer, the
excitation current through the transformer neutral during the
induced test at 1.1 times rated voltage may be used as the
injection current. Measured HV test current multiplied by the
CT ratio can then be compared against the reading on the
relay’s display;
(D)
Test for the correct operation of tripping and CBF intertripping signals
by confirming operation of the required circuit breakers at the 6.6kV
switchboards. Note that this will require the switchboard out of service
and needs to be scheduled in advance.
(E)
Test for correct receipt of the alarms at the DCS.
(F)
When the circuit is placed into service check the relay’s display for the
correct current indication.
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b)
Protection for Coal Bunkering Duty Substation / 690 Feeder Substation Combined
Circuit requirements.
(i)
At 6.6kV Station Switchboard 3, modification to the settings of the existing
SEL 751 A overcurrent and earth fault relay to suit the additional feeder load
on the circuit. For existing settings refer to Station Board 3 Coal Bunkering
Duty Substation Protection Settings.pdf.
(ii)
Reconfigure the SEL 751 A relay to accept the second 11kV Neutral CT input
and provide a second definite time neutral earth fault scheme. The scheme
must be capable of being set low enough to pick up at a 1A primary fault level.
The existing earth fault scheme for the 6.6kV system may be implemented
through the relay’s “calculated residual” facility or a replacement card
obtained with the additional IG input. The Neutral CT input must be wired
through slide links in the same panel as the relay.
(iii)
The existing CT and relay combination has a nominal secondary current of
5A. It is unlikely that a 5A nominal secondary current will allow for sufficient
sensitivity of the 11kV definite time neutral earth fault scheme as minimum
pickup is 0.5A. For example, if using a 10/1 neutral CT, a 5A card will not
allow for pickup levels below 5A primary fault current. To overcome this the
tender may consider the following:
(A)
Change the CT input card on the relay to one with a 1A nominal input
card for the IN element;
(B)
Change the CT input card on the relay to one with the sensitive IN
option (e.g. Inom = 50mA) and use a neutral CT at the transformer with
a larger turns ratio; and
(C)
Retain a 5A nominal input and use an interposing CT to increase the
current available at the relay from the neutral earthing CT.
(iv)
Tripping and CBF intertripping shall be the same as that already installed on
the relay.
(v)
Configure an additional alarm contact on the relay for the following:
(A)
11kV Feeder Earth Fault (Protection 2.)
(vi)
The Contractor must run the cable for the above alarm and terminate to the
Station Electrical DCS Cubicle 1T20-01. The required cable is a 2 Pair + Drain
0.5mm2 twisted and screened PVC/PVC Dekoron instrumentation cable
(Delta part number: CC67002). DCS configuration work will be done by The
Principal. This cable can be provided free-issue to The Contractor (refer to
Clause 4.24).
(vii)
Commissioning must include but may not necessarily be limited to:
Objective ID No. D1385418
Rev: 7 December 2016
(A)
By secondary current injection at the CT links local to the panel or the
existing Siemens test blocks test for correct relay operation of the 6.6kV
overcurrent and residual earth fault schemes;
(B)
By secondary injection at the CT links local to the panel test for the
correct operation of the 11kV Protection 2 Neutral Earth Fault scheme;
(C)
By primary current injection into the No. 2 Protection 11kV neutral CT at
the 6.6/11kV 690 Feeder Substation, confirm expected current
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measurement on the protection relay display. The primary injection may
be carried out as follows:
c)
(1)
If the neutral earthing CT is an external CT, by connecting the
primary injection leads on either side of the CT’s primary
conductor or by running a loop of wire through the CT’s
aperture; and
(2)
If the neutral CT is internal to the 6.6/11kV transformer, the
excitation current through the transformer neutral during the
induced test at 1.1 times rated voltage may be used as the
injection current. Measured HV test current multiplied by the
CT ratio can then be compared against the reading on the
relay’s display.
(D)
Test for the correct operation of tripping and CBF intertripping signals
by confirming operation of the required circuit breakers at the 6.6kV
switchboards. Note that this will require the switchboard out of service
and needs to be scheduled in advance.
(E)
Test for correct receipt of the alarms at the DCS.
(F)
When the circuit is placed into service check the relay’s display for the
correct current indication.
690 Feeder Protection Scheme Requirements:
(i)
A new wall mounted protection panel is to be supplied and installed by The
Contractor in the 6.6kV Station Switchboard 5 switch room.
(ii)
Power supply to the new protection panel must be 110V DC. The Contractor
must run a cable from the DC Ring Main Panel in the 6.6kV Station
Switchboard 5 switch room (refer to VX837390) and terminate in the new
protection panel. Two red spot style black fuses for the circuit must be
installed on the positive and negative supply and be located in the DC Ring
Main Panel. A DC supply supervision relay must be installed downstream of
the fuses. The Contractor may use 2.5mm2 2C+E 0.6/1kV PVC/PVC power
cable (Delta part number DE30331) which can be provided free issue for the
cable run. Refer to Clause 4.24.
(iii)
Protection is to be provided by an SEL 751 A relay installed in the protection
panel and connected to the 11kV Line CTs and one of the Neutral Earthing
CTs at the new 690 Feeder Substation.
(iv)
An IEC Extremely Inverse Overcurrent and Highset Overcurrent scheme fed
from the 11kV line CTs appropriately graded between the downstream
overcurrent scheme at the auto-recloser, HV fuses at the substations supplied
by the feeder and two combined circuits that can be selected to feed the
scheme from either station switchboard 3 or 5.
(v)
A Definite Time Earth Fault scheme fed from the 11kV Neutral CT
appropriately graded with the downstream Instantaneous Earth Fault scheme
that the auto-recloser. Note that due to the low earth fault level, a residually
connected earth fault scheme will not be accepted.
(vi)
The Buchholz trip signal from the 6.6/11kV 690 Feeder Substation
Transformer is to be wired as a digital input to the SEL 751 A protection relay.
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
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(vii)
Circuit Breaker Fail (CBF) protection current checked by the SEL 751 A relay
and inter-tripping to the 6.6kV Station Switchboard 5. This must be
implemented in the same way as the existing CBF protection that is initiated
by the Oil and Grit Standby / 690 Feeder Combined Circuit Protection. Current
Checked.
(viii)
Circuit Breaker Fail (CBF) protection current checked by the SEL 751 A relay
and inter-tripping to the 6.6kV Station Switchboard 3. This must be
implemented in the same way as the existing CBF protection that is initiated
by the Coal Bunkering Duty Substation / 690 Feeder Combined Circuit
Protection. Current Checked.
(ix)
A set of CT changeover links for the second neutral CT must be provided in
the panel to allow for the CT current from the second Neutral Earthing CT to
be sent to either 6.6kV Station Switchboard 3 or 6.6kV Station Switchboard 5.
The changeover links must also include a shorting link at the incoming
terminals to allow the CT to be temporarily shorted during a changeover.
(x)
All incoming CT and VT connections must be connected through slide links.
(xi)
The scheme must be capable of clearing all faults at any point on the 11kV
feeder subject to the grading requirements of the downstream auto-recloser.
(xii)
The scheme must trip the circuit breaker on Station Switchboard 5 for the Oil
and Grit Standby / 690 Feeder Combined Circuit.
(xiii)
The scheme must trip the circuit breaker on Station Switchboard 3 for the
Coal Bunkering Duty Substation / 690 Feeder Combined Circuit.
(xiv)
The relay must include the option for analogue outputs, connection of the 3
phase 11kV VT and be set up so that the following signals can be sent to the
DCS:
(xv)
Objective ID No. D1385418
Rev: 7 December 2016
(A)
11kV feeder current as measured by the relay from the 11kV line
overcurrent protection CTs. The average current of the measured
phases should be used;
(B)
11kV Feeder line – line voltage as measured from the 11kV VT. The
average voltage of the measured phases should be used;
(C)
11kV real power in kW as determined by the relay’s two-watt-metermethod power calculation from the 11kV VT and 11kV overcurrent CT
inputs; and
(D)
11kV reactive power in kVAr as determined by the relay’s two-wattmeter-method power calculation from the 11kV VT and 11kV
overcurrent CT inputs.
The relay must provide separate alarm contacts for communicating the
following alarms to the DCS:
(A)
11kV feeder earth fault;
(B)
11kV feeder overcurrent;
(C)
6.6/11kV 690 Substation Transformer Buchholz trip;
(D)
Protection relay failure;
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(xvi)
The supply supervision relay must send the following alarm to the DCS:
(A)
110V DC supply failure.
(xvii)
The analogue signals and alarms must be cabled to the DCS using 12 Pair +
Drain 0.5mm2 twisted and screened PVC/PVC Dekoron instrumentation
cable (Delta part number: CC67012). The Contractor must run the cable and
terminate to the Station Electrical DCS Cubicle 1T20-01. This cable can be
provided free-issue to The Contractor (refer to Clause 4.24). DCS
configuration work will be done by The Principal.
(xviii)
All trips, intertripping and alarm signals must be hardwired to their destination
and each outgoing trip must have its own trip link in the protection panel. The
Contractor must provide for all necessary cabling and termination.
(xix)
Each of the following outgoing trips must have their own trip link and be wired
to the 6.6kV Station Switchboard 5:
(A)
(B)
Trip to the circuit breaker for the Oil and Grit Standby / 690 Feeder
Combined Circuit on the 6.6kV Station Switchboard 5; and
CBF trip to 6.6kV Station Switchboard 5 Buszone;
The Contractor must use a 2.5mm2 8C+E Control Cable (Delta part number:
DE30359) for the cable run. This cable can be provided free-issue to The
Contractor (refer to Clause 4.24).
(xx)
Each of the following outgoing trips must have their own trip link and be wired
to the 6.6kV Station Switchboard 3:
(A)
Trip to the circuit breaker for the Coal Bunkering Duty Substation / 690
Feeder Combined Circuit on the 6.6kV Station Switchboard 3; and
(B)
CBF trip to 6.6kV Station Switchboard 3 Buszone.
The Contractor must use a 2.5mm2 8C+E Control Cable (Delta part number:
30359) for the cable run. This cable can be provided free-issue to The
Contractor (refer to Clause 4.24).
(xxi)
The Contractor may use mutlitrip relay(s) for tripping and/or intertripping if
there are insufficient contacts on the protection relay.
(xxii)
The Contractor must run a separate cable to the 6.6kV Station Switchboard 5
for the second neutral CT circuit from the changeover links. The Contractor
must use a 2.5mm2 4C+E Control Cable (Delta part number: DE30359) for
the cable run. This cable can be provided free-issue to The Contractor (refer
to Clause 4.24).
(xxiii)
The Contractor must run a separate cable to the 6.6kV Station Switchboard 3
for the second neutral CT circuit from the changeover links. The Contractor
must use a 2.5mm2 4C+E Control Cable (Delta part number: DE30358) for
the cable run. This cable can be provided free-issue to The Contractor (refer
to Clause 4.24).
(xxiv)
All terminations are to be via heavy duty pre insulated ring type or lip type
crimp lugs. Only screw type spring loaded (such as Weidmueller SAK type) or
stud terminals are allowed.
Objective ID No. D1385418
Rev: 7 December 2016
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(xxv)
All incoming CT and VT connections and all outgoing trips must be wired
through Phoenix slide links with integral 4mm ‘banana plug’ style sockets on
each side of each link.
(xxvi)
General requirements for the new SEL 751 A relay are as follows:
(xxvii)
(A)
Relay setting and operation monitoring shall be via front key pads and a
connected personal computer with menu-guided software;
(B)
The front panel LEDs shall be configured to indicate protection
operated status and be appropriately labelled;
(C)
Storage of fault data and instantaneous values during a fault for fault
recording and event recording with GPS time stamping;
(D)
Continuous monitoring of the measured values and the hardware and
software of the relay;
(E)
Provision for communication with the switchboard’s central control and
storage devices via serial interfaces;
(F)
The SEL 751-A is to be provided with a single isolated 10/100BASE-T
Ethernet copper port (Port 1) and an isolated EIA-485 serial port (Port
3).
(G)
Communication cables:
A CAT6E Ethernet cable to be run from the new SEL751A
relay to 6.6kV Switchboard 5 Communications Cubicle (CQ2)
patch panel PP001. An additional CAT6E Ethernet cable is
required between patch panel PP002 and the SEL-2730M
Managed Ethernet Switch;
(2)
A serial cable is to be run between 6.6kV Station Switchboard
5 Panel-9 (668) and the new protection panel. The RS485
serial connection to SEL751A relay in 6.6kV Station
Switchboard 5 Panel-9 (668) is to be modified to complete the
serial connection from the SEL 3530 to the new SEL751A
protection relay;
(3)
A coaxial cable is to be run between 6.6kV Station
Switchboard 5 Panel-9 (668) and the new protection panel.
The coaxial connection in 6.6kV Station Switchboard 5 Panel-9
(668) is to be modified to complete the coaxial connection from
the SEL 2407 to the new SEL751A protection relay;
(4)
Communication and time settings for the new protection relay
will be provided by The Principal; and
(5)
Refer VX837414 – Switchboard 5 Communication Block
Diagram & Termination Diagram.
Commissioning must include but may not necessarily be limited to:
(A)
Objective ID No. D1385418
Rev: 7 December 2016
(1)
By secondary current injection at the CT links local to the panel test for
correct relay operation of the 11kV overcurrent and No. 1 Protection
neutral earth fault schemes;
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(B)
d)
By primary current injection into the No. 1 Protection 11kV neutral CT at
the 6.6/11kV 690 Feeder Substation, confirm expected current
measurement on the protection relay display. The primary injection may
be carried out as follows:
(1)
If the neutral earthing CT is an external CT, by connecting the
primary injection leads on either side of the CT’s primary
conductor or by running a loop of wire through the CT’s
aperture OR;
(2)
If the neutral CT is internal to the 6.6/11kV transformer, the
excitation current through the transformer neutral during the
induced test at 1.1 times rated voltage may be used as the
injection current. Measured HV test current multiplied by the
CT ratio can then be compared against the reading on the
relay’s display.
(C)
Test for the correct operation of tripping and CBF intertripping signals
by confirming operation of the required circuit breakers at the 6.6kV
switchboards.
(D)
Test for correct operation of the supply supervision relay.
(E)
Test for correct receipt of the alarms at the DCS.
(F)
When the circuit is placed into service check the relay’s display for the
correct feeder current, feeder voltage, feeder power and feeder reactive
power indication. Check for the correct receipt of these analogue
signals at the DCS.
11kV Auto-Recloser Protection Scheme Requirements.
(i)
An IEC Extremely Inverse Overcurrent and Highset Overcurrent scheme fed
from the recloser’s line CTs appropriately graded against the HV fuses at the
substations supplied by the feeder.
(ii)
An Instantaneous Earth Fault scheme fed from the recloser’s core balance
CT. Note that due to the low earth fault level, a residually connected earth
fault scheme will not be accepted.
(iii)
Commissioning must include but may not necessarily be limited to:
Objective ID No. D1385418
Rev: 7 December 2016
(A)
By secondary current injection at the CT links local to the panel test for
correct relay operation of the 11kV overcurrent and earth fault
schemes;
(B)
By primary current injection into the core balance CT on the autorecloser, confirm expected current measurement on the protection relay
display and operation of the earth fault protection;
(C)
Test for the correct tripping of the auto-recloser;
(D)
Test for the correct operation of auto-reclose and lock-out sequence;
and
(E)
When the circuit is placed into service check the protection relay’s
display for the correct feeder current indication.
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4.19
Additional surge protection.
a)
Additional surge protection to be supplied / installed at the following locations:
(i)
680 Feeder Pole 277 (at the junction of the Ash Dam return water spur);
(ii)
RV 2-3 Substation;
(iii)
RV 3-4 Substation;
(iv)
RV 4-5 Substation;
(v)
Return water system substation; and
(vi)
Ash Dam Substation.
b)
At the RV 2-3, 3-4 and 4-5 substations, The Contractor must change the existing design
of the surge arrestor placement such that the surge arresters are earthed directly onto a
transformer tank mounted bracket. This is required to minimise the lead length between
surge arrestor and transformer bushing and between surge arrestor and transformer
tank. Refer to Typical substation requiring lightning modification.jpeg.
c)
Silicon carbide type surge arrestors have recently been replaced with MOV surge
arrestors at RV 2-3, 3-4 and 4-5 substations. The replacement surge arrestor employed
is Hubble Power Systems PDV65-Optima Rating: 9kV / Catalogue number: 217258.
The Contractor must confirm this arrestor type’s suitability for reuse subject to the
requirements of Clause 4.19 f).
d)
The cable connections on the pole at the Return Water Substation and the Ash Dam
Substation currently have no surge protection. The Contractor must install new surge
arrestors at these locations. Refer to Cable connection at Return Water Substation
.jpeg and Cable connection at Ash Dam Substation.jpeg.
e)
The Contractor shall install surge arrestors at 680 Feeder Pole 277 and an appropriate
earth at the base of the pole for connection of the arrestors. The earth downlead must
be covered with a timber batten or polymeric cover to a height of 2.44m above ground.
Refer to 680 Feeder Pole 277.jpeg.
f)
General requirements for the surge arrestors include:
(i)
The surge protection must be of Metal Oxide Varistor (MOV) technology to
IEC 60099-4;
(ii)
The surge protection must be designed for a lightning impulse level not
exceeding 95 kV and assume a typical discharge current of no less than 20kA
when taking into account the distance effects of any connecting leads;
(iii)
The surge arrester Uc shall be selected for an impedance earthed 11kV
nominal voltage system with a minimum safety margin of 16%;
(iv)
The existing silicon carbide arrestors are to be removed and disposed of by
The Contractor;
(v)
Protective bird covers are to be installed on all live surge arrester terminals;
and
Objective ID No. D1385418
Rev: 7 December 2016
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(vi)
4.20
Additional on-site commissioning and testing requirements for Current Transformers.
a)
Insulation resistance of the primary winding (where applicable) after 1 minute at 2.5kV
DC.
b)
Insulation resistance of the secondary winding after 1 minute at 1kV DC.
c)
Secondary winding resistance.
d)
Excitation test by AC voltage injection into the secondary winding to determine actual
magnetic knee point and corresponding excitation current. The results must be
compared with nameplate values.
e)
Insulation resistance of CT secondary wiring between CT and protection relay after 1
minute at 1kV DC.
f)
CT secondary wiring loop resistance test (including CT winding resistance) from
protection relay
g)
These requirements are applicable to the following CTs:
h)
4.21
All live 11kV down leads to surge arrestors, transformer terminals are to be of
an insulated type designed for use on 11kV systems.
(i)
11kV line CTs at the 6.6/11kV 690 Substation
(ii)
The two neutral CTs at the 6.6/11kV 690 Feeder Substation
(iii)
The replacement resin cast protection/metering CTs for the Oil and Grit
Standby and Coal Bunkering Duty Substation combined circuits at 6.6kV
station switchboards 3 and 5
(iv)
The line CTs of the 11kV auto-recloser
(v)
The core balance CT of the 11kV auto-recloser
Failure of the CTs to pass tests or meet excitation requirements must be made good by
The Contractor at The Contractor’s expense.
Testing requirements for factory FRA test and on-site FRA test.
a)
A separate Injection Lead is to apply a swept frequency over the range of 20Hz –
2MHz.
b
A Reference Lead is to be a coaxial cable of characteristic impedance 50 ohms
terminated to 50 ohms at the instrument.
c)
A Measurement Lead is to be a coaxial cable of characteristic impedance 50 ohms
terminated to 50 ohms at the instrument.
d)
The transformer tank is to be earthed.
e)
The measurement system earth is to be made by earthing each coaxial screen to the
transformer tank. The transformer tank earthing point shall be a common point to which
all FRA earths are made. To prevent ground loops, the measurement system earth
must not be made at the instrument.
Objective ID No. D1385418
Rev: 7 December 2016
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f)
A Magnitude Response measurement is to be carried out on each phase of each
winding.
(i)
(ii)
(iii)
4.22
For the Magnitude Response measurement on a star connected winding:
(A)
The Injection Lead and Reference Lead are to be connected to neutral
with their coaxial screens connected to the tank. The neutral is not to
be earthed; and
(B)
The Measurement Lead is to be connected to the phase under test with
its coaxial screen is to be connected to the tank.
For the winding response measurement on a delta connected winding:
(A)
The Injection Lead and Reference Lead are to be connected to the
bottom end of the phase under test. The neutral of the star connected
winding is not to be earthed. The coaxial screens of the two leads are
to be earthed to the tank; and
(B)
The Measurement Lead is to be connected to the top end of the phase
under test with its coaxial screen connected to the tank.
A transfer response measurement is to be carried out on each phase between
windings:
(A)
The Injection Lead and Reference Lead are to be connected on the
delta winding to the top end of the phase under test and their coaxial
screens are to be connected to the tank;
(B)
On the delta winding, the bottom end of the phase under test to be
earthed; and
(C)
The Measurement Lead is to be connected on the star winding to the
phase under test with the neutral earthed. The coaxial screen of the
lead is to be connected to the tank.
(iv)
Minimum measurement resolution is 1600 points.
(v)
Test data is to be provided in Cigre format.
Specific Safety Requirements for Construction and Maintenance Works on The Principal’s 11kV
Networks.
Works on The Principal site are conducted under The Principal’s safety rules. Works
specific to the 11kV Feeders are to be conducted under The Contractor’s safety rules. A
prospective contractor’s safety rules will be reviewed for adequacy by The Principal
prior to contract award.
a)
.
b)
In addition to the requirements of clauses 8.1 and 8.2, The Contractor (or its
subcontractor’s) must have safe systems or work on high voltage overhead
infrastructure. The Contractor must have:
(i)
A system of electrical safety rules safety rules applicable to overhead
networks;
(ii)
As The Contractor will be managing construction, maintenance, and
maintenance of The Principal’s 11kV network during The Works the contactor
Objective ID No. D1385418
Rev: 7 December 2016
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must have a Network Management Plan conforming with the NSW Electricity
Supply (Safety and Network Management) Regulation 2014;
c)
d)
(iii)
A list of the competency and training requirements of its staff; and
(iv)
A list of The Contractor’s network standards (where applicable).
For work on the 11kV Feeders The Contractor’s safety rules must allow for the following
activities:
(i)
Communicating isolation requirements and obtaining isolation clearance
through The Principal’s Request for Isolation of Apparatus (RIA) system. This
typically covers isolation from Ausgrid’s supply and any low voltage isolations
that Delta operators might carry out to prevent electrical back feed onto the
11kV network from low voltage switchboards;
(ii)
Carrying out switching of The Principal’s 11kV infrastructure for isolation
purposes;
(iii)
Applying access earths and working earths on The Principal’s 11kV
infrastructure for isolation purposes; and
(iv)
Issue of access permits to its own staff for the required construction and
maintenance works.
The Contractor’s safety rules should include but not necessarily be limited to the
following aspects:
(i)
Training and authorisation requirements;
(ii)
Safety equipment;
(iii)
Tools;
(iv)
Operating equipment;
(v)
Protective clothing;
(vi)
Safe working distances;
(vii)
Use of mobile plant / scaffolding, EWPs etc;
(viii)
Hazard assessment;
(ix)
Emergency rescue;
(x)
Emergency procedures;
(xi)
First aid;
(xii)
Access requirements;
(xiii)
Access Permits;
(xiv)
Specific hazards;
(xv)
Operation and switching;
(xvi)
Administrative controls;
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
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4.23
(xvii)
Use of tags and locks;
(xviii)
Proving de-energised;
(xix)
Earthing and short circuiting;
(xx)
Low voltage and high voltage work;
(xxi)
Underground cabling;
(xxii)
Commissioning;
(xxiii)
Cable identification;
(xxiv)
Working on poles and at height;
(xxv)
Barrier tapes;
(xxvi)
Switchyards and substations;
(xxvii)
Disconnection and reconnection;
(xxviii)
Testing;
(xxix)
Operating agreements;
(xxx)
Operating with other authorities;
(xxxi)
Proximity of services belonging to other organisations;
(xxxii)
Administrative forms; and
(xxxiii)
References to applicable legislation, standards, codes of practice (Regulation,
Australian standard, ENA, ISSC, Workover etc).
Programming of Works – In addition to the requirements of Clause 8.5 h) The Contractor must
also consider the following when developing a Works Program.
a)
The two feeders provide critical infrastructure that typically cannot be isolated for more
than one day. General restrictions are:
(i)
Isolation of supply to the 680 Feeder is restricted to Tuesdays and Thursdays
so as not to disrupt the RV conveyer system and consequently Mandalong
Colliery’s operations;
(ii)
Isolation of supply to the Wyee Conveyer system (currently supplied by either
680 or 690 feeders) is restricted to Tuesdays and Fridays do as not to disrupt
Mannering LDO’s operations;
(iii)
Isolation of 690 Feeder is restricted to Sundays due to the requirement to
supply the Morgan Ash dust reclamation plant;
(iv)
Isolations requiring the switching services of Ausgrid at the zone substation
need at least two week notice to arrange. These isolations are subject to
Ausgrid resourcing constraints and should therefore be kept to a minimum;
Objective ID No. D1385418
Rev: 7 December 2016
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4.24
(v)
The Ash Dam return water system can generally be de-energised for up to a
few days however this is dependent on ash dam water levels and isolation of
supply may not be permitted during and after periods of heavy rain;
(vi)
The Vales Point dozer maintenance garage (currently fed from 680 Feeder)
while not a critical load does still require reasonable continuity of supply
however outage periods not lasting more than one day can be arranged with
reasonable notice; and
(vii)
Isolations to the 11kV Feeders typically require The Principal operators to
open the main switches at the low voltage switchboards at some of the
substations due to the presence of UPS systems. This is a requirement under
The Principal Safety Rules.
b)
The Construction Substation B which is the site for the proposed 6.6/11kV 690
Substation is currently disconnected from the 11kV Feeder at 690 Pole 110. Initial
construction work on the substation can progress without any 11kV feeder isolation and
disruption to critical loads.
c)
The Ausgrid supplies will be required up until the date of final connection and
energising of the new 6.6/11kV 690 Feeder Substation in order to maintain supply.
d)
The Contractor is expected to minimise the requirement for 11kV feeder outages as
much as possible.
e)
Commissioning and some construction activities on 6.6kV station switchboards 3 and 5
will require an outage on each board. Such outages can be arranged but will need to
be programmed with sufficient. Due to other operating plant constraints, station
switchboards 3 and 5 cannot both be out of service at the same time.
Control and instrumentation cables available for free issue.
The following cables are available for free issue to The Contactor only for the purposes
explicitly designated in this specification.
Cross Section
2.5mm2
Cores
2C+E
4C+E
8C+E
12C+E
20C+E
25C+E
36C+E
Insulation
Control Cables 2.5mm2
White numbered V90 UV Black
PVC/PVC
Voltage
Stockline
0.6/1kV
DE30357
DE30358
DE30359
DE30360
DE30361
DE30362
DE30363
0.6/1kV
DE30331
Single Phase Power Cables
2C+E
2.5mm2
Red, Black, Green /Yellow
V90 UV Black PVC/PVC
Dekoron Cables 0.5mm2
0.5mm2
1 Pair +D
2 Pair +D
4 Pair +D
8 Pair +D
12 Pair+D
Objective ID No. D1385418
Rev: 7 December 2016
Screened PVC/PVC
DE30137
CC67002
CC67004
CC67008
CC67012
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4.25
4.26
4.27
Spare 6.6/11kV Transformer.
a)
The Contractor must provide the option for a spare transformer for the 6.6/11kV 690
Feeder Substation.
b)
The spare transformer is generally required to meet the requirements of Clause 4.10 e).
c)
The Principal will consider options for a refurbished quality second hand transformer. It
is accepted that acquiring a second hand transformer to the exact requirements of
Clause 4.10 e) is unlikely and in such a case The Principal may remove The
Contractor’s obligation to meet all requirements of Clause 4.10 e), this being at the
discretion of The Principal.
d)
Notwithstanding Clause 4.25 c), a spare transformer must provide for direct change-out
capability with the transformer in the 6.6/11kV Substation without major modification to
the power systems or protection. The Contractor should consider the location of the
required CTs and VTs (i.e. internal or external) and location and types of terminals to
ensure that both transformers are practically interchangeable.
e)
The Contractor is responsible for delivery to Site and placement of the Transformer in
the Vales Point Oil Handling Facility Transformer Bund. The on-site tests required
under Clause 4.10 e) must be carried out at the Vales Point Oil Handling Facility
Transformer Bund.
Control Wiring Numbering and Colours
a)
All control wiring installed by The Contractor must be in accordance with The Principal
Standard DES431762. Refer to drawing DES431762.
b)
Both ends of every wire shall be fitted with approved white non-flammable plastic
ferrules having recessed identifying numbers and/or letters filled with black paint to
correspond with the numbering of wiring diagrams. The numbering system used shall
comply with The Principal’s standard numbering scheme. Each end of the wire shall
use the same wire numbers and/or letters.
c)
All terminals with a voltage exceeding 50VDC or 32VAC must be suitably shrouded and
labelled with a warning.
Drawings to be amended by The Contractor
In addition to the drawings that The Contractor must provide for the new equipment, The
Contractor must also amend the following existing drawings that will be affected by The Works:
Drawing No.
VX801300
VX807320
VX827544
VX837356
VX837357
VX837371_1
VX837371_2
VX837382_1
Title
Vales Point Main & Auxiliary Power System Electrical System Diagram Disaster
Recovery
Power Supplies 11kV Transmission Lines 680, 690 Route Plans
Energy Australia - ZONE NO 133 11KV NETWORK SINGLE LINE DIAGRAM
Units 5 & 6 - 6.6kV Station Switchboard 5 Single Line Diagram
Units 5 & 6 - 6.6kV Station Switchboards 3 & 4 Single Line Diagram
SWITCHBOARD 5, 6.6KV_415V OIL&GRIT TRAP TRANSF (PANEL 7) 671
SCHEMATIC DIAGRAM
SWITCHBOARD 5, 6.6KV_415V OIL&GRIT TRAP TRANSF (PANEL 7) 671
SCHEMATIC DIAGRAM LEGEND
SWITCHBOARD 3 & 4, COAL BUNKERING SUBSTATIN(PANEL 8) 689
SCHEMATIC DIAGRAM
Objective ID No. D1385418
Rev: 7 December 2016
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VX837382_2
VX837390
VX837414
VX807321
VX837364_2
VX837366_1
VX837366_2
VX837384_1
VX837384_2
VX837396_2
VX837407_1
VX837409_1
VX837415_2
VX837441_7
VX837442_8
4.28
SWITCHBOARD 3 & 4, COAL BUNKERING SUBSTATIN(PANEL 8) 689
SCHEMATIC DIAGRAM LEGEND
6.6KV STATION SWITCHBOARD DC RING MAIN PANEL SCHEMATIC
DIAGRAM
SWITCHBOARD 5 COMMUNICATION BLOCK DIAGRAM & TERMINATION
DIAGRAM
Power Supplies 11kV Transmission Line 690 Enlarged View Around Power
Station Route Plan
6.6KV SWITCHBOARD 5 GENERAL SINGLE LINE DIAGRAM
SWITCHBOARD 5, BUS VT (PANEL 1) 669 SCHEMATIC DIAGRAM
SWITCHBOARD 5, BUS VT (PANEL 1) 669 SCHEMATIC DIAGRAM LEGEND
SWITCHBOARD 3 & 4, BUS VT (PANEL 10) 665 SCHEMATIC DIAGRAM
SWITCHBOARD 3 & 4, BUS VT (PANEL 10) 665 SCHEMATIC DIAGRAM
LEGEND
6.6KV SWITCHBOARD 3 & 4 GENERAL SINGLE LINE DIAGRAM
SWITCHBOARD 5 CABLE SCHEDULE DIAGRAM
SWITCHBOARD 3 & 4 COMMUNICATIONS CABLE SCHEDULE DIAGRAM
SWITCHBOARD 3, 4 & 5 COMMUNICATIONS CABLE SCHEDULE DIAGRAM
SWITCHBOARD 5 (PANEL 7) 671 DCS CABLE CONNECTION LIST
SWITCHBOARD 3 & 4 (PANEL 8) 689 DCS CABLE CONNECTION LIST
Design Review.
Prior to construction or placement of orders The Contractor must submit the relevant designs to
The Principal for review. The Contractor will be required to submit the following for the design
review.
4.29
a)
A report detailing The Contractor’s assessment of relevant factors such as those listed
in Clause 4.9 j). The Contractor will be required to present the results of studies that
have been completed in order to confirm that the design will meet requirements.
b)
A protection setting report detailing the settings of new and affected protection systems
to confirm optimal sensitivity, operating time and appropriate grading.
c)
General arrangement drawings and parts list of the 6.6/11kV 690 Feeder Substation
and its elements.
d)
General arrangement drawing of the lightning protection designs for the locations
nominated for augmentation and modification.
Construction General Requirements.
Refer to Annexure 2 of Part 1 for general construction requirements applicable to The Works.
5.0
Pricing Particulars
The Tenderer will note that the required format of the Pricing Schedules will be as shown in the
following table:
Item
The Works
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Schedule
No
Purpose
Applicable Pricing
Clauses
2-1.1
Firm Lump Sum Prices
5.1 ; 5.2
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Total Price
5.1
2-1.2
Schedule of Firm Rates
2-SP
Summary of Prices
5.1 ; 5.3
General
a)
Tenderers must consider carefully the requirements of Table A and shall make full
allowance in the Tender Price for any additional costs including overtime payments for
which The Contractor will or may be liable in order to comply with the stated completion
dates. The Tenderer will submit a proposed program for completion of the Works in the
Part 3 Returnable Schedules.
b)
The Principal reserves the right at any time prior to the Date of Issue of a Letter of
Acceptance, to delete any item(s) included in the Pricing Schedules contained in Part 3
and the Contract Sum will be reduced by the value(s) shown for any such item(s)
deleted.
c)
The Tenderer must complete the Pricing Schedules contained in Part 3 by entering
opposite each labour category or work item offered the Rate/Price and other relevant
pricing information to the extent required to complete the Schedules. The tendered
Rates/Prices will be FIRM i.e. not subject to variation in costs.
d)
The Contractor will have no entitlement to claim any increase in payments under the
Contract in the event of changes to any industrial arrangements/agreements,
(irrespective of whether one or more such arrangements/agreements may require
negotiation, registration and/or implementation).
e)
The Contractor will serve all notices and pay all fees necessary to comply with all
Legislative Requirements and the requirements of all Authorities.
f)
Where The Contractor is obliged under the terms of the Contract to work overtime to
regain program, expedite outage work, or for any other reason covered by the Contract,
this work will be carried out at The Contractor's expense. However, where no such
obligation exists, The Principal will have the right to direct The Contractor to work
overtime. The Contractor must not, in his Tender Price, include any allowance for the
extra costs that may be incurred in complying with any such direction. However, The
Principal will reimburse The Contractor in the following manner;
(i)
The penalty payments for hours worked at the Site by employees of The
Contractor for the purpose of complying with any such directions. The payments
must be reasonable and proper penalty payments paid to the employees
concerned.
(ii)
Payroll Tax and Workers' Compensation insurance premiums paid by The
Contractor which relate to the penalty payments referred to above.
g)
The Contractor must provide each employee with their individual payment/deduction
details on or prior to their recognised pay day.
h)
Where, with the written agreement of The Principal, specialist labour, materials or other
ex-works items not covered elsewhere under the Contract are supplied by a
Subcontractor, whether in the course of Schedule of Firm Rates work or otherwise, then
The Contractor will be reimbursed at the Subcontractor invoiced cost to The Contractor,
for supply of such specialist labour, materials or ex-works items, plus a handling fee,
not to exceed 5% of the Subcontractor’s invoiced cost and which is to be nominated as
a percentage in the Pricing Schedules contained in Part 3. The handling fee must
include for all procurement and other overhead administrative costs, charges, expenses
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and profit.
5.2
i)
The Contractor will note that claims for payment will be the base Subcontractor's
invoice (excluding GST) plus the handling fee. The Subcontractors invoice must be
attached to The Contractors invoice as supporting documentation.
j)
All invoices submitted for payment must have supporting documentation such as
timesheets, approved work directions or other supporting documentation as required by
The Principal. This documentation is applicable when using the Time and Billing
System (TBS) or manual invoicing. For Contracts using the TBS The Contractor and
The Principal will be required to enter into a Recipient Created Tax Invoice Agreement
to meet GST legislative obligations.
k)
The price entered must in all cases be the price of the plant and equipment delivered
and, if so required by the Specification, erected at the Site fully in accordance with the
General Conditions of Contract, Specification, Schedules, Tables, relevant plans and
drawings and the Tender annexed hereto and must include the cost of all royalties and
fees (if any) on patented articles supplied. The price must be deemed to take account
of all charges including engineering and design (other than those specifically stated in
the Specification to be excluded) which may be incurred by The Contractor in carrying
out the work under the Contract.
l)
The Contractor agrees to make available to The Principal all its financial records to
enable The Principal to verify any claim for payment received from The Contractor in
accordance with clause 32 of the General Conditions of Contract. Financial records
include, but are not limited to bank statements, third party invoices and payment
advices, pricing arrangements between The Contractor and suppliers of services
charged to The Principal in connection with a Work Direction and employee timesheets.
Firm Lump Sum Price
The Tenderer must submit a separate firm Lump Sum Price for each item listed in the Pricing
Schedules contained in Part 3 Returnable Schedules for the workscope detailed in Part 1
Clause 4 Particulars of Work. Notwithstanding the breakdown in the Pricing Schedules
contained in Part 3 Returnable Schedules the Tenderer must include for all costs in its total
tender price.
5.3
Schedule of Firm Rates
The Tenderer must complete the pricing schedules in Part 3 Returnable Schedules by
entering opposite each item offered the Rate/Price and other relevant pricing information to the
extend required to complete the schedule.
a)
Where The Principal directs that work under the Contract will be carried out on a
Schedule of Firm Rates basis, the rates charged for hourly labour must allow for all
costs such as, but not limited to profit, overheads, administration, statutory allowances,
all royalties and fees on patented articles, small tools and consumables including
welding consumables, plant and equipment (except where special plant and equipment
is required and is specifically requested, in writing by The Principal), welding machines,
lifting tackle, site establishment and facilities and supervision that is necessary to carry
out the work.
b)
Prior to commencement of work under a Work Direction, The Contractor must supply,
for the approval of The Principal, budget maximum quantities of Schedule of Firm Rates
items, the estimated monetary value of any items at cost plus, and a program for
completion, for the agreed scope of work.
c)
Each work direction submitted for approval to The Principal for items not in the
Schedule of Firm Rates, The Contractor shall obtain at least three competitive
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quotations for the materials or services and shall accept the lowest quotation unless
otherwise directed by The Principal. The Contractor shall supply to The Principal a
certified copy of The Contractors orders which must show all pricing details for checking
purposes. In addition, where the costs of an item will exceed $10,000 The Contractor
must supply evidence of competitive quotations being obtained.
d)
Reasons for continual or repetitive usage of Subcontractors and materials will require
justification to The Principal, and this may result in materials being free issued to The
Contractor by The Principal.
e)
The Contractor will note that as Legislative Requirements provide for the erection of all
temporary guard rails and protection necessary, no separate payments will be made for
the installation, maintenance and subsequent removal of such guard rails and
protection. Where the Contract includes Schedule of Firm Rates items for provision of
guardrails and protection, payment for such items will only be made for supply at the
specific direction of The Principal. Items required by Legislative Requirements must be
provided by The Contractor, independent of the Schedule of Firm Rates, and at no
additional cost to The Principal.
f)
The Contractor must be deemed to have satisfied itself as to the sufficiency of its
Rates/Prices for the work under the Contract. The Contractor must take into account all
its obligations under the Contract and all matters and such things necessary for the
proper completion and maintenance of the work under the Contract and in particular:
(i)
The difficulty and complexity of the work under the Contract;
(ii)
That the time of fixing the Rates/Prices the construction drawings and
construction details we not in existence; and
(iii)
The power of The Principal pursuant to the Contract in relation to the
programming, timing and order of execution of the work under the Contract.
The Rate or Price for an item of work must be deemed to take account of all charges
including engineering and design (other than those specifically stated in this
Specification to be excluded), which may be incurred by The Contractor in complying
with the provision of the Contact in relation to that item. The Rate must also include all
charges for such items of work irrespective of the number of separate times of ordering
required under the Contract in conformity with the approved construction program.
g)
5.4
Reasons for continual or repetitive usage of Subcontractors and materials will require
justification to The Principal, and this may result in materials being free issued to The
Contractor by The Principal.
Quantities
a)
Quantities in the Schedule of Rates are estimated quantities only and are not
guaranteed by The Principal.
b)
The Contractor will not be entitled to an increase in any of the rates in the Schedule of
Rates in the event that the quantity of an item required to perform the Contract is
greater or less than the estimated quantity shown in the Schedule of Rates.
6.0
Requirements
6.1
Responsibilities
a)
The Contractor will be responsible for the design, manufacture, construction,
maintenance, commissioning and Defects Liability of the Works described and the
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performance of all other obligations required by the Specification and Conditions of
Contract.
6.2
6.3
b)
The Contractor must supply all materials, equipment, tools, tackle, labour and services
necessary for the works except where it is stated in the Specification that the materials,
equipment labour or services are to be provided “free issue” by The Principal.
c)
The Contractor must ensure the health, safety and welfare of all its employees,
subcontractors and consultants in accordance with all Legislative requirements. The
Contractor will be required to demonstrate how it intends to manage these obligations in
the documentation described in Clause 8.1 Safety Management Plans.
d)
In addition to the substantive requirements detailed in the specification The Contractor
must abide and follow The Principal’s Site Rules and Procedures. These administrative
procedures are available for inspection during the tender period.
e)
The price provided in the schedules must include all things necessary to complete the
works including all materials, overheads (including administrative), tools, equipment,
labour, scaffolding, welding and grinding consumables and provision of all specialist
equipment and services necessary for the works.
f)
The Contractor will arrange all isolations/restorations of the plant for the works.
g)
The Contractor’s staff and Subcontractors must be appropriately qualified and trained
for the work under the Contract.
h)
The Contractor will put in place the appropriate Site access control procedures to allow
all visitors including The Principal to gain access to site.
i)
The Contractor must keep the Site and the work clean and tidy. The Contractor must
regularly remove rubbish and surplus material.
j)
In the event that The Contractor is unable to perform this obligation and The Principal
incurs any costs, losses or liabilities as a result of this failure, then The Contractor will
indemnify The Principal against such costs, losses or liabilities.
Access and Protection
a)
The Contractor must provide such temporary access and temporary protection to all
equipment to enable safe work to proceed. This temporary work must be to the
satisfaction of The Principal.
b)
The Contractor must make the Works available at all times for inspection by The
Principal.
c)
All work on Site must be carried out in such a manner so as not to obstruct operations
of any other Contractor or the operation of existing plant.
Completion
a)
Up to the Date of Practical Completion of each Portion to achieve practical completion
and during the completion of omissions and defects The Contractor must maintain and
leave the site in a clean and tidy condition.
b)
Before leaving site Contractor must repair and make good all fire stopping areas
disturbed by The Contractor during the contract to The Principal’s Approved Standard
(AS4072.1 and AS1851).
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6.4
c)
All rubbish and material no longer required shall be removed from site. Disposal shall
be in a fashion approved by The Principal.
d)
If The Contractor fails to comply within 24 hours of a written direction issued by The
Principal pursuant to this Clause, the work may be carried out by The Principal and the
total cost to The Principal, of the work, will be a debt due and payable from The
Contractor to The Principal.
e)
Upon completion of the Contract The Contractor must remove from the Site all its
Temporary Works, miscellaneous plant, materials and other things then on the Site but
not forming part of the Works.
Programing of Works
The Contractor will provide The Principal with a Program within the time and in the form
required by the Contract or otherwise directed prior to commencing work under the Contract
and at such other times as may be directed by The Principal.
The Contractor must not, without reasonable cause, depart from a Program.
a)
For the purposes of this Clause, "Work Program" means a program or schedule which
shows how The Contractor proposes to complete the works and any portions of the
works on or before the respective dates for Practical Completion of the works, and
those portions of the works.
b)
Prepare a Work Program which, as a minimum, where applicable, shows:
(i)
The duration and sequence of, and the inter-relationships between, the planned
events and activities which comprise the work under the Contract;
(ii)
A project calendar, clearly denoting which days are work days (allowing for
restrictions on working time and contingencies for which The Contractor is
responsible under the terms of the Contract. This would include but not be
limited to weekends, holidays, Christmas close-down, union designated and
other days off and manufacture and trade delays);
(iii)
The sequence of activities which constitutes the critical path or paths for the
works and for each portion or portions of the works. The critical path works
must be highlighted in red;
(iv)
The sub-network program for each portion or portions of the works and how it
or they relate to the work program for the works;
(v)
Order dates, supply lead time and site delivery dates for all critical and major
items, including those to be supplied by The Principal, as well as details of offsite manufacturing and fabrication activities. This must include both pre-outage
works and outage works;
(vi)
Any constraints outside The Contractor's control which affect the timing of
activities and events;
(vii)
Mobilisation to Site;
(viii)
Appointment of approved Subcontractors and their work program;
(ix)
The preparation of and approval process for all calculations, designs and
documents required;
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6.5
(x)
The time allowed for testing and commissioning of major items of plant or
equipment;
(xi)
The estimated plant and manpower resources and projected productivity rates
for each activity. Specific engineering and trade skills shall be identified under
“resource names” in the program with supporting resource histograms;
(xii)
Any resource, financial, engineering or other logic on which the work program
specifically relies;
(xiii)
The estimated Contract value of work to be done each calendar month
throughout the currency of the Contract;
(xiv)
The differences or divergences from the tender program must be highlighted
and agreed by The Principal prior to establishment of a “base line” for
execution; and
(xv)
Any further requirements stipulated by the Contract or required by The Principal
during the pre-planning phase.
c)
The Contractor must deliver to The Principal a detailed Works Program as per the
Tendering Table at the request of The Principal during the evaluation period. This
program shall form the basis for review and iteration during the pre-planning period.
d)
The Contractor must not, without reasonable cause, depart from a work Program
included in or required under the Contract. Any departure from the works procedure as
programmed must first be discussed with and agreed to by The Principal before
implementation.
e)
If The Principal considers that the current work program cannot be adhered to, The
Principal may request an updated work program. The Contractor must submit an
updated work program within 48 hours of such a request.
f)
The furnishing of a Work Program or an updated Work Program swill not relieve The
Contractor of any obligations under the Contract, including the obligation to not, without
reasonable cause, depart from an earlier Work Program.
g)
Notwithstanding the provision of any other Clause, The Principal’s acceptance of an
updated work Program will not constitute a direction or entitle The Contractor to an
extension of time under Part 2 General Conditions Clause 29.5, or to other relief or
remedy under or in connection with the contract.
Training
a)
The Contractor must provide training in the operation and maintenance of the works to
The Principal and the employees, consultants and agents of The Principal as required
by, and in accordance with this Contract (the cost of which is included in the Contract
Sum).
b)
The training must be designed to ensure that The Principal and the employees,
consultants and agents of The Principal will be able to efficiently, prudently, safely,
reliably and professionally operate and maintain the Works, with no assistance from
The Contractor or the employees, consultants or agents of The Contractor:
(i)
Subject to paragraph (b), from and following the Date of Practical of the
relevant Portion; and
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(ii)
6.6
In the case of those elements of the works that The Contractor is required to
operate and maintain as part of the Services, on and from expiry of the
Services Period.
Risk and Property
The Property in all materials and other things delivered to the site for incorporation in the works
will pass to The Principal upon such delivery but the works will remain at The Contractor's risk
until notification in writing by The Contractor to The Principal that the works have reached
Practical Completion.
7.0
Performance
The Contractor is to undertake all rehabilitation and maintenance works to enable the plant to
operate successfully and meet the performance objectives and service life requirements of the
Contract. That is, all items of work must be completed in a manner that:
a)
Enables the plant to operate for commercial purposes at the completion of the
upgrade and rehabilitation of the works; and
b)
Ensures the plant satisfies all Legislative Requirements.
8.0
Contractor Plans and Information
8.1
Safety Management Plans
The Contract requires:
a)
The OHS Management System must make reference to and address, as a minimum,
the following items:
(i)
General Requirements;
(ii)
OHS Policy;
(iii)
Identification of Hazards, Assessment and Control of Risks;
(iv)
Legal and Other Requirements;
(v)
Objectives and Targets;
(vi)
OHS Management Plans;
(vii)
Resources Management;
(viii)
Responsibility and Accountability;
(ix)
Training and Competency;
(x)
Consultation, Communication and Reporting;
(xi)
Reporting;
(xii)
Documentation, Document and Data Control;
(xiii)
Hazard Identification, Assessment and Control of Risks;
(xiv)
Emergency Preparedness and Response;
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(xv)
Monitoring and Measurement;
(xvi)
Incident Investigation, Corrective and Preventive Action;
(xvii)
Records and Records Management;
(xviii)
OHS Management Systems Audit; and
(xix)
Management Review.
b)
The Contractor must implement and observe the OHS Management Plan reviewed and
accredited by The Principal.
c)
A Site Specific Safety Management Plan which must be submitted, by the date or within
the period stated in Tendering Table is to be completed in Part 3 Returnable
Schedules to The Principal for review and appropriateness to manage the OHS
requirements of the contract works, and showing all information of specifications,
responsibilities, dates of implementation and monitoring processes.
This Plan should be prepared in accordance with requirements prescribed by the New
South Wales Government Guideline for service providers in the construction industry,
“How to prepare Site Specific Safety Management Plans and Safe Work Method
Statements” or Contractor equivalent contingent upon compliance with Delta’s existing
site requirements.
d)
The Site Specific Safety Management Plan must make reference to and address, as a
minimum, the following items:
(i)
Statement of WHS responsibilities;
(ii)
Statement of WHS Policy;
(iii)
Legislative compliance;
(iv)
WHS Consultation processes;
(v)
Risk Management process;
(vi)
Induction and WHS training;
(vii)
Inspection and test;
(viii)
Qualification and licensing;
(ix)
Site emergency procedures;
(x)
Site fire-fighting procedures;
(xi)
Occupational health and safety disputes resolution;
(xii)
Site first aid provisions;
(xiii)
Protective clothing, footwear and personal protective equipment;
(xiv) Incident/injury reporting, management and rehabilitation;
(xv)
Arrangements for workers compensation;
(xvi) Safety officers and safety representatives;
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(xvii) Storage, handling and registration of hazardous substances;
(xviii) Site housekeeping and rubbish removal;
(xix) Work method statements; and
(xx)
8.2
Toolbox talks.
e)
Notwithstanding any Site Specific Safety Management Plan reviewed by The Principal
or included in the Contract, The Contractor must observe and satisfy all its obligations
to its employees and other persons in relation to the health and safety of such
employees and persons whether its obligations are imposed by Contract, by common
law or by legislation.
f)
The Contractor must implement and observe the Site Specific Safety Management Plan
reviewed by The Principal.
g)
The Principal reserves the right to review The Contractor’s performance against the
Specification and/or Site Specific Safety Management Plan. This may be in the form of
Audits or Compliance Checks. These will be undertaken for the benefit of The Principal
and not The Contractor.
Guidelines for Preparing Site Specific Safety Management Plan Documentation
a)
b)
Introduction
(i)
Before the Contract commences, The Contractor must submit Safety
Management plan documentation detailing the WHS systems and procedures
that will apply during the term of the contract. The safety documentation must
reflect the identified hazards and control measures within the known work
scopes.
(ii)
The Principal will review and accredit the Site Specific Safety Management Plan
or appropriate documentation before work under the contract commences.
(iii)
The Contractor's Site Specific Safety Management Plan will form the basis by
which The Contractor’s WHS Management will be audited by The Principal.
Site Specific Safety Management Plan Elements
(i)
Contract Description
The brief description of the work associated with the Contract should be
documented. The description should be sufficiently detailed to give persons
unfamiliar with the Contract an overview of the type of work being carried out,
and under what conditions.
(ii)
The scope of work will include, as a minimum requirement, the following details:
(A)
A summary of major activities and types of work to be performed;
(B)
A list of tasks or specialist procedures that may require detailed WHS
work procedures and training; and
(C)
A list of areas of Contract requiring special consideration from an WHS
perspective, e.g. presence of public, traffic management, work
restrictions (e.g. work times, confined spaces), exposure to hazards
(e.g. noise, dust, elevated heights).
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(iii)
c)
d)
Contract WHS Structure and System
(A)
The Contractor's Site Specific Safety Management Plan will be
established around the organisation’s existing WHS management
systems and associated procedures and controls. Reference will be
made to existing procedures and documentation in the site specific
safety plan.
(B)
The Contractor must outline its management structure, responsibilities,
standards and control systems applicable to the contract to ensure
WHS requirements are adequately addressed. The following
information shall be included:
(1)
The organisation’s WHS policy to be displayed at work sites;
(2)
An outline of the organisation’s WHS structure, i.e. names
and/or positions of those with specific WHS responsibilities;
(3)
Summary of WHS roles and responsibilities of The
Contractor’s staff involved in the contract; and
(4)
The position and/or name of The Contractor’s senior person
who will liaise with the organisation on WHS matters.
Contract Induction and Training
(i)
WHS legislation requires all employers to ensure that their employees have the
skills and training required to carry out their work in a safe manner. The
Contractor must ensure that The Contractor’s document their safety training
program, have appropriately skilled employees, suitable training programs and
adequate supervision for the contract works.
(ii)
The following information will be provided:
(A)
An outline of the Contract induction procedures for employees and
subcontractors;
(B)
The details of induction course content;
(C)
A register of personnel who have satisfactorily completed the Contract
induction;
(D)
The details of employee WHS training which has or will be provided
relevant to the contract requirements; and
(E)
A register of names and/or positions of contract employees who may
be required to supervise or undertake specialist work activity, together
with authorisations, permits, competency certificates, licences etc.
Safe Work Practices and Procedures
(i)
Relevant safe work practices and procedures must, where appropriate, be
developed for the Contract. Where possible, The Contractor’s existing WHS
procedures will be used. Contract specific safe work procedures may need to
be developed on the basis of particular Contract hazards. These may be
identified when undertaking a risk assessment.
(ii)
The following information must be provided:
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e)
(A)
A list of and copies of the organisation’s safe work procedures or
instructions relevant to the Contract;
(B)
A list of and copies of Contract specific safe work procedures or
instructions;
(C)
The details of site operations that will be subject to permit to work
systems;
(D)
The details of employees and/or Subcontractors issued with copies of
safe work procedures and instructions; and
(E)
Safe work procedures and instructions should be recorded on Safe
Work Procedure/Instruction Register.
Risk Management
(i)
Risk Management is an integral part of the Site Specific Safety Management
Plan and considers the following:
(A)
The identified hazards associated with contract tasks and activities;
(B)
The level of risk which has been determined; and
(C)
Appropriate risk control measures which have been established.
(ii)
Each major or significant task or activity associated with the Contract will be
assessed in terms of the associated hazards. When all hazards have been
identified, the most likely outcome as a result of an incident will be determined.
(iii)
A primary goal will be to eliminate significant risks associated with the Contract.
Contractors should detail risk control measures that adequately address all
identified risks. When determining risk control strategies, the hierarchy of risk
controls, summarised below, should be considered:
(A)
Elimination: Stop using the equipment or substance, or stop
undertaking the process, causing the risk (e.g. use mechanised
equipment for handling loads instead of handling them manually);
(B)
Substitution: Use an alternative substance, equipment or process that
poses less risk (e.g. use water based instead of solvent based
substances);
(C)
Isolation: Separate personnel from the source of the risk (e.g. by
putting the operator of noisy equipment in a soundproof booth);
(D)
Engineering controls: Reduce exposure to the risk by making physical
changes to equipment, processes or the work environment (e.g. using
local exhaust ventilation to suck dust or vapours away from workers'
breathing zone);
(E)
Safe work practices: Adopt work procedures that minimise exposure to
the risk (e.g. wet sweeping a dusty environment rather than dry
sweeping it, to minimise the amount of airborne dust);
(F)
Personal protective equipment: Minimise exposure to the risk through
the use of equipment such as ear muffs, goggles, gloves, hard hats
etc. It must be remembered the use of personal protective equipment
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is usually the least effective method of controlling exposure to hazards,
and it should be used only if other methods of risk control are not
practicable or not sufficient; and
(G)
f)
g)
h)
Where safe work procedures or instructions are developed, they must
clearly spell out the work sequence, highlighting the procedures
required to adequately control each risk identified in the risk
assessment. All employees involved in the activity shall receive
appropriate training in the safe work procedure.
OHS Inspections
(i)
OHS inspections play an important role in the identification of hazards at the
workplace and in the development of control measures. The Site Specific
Safety Management Plan must outline the procedures and methods by which
Contract workplaces will be inspected on a regular basis.
(ii)
The following information must be provided:
(A)
The details of how OHS inspections will be undertaken during the
Contract, considering checklists to be used, frequency of inspections,
team members, actioning of inspection findings;
(B)
The details of hazard reporting procedures for the contract, including
hazard report forms; and
(C)
The details of specific activities or areas targeted for inspection, i.e.
plant, hazardous materials, electrical safety.
WHS Consultation
(i)
Consultation with employees provides an important mechanism whereby WHS
issues can be dealt with in a manner that promotes ownership and prompt
resolution.
(ii)
The following information must be documented:
(A)
A list of current employer and employee WHS representatives;
(B)
Details of the membership and operation of the WHS committee; and
(C)
Reference to The Contractor’s issue resolution procedures.
Emergency Procedures
(i)
There is the potential for a range of emergency situations to occur both on site
and off site in relation to contract works. These situations need to be identified
and specific emergency procedures developed and made known.
(ii)
The following information must be documented:
(A)
An overall emergency plan and structure for the Contract;
(B)
A register of emergency equipment and locations, i.e. first aid
equipment, fire extinguishers;
(C)
A register of current qualified first aiders; and
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(D)
i)
j)
Incident Recording and Investigation
(i)
All incidents associated with the Contract involving personal injury, medical
treatment or property damage shall be recorded and investigated.
(ii)
The following must be documented:
(A)
The details of incident reporting and investigation system and
procedures;
(B)
The details of how incidents will be notified to The Contractor’s
organisation and The Principal; and
(C)
The details of how incident statistics are to be compiled and
distributed.
OHS Performance Monitoring
(i)
8.3
Arrangements/coordination with other work site occupants in the event
of an emergency.
The following must be documented:
(A)
The details of how WHS performance statistics associated with the
Contract are reviewed;
(B)
The details of how monthly WHS performance reports will be compiled
for review by The Contractor;
(C)
The nature of WHS performance information presented to employees
on a regular basis; and
(D)
An outline of the auditing program to evaluate Site Specific Safety
Management Plan effectiveness.
Quality Management Plan
a)
The Contractor will plan, establish and maintain a quality system based on ISO 9001 or
an acceptable equivalent. If the works contain a component of construction the system
must comply with the guidelines as set out in HB90.3.
b)
The Contractor must prepare and submit to The Principal for acceptance, a Schedule of
the specific records intended to be maintained for the Contract within the time frame
indicated in Table A.
c)
The Contractor must provide a program for the works, plan and document the
inspections, tests and verifications to be performed by The Contractor and its
Subcontractors.
d)
The Contractor must submit the quality documentation in accordance with the
documentation submission matrix shown in Table E.
e)
Subsequent to the award of the Contract and until Final Completion, The Contractor's
quality system may be subject to audit and surveillance by The Principal. The
frequency and depth of such audit and surveillance will depend on the adequacy of The
Contractors QMS system and The Contractor's performance during the Contract.
f)
Within 4 weeks of the Letter of Acceptance submit a controlled copy of the Quality
Management Plan prepared for the Contract, covering the relevant elements of The
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Contractor’s Quality Management System. Include a description of The Contractor’s
management structure for control of the work (including details of responsibilities and
authorities), and an index of The Contractor’s quality procedures and proposed
Inspection and Test Plans (with associated checklists).
8.4
g)
Implement and maintain the Quality Management Plan. Update the Quality
Management Plan during the course of the Contract. Incorporate the Quality Plan into
all work.
h)
Submit certification that each Subcontractor’s Quality Management Plan and/or ITPs
meet requirements no later than 60 days before work for which they apply commences,
at least covering that work. Do not start that work before the certification is submitted.
Submit monthly certification that the implementation of the quality management plans
and applicable quality management meet the requirements of the Contract. Submit
revisions to the certification following reviews, revisions and amendments.
Environmental and Waste Management Plans
a)
The Contractor will prepare, and issue to The Principal, an Environmental Management
Plan (EMP). The EMP must address as a minimum, the following issues:
(i)
Soil erosion, sedimentation and water quality;
(ii)
Noise and vibration control;
(iii)
Hazards and risks;
(iv)
Waste minimisation and management;
(v)
Indigenous and non-indigenous heritage and archaeology;
(vi)
Hazardous substance and dangerous goods management;
(vii)
Air quality control (including fugitive dust);
(viii)
Flora and fauna management, visual screening and landscaping;
(ix)
Traffic control and access, hours of operation;
(x)
Contaminated soils/acid sulphate soils
(xi)
Incident response;
(xii)
Monitoring, checking and corrective action; and
(xiii)
Complaints management procedure.
b)
The Contractor will undertake all environmental monitoring as required by the EMP.
Monitoring records must be retained by The Contractor and The Principal will be
advised of any non-conformance as soon as it is known.
c)
The EMP must comply with all requirements of statutory/regulatory authorities that may
require specific issues to be addressed by the EMP. The requirements will include the
NSW Environment Protection Authority, the Department of Lands and Water
Conservation (DLWC) and the National Parks and Wildlife Service (NPWS). In the
event of a discrepancy between the EMP and the Conditions of Contract, the
Conditions of Contract will prevail.
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d)
The Contractor must review and revise the EMP on a 6 monthly basis or at the direction
of The Principal to ensure the EMP is in line with current site practices and legislation.
e)
Where The Principal has an environmental plan for the site, The Contractor will also
comply with The Principal’s environmental plan.
f)
As a minimum, The Contractor must comply with the requirements of all relevant
legislation. This will include but not be limited to the following:
(i)
Protection of the Environment Operations Act 1997;
(ii)
Soil Conservation Act 1938;
(iii)
Waste Avoidance and Resource Recovery Act 2001;
(iv)
Ozone Protection Act 1989;
(v)
Water Management Act 2000;
(vi)
Environmental Hazardous Chemicals Act 1985;
(vii)
Native Vegetation Conservation Act 1997;
(viii)
Threatened Species Conservation Act 1995;
(ix)
Fisheries Management Act 1994;
(x)
National Parks and Wildlife Act 1974;
(xi)
OHS Amendment (Dangerous Goods) Act 2003 No 38;
(xii)
Environmental Planning and Assessment Act 1979;
(xiii)
All Applicable State Environmental Planning Policies (SEPP’s);
(xiv)
Relevant Local Environment Plan and Regional Environmental Plan; and
(xv)
Environment Protection and Bio-diversity Conservation Act (EPB and C Act).
g)
In addition, The Contractor must comply with any specific conditions/requirements of
development consent, construction approvals, licenses and Environmental Impact
Assessment/approval documents and any other Approvals. The Contractor will also be
responsible for obtaining all licences and/or approvals unless otherwise stated in the
Contract. The Contractor will be responsible for the payment of fees associated with
such Approvals.
h)
The Contractor will be responsible for the training of all Contract Personnel and
Subcontractors in relation to the requirements of the EMP. Records of such inductions
will be made available to The Principal on request.
i)
The Contractor will inspect the works on a weekly basis to ensure all requirements of
the EMP are met. Any non-conformances to the EMP must be reported to The Principal
on a weekly basis, or immediately in the event of a significant non – conformance.
j)
The Contractor must ensure that adequate facilities and equipment are readily available
to contain, remove and decontaminate affected areas in the case of an accidental spill
or discharge of a pollutant. Such equipment may include but not be limited to oil booms,
oil absorbent pads and sawdust. All oil/fuel contaminated material must be disposed off
site to an EPA licensed facility.
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k)
The Contractor must maintain plant and equipment in proper working order to prevent
the emission of fuels, oils, fume, dust and other objectionable matter into the
environment.
l)
The Contractor must ensure that all fuels, oils and chemicals are stored in an
impervious bunded area. The bunded volume must be sufficient to contain a minimum
of 110% of the total volume of liquids stored. All drums containing fuel must be stored in
a bunded area.
m)
If any pollution incident occurs as a result of an act by The Contractor, The Contractor
must, at no cost to The Principal, comply with all instructions given to The Contractor by
The Principal or any relevant Authority to clean-up the contaminated areas and to
prevent any further pollution. The Contractor will be responsible for the payment of any
fines or charges associated with such incidents. The Contractor must immediately notify
The Principal of any such incident.
n)
The Contractor must take all proper precautions to minimise any nuisance arising from
dust caused by its activities. Such precautions may include but will not be limited to
spraying the roads with water or other suitable liquids, the removal of mud from the
wheels and bodies of hauling equipment before they enter the public roads, and the
removal of mud spilt by equipment on public roads. Washing down of vehicles will only
be conducted in an area approved by The Principal.
o)
The Contractor must keep the clearing of trees, timber and scrub to the absolute
minimum area necessary to conduct its operations in a safe and reasonable manner.
For work within National Parks, including The Principal land, The Contractor must
obtain the written approval of the National Parks and Wildlife Service and The Principal
before removing any trees or vegetation contained within the National Park. The
Contractor must abide by all Local Council tree preservation orders.
p)
At the direction of The Principal, The Contractor will attend meetings to assess the
potential environmental risks of the Works. Such meetings may occur at the
commencement of the Contract or prior to commencement of a new work process. Any
additional actions identified in such meetings must be implemented by The Contractor
and integrated into the Environmental Management Plan at no additional cost to The
Principal.
q)
The Contractor will provide onsite waste and recycling facilities unless otherwise
directed by The Principal. Disposal or recycling of wastes generated by The Contractor
and not included on The Principal's recycling schedule will be the responsibility of The
Contractor. The disposal method and destination for this waste is to be nominated on
The Contractor's Waste Schedule which must be submitted to The Principal prior to the
Date of Possession of Site.
r)
The Contractor must provide a list of major waste streams expected to be generated by
their activities at the Site. This includes the activities of proposed Subcontractors. The
list will include, but not be limited to; lubricants, solvents, hazardous
chemicals/materials, paper, glass, plastics, packaging material, lagging and cladding
material, green waste, used plant components and construction waste. This Schedule
must nominate the collection method and final destination of the waste or recyclable.
s)
All employees of The Contractor and its Subcontractors must be made aware of the
procedures for collection and disposal of waste or recyclables, which are detailed on
The Contractor's Waste Schedule, prior to each employee commencing any work at the
Site. Contractors must maintain a register of staff inducted in waste procedures and
this will be accessible to The Principal’s staff on request.
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8.5
t)
When purchasing goods and/or services on The Principal's behalf The Contractor must
establish the disposal method recommended by the supplier for the product and
packaging. The Contractor must observe any recommendation to recycle or re-use the
product or packaging. Consideration should be given to products that have recycled
content wherever they are cost and performance competitive.
u)
The Contractor must ensure that all waste is disposed of in accordance with the New
South Wales, Environmental Protection Authorities, ”Environmental Guidelines:
Assessment, Classification and Management of Liquid and Non-liquid Wastes.”
v)
Any approach made to a Contractor by a member of the public in relation to the
environmental performance or impact of the power station operations on the
environment is to be regarded by The Contractor as an environmental
complaint/inquiry. An environmental complaint is considered to be an environmental
incident and The Contractor must raise an Environmental Incident Report Form and
alert The Principal in the event of an environmental complaint.
Documentation and Drawings
a)
b)
Tender Documents
(i)
The documents comprising the Tender must be supplied in duplicate in
substantial folders of sheet size 297 mm long by 210 mm wide (A4). Where it is
essential to include a larger size of sheet it will be folded to suit the above.
Drawings must be supplied to normal working scale and bound in soft covered
folders of sheet size not greater than 1189 mm long by 841 mm wide and
complying with metric `A' series drawing sizes. In addition, it is preferred that
for easy reference main drawings will also be provided in a reduced form of
uniform size 297 mm long by 420 mm wide (A3).
(ii)
Each folder must have an index of contents and the pages must be numbered
serially. However, the Specification and other bound brochures may be
identified as individual items.
(iii)
All drawings must be completed strictly in accordance with the requirements of
DES AS 010 - CAD Production (copy available on request).
Notices
The Contractor must supply and deliver to The Principal, two copies of all notices
served in complying with Legislative Requirements and the requirements of Authorities.
c)
Specification Drawings
(i)
The drawings included in and forming part of the Specification are listed in
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TABLE B - DRAWINGS AND DOCUMENTS FOR TENDERING PURPOSES of Part 1.
(ii)
It must be noted that notwithstanding the fact that drawing numbers are shown
without amendment numbers or letters in the body of the Specification, each
drawing included in the Specification will be deemed to have the appropriate
amendment number or letter as detailed in
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TABLE B - DRAWINGS AND DOCUMENTS FOR TENDERING PURPOSES of Part 1.
d)
e)
Quality of Drawing Submissions
(i)
Engineering documents such as drawings, programs, graphs, diagrams,
Schedules, etc. will be forwarded by The Contractor to The Principal and be
suitable for xerographic production and be at full size, in an approved electronic
format.
(ii)
The Principal reserves the absolute right to convert all drawings and documents
to raster format for permanent storage in an image database.
Electronic Copies of Documentation and Drawings
(i)
The Contractor must submit a copy of all drawings, check sheets, reports,
programs, strategies and plans in an electronic format.
(ii)
The electronic information must be provided in Microsoft Office 97 or later
format except for drawing and work programs.
(iii)
Drawings must be supplied in AutoCAD (refer clause 8.5f)) format. Programs
of work and plans must be supplied in Microsoft Project format.
(A)
f)
All CAD drawings must be fully AutoCAD release 2007 (or earlier)
compatible, and be supplied as *.DWG files. All files are to have any
external reference files (XREFs), bound to the drawing and all CAD
files shall have an AutoCAD audit performed and shall be purged of
unnecessary data before submission.
(iv)
It is preferred that the information be transferred electronically via E-mail. The
information can be alternatively supplied on compact disk.
(v)
A document transmittal form of suitable format must be included with all
submissions.
Accepted Contract Drawings
(i)
The Contractor must submit drawings in accordance with The Principal
Corporate Standard DES AS 010 – Standard Procedure for CAD Production or
Modification of Drawings.
(ii)
All accepted drawings will be registered by The Principal in The Principal's
Drawing Management System upon receipt of the registration data from The
Contractor.
(iii)
Immediately design alterations are made, the associated drawings must be
amended accordingly. Where a drawing is amended during the Contract further
copies of the drawing must be submitted within two weeks of such amendment
being made. Such drawings must clearly indicate the extent of the amendment
made and the date on which it was made.
(iv)
All drawings submitted by The Contractor, whether final or preliminary drawings
will be particular to the Contract and will, where applicable, be drawn to scale.
Each drawing must include a reference to the location, Contract No., Unit No., if
applicable, plant item and part concerned for proper identification. Each
drawing must be clearly marked indicating the basis of issue.
(v)
All drawings and subsequent amendments provided under the Contract will be
signed by a responsible representative of The Contractor as checked and
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approved.
(vi)
g)
Manuals
(i)
The equipment supplied under the Contract must be accompanied by operating
and maintenance documentation.
(ii)
The documentation must be functionally grouped and labelled. All
documentation is to be bound by loose-leaf type binder to allow
revisions/updates to be easily incorporated. Each page must include a header
detailing date and revision number of the document.
(iii)
Maintenance drawings, instruction manuals, logic and interconnection diagrams
must relate specifically to the items of equipment supplied.
(iv)
The Contractor will provide six (6) hard copies and one (1) electronic version of
all final manuals.
(v)
The operating section of the manual must describe in detail the procedures for
putting into service, setting and adjusting, checking before and during
operation, routine testing, and operating of all the plant supplied under this
Contract. As far as it is relevant, the procedures will be for normal and
emergency conditions and must cover both manual and automatic modes.
(vi)
The maintenance section of the manual will:
(vii)
h)
Copies of the drawings, manuals, documents supplied by The Contractor will be
the property of The Principal’s and registered within The Principal’s Records
Management System. They must not be used or copied otherwise than for the
use, repair maintenance, rehabilitation or alteration of the works or the
procurement of spare parts for the Works by The Principal its Contractors, SubContractors or agents. The Principal request that copyright, intellectual property
etc. clauses are not placed on any documents provided under the works.
(A)
Describe in detail all procedures for operating and interpreting the
hardware and system software tests/diagnostics;
(B)
Describe in detail The Contractor’s recommended preventative
maintenance including frequency of inspections and guidance in
locating and rectifying faults; and
(C)
Include copies of all drawings referred to in their text together with all
other drawings necessary for a full understanding of the function,
operation, testing and maintenance of the plant.
The hardware section of the manual must provide permit routine maintenance
and fault finding of all items of system hardware. This must include a
component list for all equipment supplied under the contract
(brand/model/number per unit) and manufacturer’s manuals and data sheets for
each item to allow the maintenance/replacement of such items.
Program
The Contractor must submit Programs which detail the manner in which the Works and
the Services will be carried out. Programs will be Critical Path networks and must meet
the following requirements:
(i)
The programs must consist of activities which represent The Contractor's
proposed method of carrying out and completing the works and the Services;
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i)
8.6
(ii)
The programs must be in sufficient detail to enable The Principal to co-ordinate
the activities of The Contractor with the activities of The Principal's staff and
other Contractors;
(iii)
Each program will have milestones which reflect the Table A program
requirements and the KPI evaluation requirements;
(iv)
The programs must include all aspects of the works and the services, planning,
surveys, design, drafting, rehabilitation, installation commissioning and
operation; and
(v)
Programs will, as well as being provided in hard copy be provided as electronic
media in MS Project format. Tenderers that are unable to comply with this must
provide details of any alternative being offered.
Confidential Information
a)
Subject to Clause 8.5, drawings, specifications and other information, samples,
models, patterns and the like and Confidential Information supplied by either
The Contractor or The Principal and marked or otherwise identified as
confidential shall be treated as confidential and shall not be disclosed by The
Contractor or The Principal to a third party except with the prior agreement of
the other party to the Contract.
b)
All detailed plant drawings and operating/ instruction/maintenance manuals
supplied by The Principal are to be treated as confidential by The Contractor
irrespective of being marked confidential or not.
Records
a)
Implement a system to control records to provide a complete verification history of
conformance of the work under the Contract, including procedures for:
(i)
Maintaining records in safe storage until the issue of the payment schedule
issued in response to the Final Payment Claim;
(ii)
Ensuring records are secure against deterioration, damage and loss; and
(iii)
Filing and indexing records so that they are retrievable by all parties who may
need to reference them.
b)
Retain all product and service conformance records as objective evidence of
conformance with the Contract requirements. Include all Subcontractors’ (including
consultants’ and suppliers’) records and certificates. Maintain a register of all quality
records.
c)
Retention Period: Retain all product and service conformance records for a period of
not less than 7 years after Practical Completion.
d)
Submit copies of product and service conformance records as specified, including:
Product/Service Conformance Records
Completed Inspection and Test Plans and
associated checklists (including inspection
and certification of formwork and scaffolding)
Test results obtained from testing
laboratories and the like
Quality or test records obtained from
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Time Records Required
With each Progress Claim as specified, and
when otherwise required by The Principal
With each Progress Claim as specified, and
when otherwise required by The Principal
With each Progress Claim as specified, and
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Product/Service Conformance Records
manufacturers and suppliers
Contractor’s certification of quality
conformance and performance
Operation and Maintenance Manual with
Guarantees
Register of product and service conformance
records
8.7
Time Records Required
when otherwise required by The Principal
With each Progress Claim and when
otherwise required by the Contract
Prior to Practical Completion
Within 14 days of Practical Completion
Inspection and Test Plans
a)
Plan, document and implement the inspection and test activities for all phases of the
work. Prepare Inspection and Test Plans plus any necessary associated checklists in
accordance with the Australian Standard AS9001:2015 Quality Management Systems
Guidelines (QMS Guidelines), incorporating the Hold and Witness points specified in
the Contract. Include special or particular requirements in the acceptance criteria used
to inspect and verify work under the Contract.
b)
The QMS Guidelines are available at:
http://www.construction.nsw.gov.au/cppm/guidelines.html
c)
For each of the activities listed in subclause “Inspection and Test Plan Schedule” below,
submit an Inspection and Test Plan (ITP), plus any necessary associated checklists, to
The Principal at least 14 days prior to Possession of Site, and then submit ITP’s for any
emergency work prior to that work commencing.
d)
Show on each ITP the applicable mandatory “Hold” and “Witness” points listed in
subclause ”Inspection and Test Plan Schedule” below as requiring attendance by The
Principal. Show any mandatory “Hold” or “Witness” points for tests or inspections
required by the Contract to be carried out by The Contractor. Show any mandatory
“Hold” and “Witness” points that are required by statutory authorities. Also show “Hold”
and “Witness” points that are considered necessary for The Contractor to verify the
conformity of work to be carried out by employees and subcontractors.
e)
Describe in the ITPs all work and materials required by the Contract to be inspected or
tested, and by whom and at what stage or frequency.
f)
A “Hold” point (denoted by H on ITPs) is defined as a point beyond which work may
NOT proceed without authorisation by the appropriate party (who may be The Principal,
a statutory authority or The Contractor). Give notice to the appropriate party that the
particular stage of the work will be reached.
g)
A “Witness” point (denoted by W on ITPs) is defined as a point at which a particular
activity, or state of completion or readiness, is to be witnessed by the appropriate party,
but work may proceed past this point if that party fails to attend. Give notice to the
appropriate party. The required notice is 24 hours unless otherwise specified.
h)
In addition to “Hold” and “Witness” points requiring The Contractor’s verification of work
performed, show where work is to be self-inspected by the person performing the work
(denoted by X) and where surveillance (monitoring) will be provided by The Contractor
(denoted by S).
i)
Note that surveillance (monitoring) by The Principal will apply to all work associated
with the Contract not otherwise covered by a “Hold” or “Witness” point. Prepare the
ITPs to reflect this.
j)
The required ITPs must each include any checklists that are necessary to summarise a
number of activities, attributes or standards that need to be verified at a particular
inspection or test.
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8.8
Verification
a)
For each work activity requiring an ITP, divide the required work into “work areas” or
“lots”, each “work area” or “lot” being a discrete section or quantity of the total work
usually defined by location, which, for that activity, will be completed before moving on
to another area.
b)
A copy of the ITP (and associated checklists) for each activity must be assigned to each
work area to allow progressive verification with the inspections and tests carried out.
c)
Checklists must be completed by those who perform or directly supervise the identified
activity.
d)
Nominate experienced personnel who are authorised by The Contractor to verify, by
notation on the ITPs, that the quality of the work inspected or tested is as specified.
e)
The Principal will endorse mandatory “Hold” points, and may endorse “Witness” points,
when attending, at each work area. Such an endorsement will allow The Contractor to
continue with following work but will not release The Contractor from the obligation to
achieve the specified requirements of the Contract.
f)
It is specifically noted that hold points will be programed and enforced for all pressure
welding work including but not limited to:
g)
8.9
8.10
(i)
Welder qualification record;
(ii)
Weld procedure verification;
(iii)
Positive Material Identification;
(iv)
Visual inspection by competent welding supervisor; and
(v)
Non-destructive testing results.
The Principal will specifically perform a mandatory final inspection via a mandatory
“Hold” point identified on the program directly prior to closure of access doors. If this
hold point is passed by The Contractor, confined spaces will be required to be reopened and inspected and will not be the basis for a time extension.
Inspection and Test Plan Schedule
a)
Prepare and use Inspection and Test Plans (ITP) for the following particular activities.
Incorporate the listed Hold and Witness points which require attendance by The
Principal.
b)
The ITP must utilise daily reporting forms to record climatic conditions, surface
inspection and preparation, and lining activities and shall contain details (and results) of
all testing.
c)
The Contractor is to advise The Principal at least 24 hours in advance of their intention
to carry out surface preparation and product application, to allow such inspections to be
scheduled.
Design Review
(a)
The Contractor will give The Principal one hard copy and one electronic copy of the
Design Documents fit for purpose, at the time or times required by the program or, if no
time is stated in the program, within a reasonable time, allowing The Principal [7 days]
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to review and comment on the compliance of the Design Documents with the
requirements of the Contract.
(b)
If within the period referred to in Clause 8.10(a), The Principal gives The Contractor a
notice stating that the Design Documents do not comply with the requirements of the
Contract, The Contractor must:
(i)
Amend the Design Documents so that they comply with the requirements of the
Contract and any comments of The Principal regarding the compliance of the
Design Documents with the requirements of the Contract; and
(ii)
Promptly submit such amended Design Documents to The Principal, in which
case Clause 8.10(a) and this Clause 8.10(b) will apply in relation to the
amended Design Documents.
(c)
The Principal is not obliged to review or comment on any Design Documents. Any
review of or comment on any Design Documents by The Principal in accordance with
the Contract is solely to monitor the performance of The Contractor. The Contractor is
fully responsible for designing the relevant part of the Works in accordance with the
Contract.
(d)
The Contractor must maintain a register of all Design Documents and, upon request
must provide The Principal with a copy of the register.
(e)
The Contractor must not unless otherwise directed by The Principal, commence any
part of the construction, manufacture, supply or installation of the relevant part of the
Works until:
(i)
The Design Documents relevant to that part of the Works have been provided
to The Principal in accordance with this clause;
(ii)
The time period by which The Principal may review and comment on the
Design Documents has expired;
(iii)
The Design Documents have been amended in accordance with comments
made (if any) by The Principal under this Clause; and
(iv)
Without limiting quality, not make any amendments to the Design Documents
unless the proposed amendments have been provided to The Principal in
accordance with this Clause.
9.0
Works or Services Provided By The Principal
9.1
Site
9.2
a)
Electric Power at 240/415 volt, 100 amp, 3 phase 50 cycle AC on the four-wire system
at the designated points; and
b)
Domestic water supply from a designated point.
Site allocation
The Principal will allocate to The Contractor an area away from the working areas for the
erection of The Contractor's site facilities. The Principal may also allocate areas closer to the
working areas for The Contractor's use but such location is dependent on site conditions and is
not guaranteed. The latter areas will be available for restricted periods only and where, due to
the reasonable requirements of The Principal, it is necessary for the facilities in these areas to
be transferred to other areas, The Contractor must carry out the transfer when requested to do
so to the satisfaction of The Principal and at no cost to The Principal.
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9.3
“Free Issue”
a)
b)
General
(i)
The Contractor will pick up "free-issue" material from a location on the Power
Station site nominated by The Principal;
(ii)
The Contractor must give one week's written notice requesting supply of "freeissue" material by The Principal;
(iii)
The Contractor must notify The Principal of all additional "free-issue"
replacement parts or material requirements as soon as the requirement is
known, so that arrangements can be made for the supply of the parts or
material. The notification will include, where known, The Principal's Drawing
Number and Component Item Numbers; and
(iv)
All lubricants will be provided "free-issue" except where it is stated in this
Specification that lubricants are to be provided by The Contractor.
Specific items:
The Principal will provide the following items:
10.0
(i)
Spare parts in accordance with Clause 19.2; and
(ii)
Site Access Induction information.
Terminal Points
The Contractor will make the connection to the terminal points. This will include but not be
limited to supply of gaskets, fittings and termination strips.
11.0
The Principal’s Representative
The Principal’s Representative for these works will be:
Vince Reedy
Email: [email protected]
12.0
Contact Officers
Specification inquiries shall be directed to the following:
Simon Nawrot
Asset Management Specialist
Vales Point Power Station
Vales Road
PO Box 7285
Mannering Park NSW 2259
Phone (02) 4352 6084
Mobile 0417 202 680
Email [email protected]
13.0
Contractor’s Management and Staffing
13.1
Contractor's Representative
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13.2
13.3
a)
The Contractor must have in Australia, during the term of this Contract, a
representative or agent with the authority to deal expeditiously with all matters (viz.,
Administrative, Mechanical, Electrical, Building, Civil and Operational) which may arise
in connection with the carrying out of the Contract, and will, have a competent
representative either present on Site or on call to be available on Site within 4 hours of
being so requested by The Principal.
b)
The Contractor must notify The Principal in writing of the name of such representative
and of any subsequent changes. Any direction of The Principal will, if given to the
representative in connection with the carrying out of work under the Contract, be
deemed to be a direction issued or given to or served upon The Contractor in
connection with the carrying out of work.
c)
Matters relating to the Contract which are within the knowledge of a representative of
The Contractor will be deemed to be within the knowledge of The Contractor.
d)
Notwithstanding the first paragraph of this Clause, The Principal may in the absence of
The Contractor and The Contractor's Representatives take such action as The
Contractor is liable to take, which it considers necessary to prevent loss of or damage
to any property or to prevent personal injury to any person. The cost of any action so
taken by The Principal will be recoverable by The Principal from The Contractor as a
debt due to The Principal by The Contractor.
e)
Any action taken by The Principal under this clause will not relieve The Contractor of
any of its liabilities or obligations under the Contract.
f)
If the nominated representative is not competent to deal with specialised sections of the
Contract then an additional representative or representatives must be nominated to
deal with matters relating to that specialised section or sections. Each additional
representative will be subject to the same conditions as the main representative during
such period or periods that The Principal requires their presence in Australia.
Contractor’s Site Manager
a)
The Contractor must, for the duration of the Contract, have a Site Manager who is
capable of dealing with and making decisions in relation to all matters arising in
connection with the execution of the work under the Contract at Site.
b)
The Site Manager must have had previous experience in supervising work of a similar
type and magnitude and will coordinate the work of The Contractor and its
Subcontractors at the Site.
c)
The Site Manager must maintain, to the satisfaction of The Principal, a reasonable
standard of discipline amongst The Contractor's and Subcontractor's employees whilst
they are on the Site.
d)
The Site Manager will, when requested by The Principal, attend any meetings
convened for the purpose of coordinating the work under the Contract.
Contractor’s Staff and Employees
a)
The Contractor must provide a sufficient number of suitable personnel throughout the
execution of the work under the Contract at Site and the Defects Liability Period(s) to
perform efficiently all work under the Contract. The personnel must have had thorough
experience in the erection, construction, commissioning, operation and maintenance of
plant, buildings, structures and services comparable with that being supplied,
constructed or rehabilitated under the Contract.
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b)
Where extensive welding is carried out The Contractor must have on the Site
competent qualified welding supervisors and NATA approved non-destructive test
operators responsible for weld inspection procedures including non-destructive testing.
One of these supervisors must be on the Site whenever welding of important parts,
including all pressure welds, is in progress.
c)
All staff and employees must undertake a Site Access Induction prior to commencing
work on site. This induction consists of site specific safety and environmental
awareness. This induction is additional to any Work Cover Safety Induction required
under the WHS Laws or by NSW Workplace Health and Safety Statutory requirements.
d)
The Contractor must ensure that the key personnel identified in Schedule 3-16 (or
alternatives approved by The Principal in writing prior to the engagement of the
alternatives) are dedicated to the Works and the service.
If any of The Contractor’s key personnel:
(i)
Leaves their engagement in relation to the Works;
(ii)
Gives notice of their intention to leave their engagement in relation to the
Works; or
(iii)
Becomes incapacitated,
The Contractor must immediately notify, and discuss the appropriate
replacements with The Principal for approval prior to the replacement.
c)
13.4
13.5
The Principal may direct The Contractor to have removed from the Site or from any
activity connected with the work under the Contract within such time as The Principal
directs, any person employed in connection with the work under the Contract who, in
the opinion of The Principal, is guilty of misconduct or is incompetent or negligent. The
person must not be employed on the Site or on activities connected with the work under
the Contract without the prior approval of The Principal.
Industrial Relations
a)
The Principal has an obligation to maintain reliability of supply to its customers and The
Contractor will take all reasonable and proper action to promote and obtain industrial
harmony between its employees, agents and Subcontractors and those of The Principal
and other Contractors on the site.
b)
The Contractor must comply with the provisions of the appropriate industrial relations
legislation during the course of the Contract.
c)
The Contractor must ensure that its industrial arrangements/agreements will not
jeopardise or restrict The Principal’s ability to operate and maintain the site as a whole
as and when required.
d)
The Tenderer must include details of the proposed industrial arrangements (such as
name of award(s)/agreements) with the Tender. The Tenderer will also provide the
expected hours of work proposed for the Contract work.
Outage Safety Management and Co-ordination Meeting
a)
General: The Principal will conduct an Outage Safety Management and Coordination
Meeting prior to the outage Work commencing on site.
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13.6
b)
Purpose: Meeting is to confirm detailed requirements in relation to safety management
and coordination and to ensure the consistent application of safety management
requirements by all Contractors working on site during outage works.
c)
Requirement: Ensure mandatory attendance and participation at the Outage Safety
Management and Coordination Meeting by senior management representatives of The
Contractor and its subcontractors.
d)
Failure to Comply: Failure to comply with mandatory attendance and participation by
the senior management representatives will be cause for issue, by The Principal, of a
Safety Site Notice to The Contractor.
Contractor Personnel Screening
a)
13.7
As part of the works and services, all new Contractor employees that are given access
to The Principal’s premises and IT systems are to have verification checks performed.
This will include the following controls:
(i)
Availability of satisfactory character references e.g. one business and one
personal;
(ii)
A check (for completeness and accuracy) of the employee’s curriculum vitae;
(iii)
Confirmation of claimed academic and professional qualifications; and
(iv)
Independent identity checks (passport or similar document).
b)
A similar screening process should be carried out for all subcontractor employees and
temporary staff.
c)
In addition to the above, police checks are to be carried out on all Key Contractor
employees new to The Principal’s IT systems. The cost of such police checks will be
borne by The Principal. If the Key Contractor employee is changed during the period of
the contract for any reason other than the employee resignation, death or a request by
The Principal for a change, the cost of such police checks will be borne by The
Contractor.
Working Hours
The working hours and working days will be as stated in the Contract and if not so stated as
notified by The Contractor to The Principal prior to commencement of work on Site and will not
be varied without the prior approval of The Principal except when in the interests of safety of the
work under the Contract or to protect life or property The Contractor finds it necessary to carry
out work outside the working hours or on other than the working days stated in the Contract. In
such cases The Contractor will notify The Principal in writing of the circumstances as early as
possible.
All costs attributable to the supervision by or on behalf of The Principal of work during times
approved pursuant to the last paragraph will be borne by The Principal.
14.0
Site Conditions
14.1
Contractor Acknowledgments Regarding the Conditions Existing on Site
The Contractor acknowledges that:
a)
It has reviewed the content of the documents regarding the Site contained, or referred
to, in the Contract;
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14.2
b)
It has provided copies of those documents to its Subcontractors (where applicable) and
has satisfied itself that those subcontractors have reviewed and understand the
contents of those documents;
c)
It has visited and undertaken a detailed inspection of the Site, the whole of any
improvements on the Site and all services, structures, voids, materials and/or ground
conditions on, under or in the Site; and
d)
As a result of the above, it has obtained a detailed knowledge of, and, where relevant,
has ensured that its subcontractors have also obtained a detailed knowledge of, the
Site and the whole of any improvements on it and all services, structures, voids,
materials and/or ground conditions on, under or in the Site.
Risk of Conditions Existing on Site
The Contractor acknowledges that prior to entering into the Contract and in the light of
acknowledgements in clause 10.1 it has made a careful and complete examination and
assessment of all information obtained by it or made available to it by The Principal and others
and the items in a) to g) below and accepts, in their respective state and condition, the
following:
(a)
The Site and the whole of any improvements on it and all hazardous substances,
services, structures, voids, and ground conditions on, under or in the Site on which
any part of the work under the Contract is to be carried out or which is to be utilised in
the performance of the work under the Contract;
(b)
The soil,
(c)
Face water and groundwater in, on and under the Site;
(d)
Hydrological and climatic conditions;
(e)
The nature and extent of the difficulties, risks and hazards of and incidental to the
performance of the work under the Contract including prior works, existing structures,
materials and conditions;
(f)
The extent and nature of work and materials necessary for the performance of the
work under the Contract; and
(g)
The means of accessing the Site.
Subject only to its express payment entitlements under the Contract, The Contractor is solely
responsible for, and assumes the risk of, all costs and any losses and expenses in respect of
the physical conditions and characteristics of the Site and hazardous substances.
14.3
Acknowledgement and Site Information
The Contractor acknowledges that:
a)
The Principal (or others on its behalf) has made available to The Contractor certain
information, data or documents relating to the conditions on, under or in the vicinity of
the Site (‘Site Information’);
b)
The Site Information may not be complete and/or accurate; and
c)
The Principal:
(i)
Does not warrant or make any representation about the accuracy or adequacy
of the Site Information; and
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(ii)
d)
Makes no representation as to the completeness or accuracy of the Site
Information.
Contractor to warrant that it has made and relied upon all its own investigations.
15.0
Site Safety
15.1
Legal Obligations
The Contractor must conform to the provisions of all WHS Laws and applicable NSW
Workplace Health and Safety Statutory requirements made thereunder and in force from time to
time during the period of the work under the Contract.
15.2
a)
At all times during the undertaking of work under the Contract The Contractor shall
identify and exercise all necessary precautions and take all reasonably practicable
steps to ensure the health and safety of all persons on the site or who may be affected
by work under the Contract.
b)
The Contractor:
(i)
Shall comply and shall ensure that it and the subcontractors and either’s
employees and agents comply with the WHS Laws;
(ii)
Warrants that it is familiar with and has the capability, appropriate resources
and processes to comply with the WHS Laws;
(iii)
Shall develop and implement WHS processes and programs, including a
subcontractor management system, to identify and manage WHS
requirements;
(iv)
Shall ensure that any person engaged to provide any part of work under the
Contract who is required by any Legislative Requirement to have an Approval
in order to perform that part of work under the Contract has obtained the
Approval prior to the commencement of that part of work under the Contract;
and
(v)
Shall provide The Principal within such time as required by The Principal with
the report required as per the WHS Regulation.
Safety Training and Competency Requirements
a)
Certification of Personnel
The Contractor must maintain a record of all certificates required to carry out the work.
b)
Induction
(i)
In accordance with contract requirements The Contractor must, prior to
commencement on Site, ensure that all employees under his/her control
(including Subcontractors) who are to work on the Site undertake:
(A)
General health and safety induction training conducted by a Work
Cover accredited trainer (green card);
(B)
Work activity based health and safety induction training conducted by a
Work Cover accredited trainer;
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c)
(C)
Site specific health and safety induction training delivered by The
Contractor (or The Principal) covering Site conditions, specific health
and safety hazards associated with the Site and environmental
procedures.
(D)
Site Access Induction provided by The Principal.
Specific Health and Safety Training
In accordance with the requirements of the contract The Contractor must ensure that all
employees under his/her control (including Subcontractor's) who are required to carry out
specific health and safety work procedures or practices, such as confined spaces work
procedures, undertake specific health and safety training and are assessed as
competent. The Contractor must provide to The Principal, on request, evidence of the
acquired training and competencies.
d)
Behavioural Safety
Contractor and Subcontractor personnel must participate in The Principal‘s Zero Incident
Process (D-ZIP). D-ZIP is a Behaviour Based Safety initiative implemented on all of The
Principal’s sites. Training for Contractor and Subcontractor personnel is available, upon
request, from The Principal.
15.3
Consultation
a)
b)
c)
Contractor Site Safety Notices
(i)
The Principal has the right to issue Contractor Site Safety Notices and to
charge to The Contractor costs incurred for rectification upon failure to comply.
(ii)
The Principal Contract Representative must be notified of, and given a copy of,
any Contractor Site Safety Notice issued to a Contractor.
Safety Officer
(i)
All Contractors must have an appointed management representative to perform
the duties and responsibilities of The Contractor’s Site Safety Officer.
(ii)
This representative is to liaise with The Principal’s contract representative.
Safety Representative
The Contractors Site Specific Safety Management Plan must provide for involvement of
The Contractor’s Site employees. This may be via an elected safety representative to
speak on the behalf of The Contractor’s Site employees on the matters of safety.
15.4
Risk Management and Process Control
a)
The Contractor must have a documented process to ensure that hazards are identified,
assessed for their risk and control measures implemented.
b)
Documented Risk Management process and methodologies should be consistent with
the requirements of AS/NZS ISO 31000 Risk Management Principles and Guidelines or
equivalent.
c)
Documented risk assessments must be submitted to The Principal which must describe
the work to be undertaken, identify the hazards associated with the work, and describe
the risk control measures to be used.
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15.5
d)
Risk assessments must be performed following inspection of the location of the work.
e)
The Contractor must provide to his/her employees instruction, training and provide
information on Risk Management.
f)
The Principal and The Contractor acknowledge and agree that The Contractor has
control of:
(i)
The manner in which work under the Contract is performed; and
(ii)
All matters arising out of or as a consequence of the carrying out of or failure to
carry out work under the Contract that give rise or may give rise to risks to the
health or safety of any person.
Emergency Response and Incident Notifications
a)
b)
Emergency Response
(i)
Contractor Site management is responsible for ensuring all employees are
informed of and comply with Site Emergency Response Procedures.
(ii)
The Contractor, its Subcontractors and their respective employees must be
familiar with and comply with the emergency response procedures applying to
the Site.
(iii)
Details of The Principal's procedures for emergencies requiring ambulance,
firefighting or police action will be made available to The Contractor's Site
Manager.
Site First Aid
The Contractor will, in all respects, be fully responsible for ensuring the provision of first
aid services in accordance with legislative requirements, to its employees and those of its
Subcontractors including transport for injured persons to hospital or other appropriate
destination as and when required.
c)
Incident/Accident Notification
(i)
In addition to any statutory requirements or regulations, The Contractor must
promptly report to The Principal, all accidents or incidents involving its
employees and those of its Subcontractors.
(ii)
Within 2 Business Days of any incident, lost time incident or injury provide a
report to The Principal giving complete details of the incident, lost time incident,
injury or damage, including the results of investigations into its cause and any
recommendations or strategies for prevention of a recurrence.
(iii)
Immediately notify the The Principal of any act, fact or circumstance associated
with the activities of The Contractor or any other person that might affect the
ability of The Contractor to perform any part of work under the Contract in a
manner that is safe and without risks to the health or safety of any person.
(iv)
Prior to the commencement of work under the Contract, provide The Principal
with a copy of any Approval that any person engaged to provide any part of
work under the Contract is required by any Legislative Requirement to have in
order to perform that part of work under the Contract.
(v)
Maintain and prepare such necessary records, documents and information
concerning the health, safety and welfare of persons arising out of or as a
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consequence of the carrying out of or failure to carry out work under the
Contract.
(vi)
15.6
As The Principal may require, provide a report to The Principal concerning:
(A)
The health, safety and welfare of persons arising out of or as a
consequence of the carrying out of or failure to carry out work under the
Contract; and
(B)
The Contractor’s compliance or non-compliance with its WHS
obligations under the Contract.
(vii)
At all reasonable times provide The Principal with access to such records,
documents and information as may be necessary to establish The Contractor’s
compliance or non-compliance with its WHS obligations under the Contract.
(vii)
The Contractor must supply statistics in a form acceptable to The Principal.
Site Rules
a)
Clean Up and Housekeeping
The Contractor is responsible for the removal of rubbish and orderly housekeeping in
their works area. The Principal may charge The Contractor if clean up needs to be done
after the issue of a “Contractor Site Safety Notice”.
b)
c)
Site Security
(i)
A security Contractor, contracted to The Principal, controls site security.
(ii)
All persons on site must carry identification cards. Contractors’ visitors are
issued with visitor identification cards upon entry and whilst on site must be
accompanied by an Inducted Contractor’s representative at all times.
(iii)
Contractors are responsible for the security of their works and equipment.
Smoking
It is The Principal policy that buildings and plant areas are designated NO SMOKING
areas.
d)
Traffic Requirements
(i)
The speed limit on Site is 20 km/hr. or as signposted otherwise.
(ii)
Contractors are to ensure that all employees, visitors and delivery drivers
observe the speed limits as The Principal may deny access to persons, who
contravene the limits, to drive on Site.
(iii)
All Contractors employees will park in the nominated external car parks.
Parking on Site will be in nominated areas or with due regards to the operation
of the station.
(iv)
All vehicles used on Site must be registered and road worthy. Vehicles that are
generally used for Site work must carry a first aid kit complying with legislative
requirements.
(v)
All vehicles used by The Contractor and Subcontractors on Site must be clearly
identifiable with the company logo/name.
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e)
f)
g)
15.7
Protective Clothing and Equipment
(i)
In addition to any Statutory requirements or regulations The Contractor must
comply with directives issued from time to time by The Principal specifying any
protective clothing or equipment that may be required to be used during the
conduct of work under the Contract.
(ii)
Unless otherwise directed or specified The Contractor, its employees and those
of its Subcontractors must wear, as a minimum requirement, a long sleeved
shirt and long trousers or combination overalls together with safety footwear,
protective safety eyewear and safety helmet.
(iii)
Note: Orange Helmets are not to be worn on The Principal’s Sites or Property.
(iv)
High visibility clothing that complies with AS/NZS 4602 High visibility safety
garments, AS/NZS 1906.4 Retro reflective materials and devices for road traffic
control purposes - High visibility materials for safety garments is to be worn by
all employees working on The Principal sites.
Restricted Areas – Protection of adjacent plant
(i)
Areas on Site may from time to time be restricted due to the nature of work.
Notification will be by observance of the Access to Apparatus Rules
isolation/access procedures and/or by Site notice.
(ii)
The Contractor is to take all precautions to protect plant adjacent to their
works.
Subcontractor Approval
(i)
All Subcontractors are subject to approval. The Subcontractor's Site manager
will be interviewed to determine their suitability. Appropriate forms must be
completed and approved before the Subcontractor and staff will be issued a
security card.
(ii)
The Subcontractor is approved based on the work to be undertaken by the
Subcontractor. The Contractor must not vary or delete this work to the
Subcontractor unless approved in writing by The Principal prior to such change.
Commissioning
Commissioning will be performed under the control of the Access to Apparatus Rules and the
requirements of the Specification. Practical completion shall not be achieved until
commissioning is completed and the unit returned to full load (660MW) such that the boiler can
be demonstrated to sustain full pressure and temperature in a quiescent state.
15.8
Plant and Equipment
a)
Excavations near Cables and Pipelines
(i)
All excavation work on The Principal Controlled Sites must be completed in
accordance with ARP-21 - Authority to Dig.
(ii)
This procedure describes the process to identify underground services and
gain approval to excavate on The Principal property. The Authority to Dig form
is to be completed in accordance with the relevant excavation legislation and
codes of practice. This Procedure and the Authority to Dig form is not a Permit
to Work.
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(iii)
b)
c)
d)
Where work involves excavation the Site-Specific Safety Management Plan
must provide procedures for locating cables and pipelines and for work method
statements in the event that a cable is unearthed.
Electrical Installations
(i)
All electrical installations carried out by The Contractor must comply with The
Principal’s Site requirements and the conditions and the requirements of the
network operator, where applicable.
(ii)
The Contractor must ensure that all flexible extension cords, portable tools and
electrical plant supplied at a voltage above 50 volts AC and 120 volts DC (extra
low voltage) are inspected, tested and tagged in accordance with the
WorkCover Code of Practice “Electrical Practices for Construction Work”.
(Refer to WHS Laws and applicable NSW Workplace Health and Safety
Statutory requirements).
(iii)
The Contractor must ensure that all electrical appliances in amenities
sheds/Site offices are inspected and tagged upon arrival or relocation on Site
and then at least three monthly intervals thereafter by a licensed electrician in
accordance with the Work Cover Code of Practice “Electrical Practices for
Construction Work”.
(iv)
All work in a Hazardous Area must be performed by personnel who have
"competencies for working with electrical equipment in hazardous areas
(EEHA)" as defined in AS/NZS 4761.
Lighting
(i)
The Contractor is to provide adequate lighting for their works and for other
users of the Site to have safe access and egress.
(ii)
Low voltage equipment must comply with relevant Australian Standards or
have suitable earth leakage protection.
Overhead Cranes as Work Platforms
The use of overhead cranes, as work platforms may be required for the completion of
special work. This may be allowed provided a risk assessment is performed.
e)
f)
Mobile Plant and Equipment Near Electrical Conductors
(i)
Mobile cranes or similar equipment must not approach electrical conductors
unless a risk assessment has been performed.
(ii)
The basis of this risk assessment must comply with NSW Workplace Health
and Safety Statutory requirements.
Use of Radio/Mobile Phones
(i)
Radio equipment must be licensed and these licences must be able to be
produced on demand by the Inspectors from the Department of
Communications.
(ii)
The use of radios and mobile phones near computer and PLC equipment is
prohibited. PLC equipment is generally located in switch rooms or control
rooms.
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g)
Safety Guards, Handrails and Flooring
Where work requires the removal of safety guards, handrails or flooring the work area
is to be made safe by conducting a risk assessment and developing safe work
procedures which are nominated in the Site Specific Safety Management Plan. Safe
work procedures must ensure that the safety guards, handrails or flooring are removed
for the minimum time necessary to complete the specific component of work associated
with their removal. Immediately upon completion of this work component all safety
guards, handrails or flooring are to be refitted. If work is suspended for a temporary
period the work area is to be made safe in accordance with the safe work procedures
nominated above.
15.9
15.10
15.11
Confined Spaces
a)
Access for work in confined spaces will only be granted under a Permit to Work.
b)
Where the works under the Contract requires entry to a confined space The Contractor
must carry out a risk assessment of the work to be conducted in the confined space
prior to the commencement of the work and other requirements as defined in the WHS
Laws and NSW Workplace Health and Safety Statutory requirements.
c)
The Contractor must determine from the risk assessment the training and competencies
required of their employees or Subcontractor's to work in the confined space. The
Contractor must provide to The Principal evidence of the acquired training and
competencies.
d)
The Contractor must ensure that their employees or Subcontractors, who are required
to work in or enter a confined space, are provided with appropriate training in
accordance with Legislative Requirements for Safe Working in a Confined Space
(including those in the WHS Laws). The Contractor must provide to The Principal
evidence of the acquired training and competencies.
Control of Radiographic Sources and Radiography
a)
Radiography on Site must be performed in accordance with statutory requirements.
b)
In the event of an accident involving Contractors radioactive sources The Principal’s
procedures must be followed.
Fire Protection
a)
The Contractor will be responsible for the fire protection of its own buildings, plant and
equipment and must assist in the fire protection of the buildings, plant and equipment of
The Principal and other Contractors. The method of complying with this requirement
must be detailed in the Site-Specific Safety Management Plan.
b)
The Principal has provided fire-fighting equipment for the purposes of fire protection of
The Principal's buildings, plant and equipment to meet normal operating needs.
Additional precautions are to be taken to cover the specified work. The Contractor must
provide additional, appropriate and adequate firefighting equipment in areas where The
Contractor is working. The Contractor must provide, as a minimum, the firefighting
equipment listed in Table D of Part 1.
c)
The Contractor must ensure adequate firefighting equipment is appropriately positioned
whilst carrying out work at the Site. This will include the positioning of The Contractor's
portable firefighting equipment close by to where hot cutting or welding work is being
carried out. (Refer also to 15.13)
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d)
15.12
15.13
The Contractor must maintain and regularly service its firefighting equipment to a
condition satisfactory to The Principal and must recharge its extinguishers after use
regardless of how they were discharged. Provision for the maintenance and servicing
of The Contractor's firefighting equipment must be in accordance with relevant
Australian Standards.
Chemicals
a)
The Tenderer is to make a register of all chemicals that are anticipated to be brought
onto the Site for use during works under the contract. This list is to include but is not
limited to dangerous goods, hazardous substances, non-hazardous substances (e.g.
cleaning agents) and gas cylinders.
b)
The Contractor must not bring any chemical onsite without the prior notification to and
the approval of The Principal.
c)
The Contractor must maintain a register of all chemicals on Site in a manner and format
acceptable to The Principal. The register must include the maximum expected storage
quantity of each chemical and the storage location on The Principal’s site. The register
must be readily available for inspection by The Principal. The Contractor must provide
current Safety Data Sheets for all chemicals listed in its register.
d)
The Contractor must not bring any chemicals on Site that are not listed on the chemical
register or exceed the previously notified maximum storage quantity without the prior
notification to and the approval of The Principal. Once approval is granted the chemical
register must be updated and a copy submitted to The Principal.
e)
The Contractor must include in the register a disposal plan for chemical remnants and
empty chemical containers. The Contractor is not to dispose of any chemical remnants
or empty chemical containers at The Principal’s site/s without the prior notification to
and the approval of The Principal.
f)
The Contractor must comply with the requirements of the relevant legislative
requirement in regard to risk management of the storage, handling, transport and
disposal of hazardous substances and dangerous goods.
g)
The Contractor must have site specific risk assessments for the storage and use of any
chemical that is a hazardous substance or dangerous goods. The risk assessment must
include site specific procedures to control an incident involving the spillage/leakage of
the hazardous substance or dangerous good.
Hot Work
a)
For all Hot Work involving grinding, welding, thermal or oxygen cutting or heating and
other related heat producing or spark producing operations The Contractor must
perform a risk assessment to determine the control measures required to prevent
combustion of any surroundings.
b)
Hot Work risk assessment control measures must be provided to The Principal for
review and approval, prior to the commencement of any Hot Work involving grinding,
welding, thermal or oxygen cutting or heating and other related heat producing or spark
producing operation, where there is the potential for ignition of bush and/or bush fire
damage to surrounding property.
c)
Areas on Site where Hot Work may represent a risk to personnel and plant, for
example, flammable liquids, vapours or gases, combustible liquids, dusts fibres of other
flammable or explosive substances are designated High Risk Areas. The Contractor
will obtain from The Principal information of any High Risk Areas, where there may be
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hazardous conditions or flammable materials present that may present a risk when Hot
Work is carried out.
15.14
15.15
15.16
d)
Where The Contractor is required to carry out Hot Work in High Risk Areas it must be
carried out in accordance with The Principal's Access to Apparatus Rules under an
appropriate Permit to Work. The area must be inspected by The Contractor's
supervisor to ensure the work can be conducted in a safe manner.
e)
The Contractor must use the procedures in The Principal’s Access to Apparatus Rules
or submit an equivalent detailed procedure for Hot Work. The procedure must provide
for use of a written permit for The Contractor's supervisor to authorise the work to
proceed. The Principal must review the form of the permit.
Access to Apparatus Rules
a)
The Principal has a system in place to manage access to apparatus on Site called the
Access to Apparatus Rules. Formal written approval will be given by The Principal prior to
any work on equipment. Approval is given via a Permit to Work or Sundry Apparatus
Approval for Access Form. The Contractor must be trained and competency assessed to
carry out certain functions under The Principal’s Access to Apparatus Rules and their
associated procedures.
b)
The Principal may, under certain circumstances, permit a Contractor to apply The
Contractor’s isolation procedures while carrying out work under the Contract at the Site.
Where The Contractor's isolation procedures are to be used, The Principal’s approval
must be obtained in writing prior to any work starting on site.
c)
The Contractor must ensure that any locks issued to personnel of The Contractor are
returned to The Principal upon completion of the works. Any locks that are not returned
will be charged to The Contractor at a rate of $250.00 per lock.
Scaffolding and Rigging
a)
The Contractor must comply with all relevant requirements of AS/NZS 4576.
b)
The Contractor will be responsible for using appropriate materials, erecting and
inspecting scaffolds, approvals for use and follow up routine inspections and
maintenance as required by AS/NZS 4576.
c)
The scaffolder must be competent and have the relevant certificate of competency for
building and inspecting scaffolds.
d)
In addition to the requirements of AS/NZS 4576, The Contractor must have in place a
system (for example, a “scaff tag” system) for the erection, approval, registration and
regular inspection of any scaffolding erected in the course of the work under the
contract. Regular inspections of slings, chains, lifting devices and harnesses must be
carried out and the results recorded.
e)
The control documentation must be constantly maintained and be available to The
Principal without notice.
f)
When scaffolding is no longer required, the scaffolder must dismantle the scaffolding
before the date of the next scheduled inspection.
Underwater Diving
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All diving Contractors must comply with Australian Standard 2299. It is also The Contractor's
responsibility to abide by any Site instructions and Access to Apparatus Rules.
15.17
15.18
15.19
15.20
Work Method Statements
a)
The Contractor for all work activities should prepare Work method statements. Work
method statements will be examined by The Principal contract representative to satisfy
themselves that the work method statements are not blatantly inaccurate and are
consistent with accepted risk management techniques.
b)
Safe Work Method Statements must be prepared as specified by NSW Construction
Consultative Committee – How to prepare Site-specific Safety Management Plans and
Safe Work Method Statements.
Workplace Inspections
a)
The Contractor’s Safety Officer and Safety representative must undertake regular
safety inspections of The Contractor’s work areas. The Contractor must retain records
of each inspection and forward a copy to The Principal contract representative.
b)
The workplace Inspection procedure chosen must conform to either The Contractor’s
Site Specific Safety Management Plan or to a recognised Industry Safety Code.
c)
The Business Unit Safety Manager or representative will, at intervals determined with
The Principal contract representative, carry out random workplace inspections of the
contract works.
Impairment Testing
a)
On site drug (saliva) testing will be undertaken randomly and where The Principal has a
cause to do so.
b)
Alcohol testing will be undertaken randomly and where The Principal has a cause to do
so.
Asbestos
a)
Asbestos Bearing Materials
For work involving the removal of asbestos bearing materials the work must be
performed in accordance with the Contract, Legislative Requirements and the relevant
Australian Standards. (Refer to the WHS Laws and applicable NSW Workplace Health
and Safety Statutory requirements.)
16.0
Site Security, Access and Removals from Site
16.1
Site Security
a)
The Principal's Site/Power Station Site is maintained under a security system.
b)
The Contractor, and its Subcontractors and their employees must comply with the
requirements of The Principal in regard to entering and leaving the Site and while they
are on The Principal's premises. The Principal reserves the right to inspect the
contents of all vehicles entering and leaving the Site.
c)
The Principal will accept no responsibility for the loss of, or damage to, The Contractor's
or its Subcontractors' and their employees' tools, equipment, clothing, etc.
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16.2
16.3
Site Access
a)
The Contractor and its Subcontractor's employees must provide their details including
name and current home address to The Principal’s representative who will arrange the
issue of a Photo Identification Card. All staff of The Contractor and its Subcontractors
staff are required to wear at all times whilst on the Site/Power Station Site their
Contractor Photo Identification Card.
b)
All identity cards must be returned to The Principal upon completion of The Contractor's
Contractual obligations and/or termination of an employee's services.
c)
In the event that an identity card or ATAR access lock is lost, the matter must be
reported immediately to The Principal who will arrange for issue of a new card or in the
case of a lost ATAR access lock, undertake a corrective process. A fee will be charged
by The Principal to The Contractor for all unaccounted Contractor’s identity cards of
$250 per card (this includes the subcontractor cards) and $250 per ATAR access lock
at Practical Completion. In accordance with Practical Completion the final claim for
payment will be withheld until all identity cards and ATAR access locks have been
returned to The Principal. Failure to return identity cards and ATAR access locks will
result in The Contractor being required to submit an adjustment note to the value of the
number of missing identity cards and ATAR access locks multiplied by $250 and this
amount will be offset against the final claim for payment.
d)
The normal access to the Power Station Site is through the main gate which is manned
to control vehicular access. Special access to other parts of the Power Station Site
may be arranged subject to conditions on traffic control and security.
e)
Only marked Contractor's vehicles will be permitted entry to the Site/Power Station Site.
Private vehicles (except those with access permits) will not be granted access. Access
permits may be issued following an application in writing by The Contractor to The
Principal. Normally, they will only be issued to senior staff. The Contractor must apply
for access permits for issue to its Subcontractors. All vehicles granted access must
have current Motor Vehicle Insurance and a copy provided to The Principal.
f)
Site parking regulations and speed limits must be strictly observed. Offenders may be
refused further access to The Principal's property.
g)
Non employees are only permitted on Site on official business. Children are not
permitted on the Site.
h)
Traction and prime mover vehicles that are primarily designed for travelling on public
roads and are used on the Power Station Site must be registered with the appropriate
State Authority unless exempted in writing by The Principal. All non-registered plant
must be maintained to a satisfactory standard, as required by The Principal.
Removal from site
Neither The Contractor nor its Subcontractors will remove materials or equipment from the Site
unless accompanied by a signed docket ('Removal from Site Form' or 'Pass Note for The
Principal Property') which must be presented to The Principal's security staff when the removal
takes place. The Contractor must give adequate notice for the removal from the Site of all
items owned by The Principal so that The Principal must have adequate time to arrange
insurance, notifications and clearances.
17.0
Environment
17.1
Environment Management
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17.2
17.3
17.4
a)
The Principal maintains a comprehensive Environmental Management program that
targets compliance with all statutory Environmental Regulations and continual
improvement of Environmental performance.
b)
The Principal strives to reduce Environmental impacts where suitable economically
viable technology exists to reduce or eliminate emissions or discharges, these
technologies will be implemented and The Principal encourages their Contractors to do
the same.
c)
All operational sites maintain an environmental management system based on the
ISO14001 Environmental Management System.
d)
The Principal employees with such controlling roles have the authority to cause work to
cease immediately if environmental harm has occurred or is likely to occur.
Environment training and competency requirements
a)
Prior to commencement on The Principal site, all Contractors will be made aware of the
relevant Environmental objectives of the site and undertake induction training. They
must demonstrate the required knowledge and skills to perform the work in an
environmentally responsible manner.
b)
Should any task require Environment licence approvals, these will be directed to The
Principal Environment Manager.
Contractor Environment Responsibilities
a)
Contractors must comply with the requirements of all relevant statutory bodies and with
the Protection of Environment Operations Act 2005 (NSW) and all associated
Regulations.
b)
Maintain awareness of new Environment legislation.
c)
Report any environment incidents.
d)
Implement an Environment Management Plan.
e)
Implement a Waste Management Plan.
Environmental Incident Report
a)
The following general procedure is to be followed on observing an Environmental Issue
and is required under the Protection of the Environment Operations Act. All employees,
Contractors and visitors are responsible for the reporting of an environmental issue. If
an employee/ Contractor detects an incident or potential incident, then immediate action
should be taken to isolate, reduce or remove the hazard where such action does NOT
involve risk to themselves or other personnel.
b)
The incident is to be reported immediately to the Shift Manager via the PCR (phone
555) with accurate information on:
(i)
The type of Issue (oil, chemical, ash, coal, bushfire, gas etc.);
(ii)
Location and extent of Issue;
(iii)
Any circumstances requiring the use of specialised equipment;
(iv)
Name and phone number of person reporting the Issue;
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17.5
17.6
17.7
(v)
Any injuries to personnel; and
(vi)
Extent of any hazard reduction actions undertaken.
Environmental Emergency Response
a)
The Principal have trained Environmental Emergency Response staff onsite, in the
event of an Environment incident.
b)
Contractors must have in place procedures for Environment Emergency Response for
the work they complete.
c)
The safety of personnel involved in environmental emergency issue response must be
given the highest priority. Only properly trained personnel equipped with appropriate
safety gear and protective clothing may be permitted to take part in operations where
the risk of injury is evident. Any response action is to consider the requirements for
support systems such as back-up personnel and equipment, first aid, showers, hoses
etc.
The Principal Environment Protection Licence
a)
The Principal site is covered under a NSW Government Protection Licence.
b)
Should any work a Contractor carries out pose a risk or breach of licensing
requirements, the Environment Manager is to be contacted immediately.
Water Protection
a)
Water Restrictions
Contractors are expected to abide by any Council enforced water restrictions when
working on site with domestic water supply.
b)
Water Contamination
Any incidents involving water contamination are to be reported immediately.
17.8
Hazardous Substances
a)
The Contractor must take all precautions necessary to prevent the discharge of any
pollutants as defined by the Protection of the Environment (Operations) Act, into any
waters.
b)
All plant and equipment maintenance will be carried out on a concrete paved area, the
drainage from which must be provided with oil separation traps before discharge into
any waters.
c)
Oil, grease, paints, chemicals, solvents, and liquids other than water are NOT to be
disposed of down drains, toilets, or into watercourses.
d)
Oil Spills
(i)
If an oil spill occurs, the Contract Representative must be advised immediately.
(ii)
All oil or fuel spilt or leaking from any item of plant or equipment must be
cleaned up immediately and the Contract Representative is to be notified of all
details.
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(iii)
If any waters become contaminated by oils or similar materials or otherwise
polluted as a result of any act of The Contractor The Contractor will, at no cost
to The Principal comply with all directions given to them by any relevant
Authority to clean-up the contaminated areas and to prevent any further
pollution.
(iv)
All above actions taken by The Contractor and equipment used in preventing or
removing pollution are to be approved by The Principal.
(v)
Oil absorbent material is to be applied immediately to oil spilt. When the oil is
absorbed, the oiled compound is to be swept up and disposed of properly - not
washed down drains. (Granular oil-sorb material is not preferred).
(vi)
Any remaining oil is to be removed by use of an approved degreaser, followed
by hosing with water into a contaminated water drain. Special attention is to be
paid to oil films on steel platforms and steps which may cause a safety problem.
.
e)
Bunding of hazardous substances
(i)
All environmentally hazardous liquids are to be stored in bunded areas. Oil fuel
and Hazardous Materials must be stored in bunded areas. The net capacity of a
bund must be at least 150% of the net capacity of the largest tank or drum.
(ii)
Areas where spillage is possible, or oil handling equipment is located, are to be
bunded prior to any work being done. Someone must be present at all times
when oil transfer is in progress.
(iii)
Drainage areas are to be protected from ingress with suitable protection or
containment equipment
f)
Supplies of oil absorbent material are to be available wherever oil handling and work on
oil systems is taking place.
g)
Use of hazardous substances, chemicals, pesticides must be included in a risk
assessment.
h)
All hazardous substances, chemicals and pesticides usage must be approved by the
Contract Representative/Environment Manager before being brought ontothe Site.
i)
Chemical deliveries
Bulk deliveries of chemicals to site need to have Safety Manager and Environment
Manager’s approval.
j)
17.9
(i)
Twenty Four (24) hours’ notice of deliveries is required.
(ii)
Contractors are to set up suitable storage and bunding for chemicals they bring
on site.
Vapours from chemicals
(i)
Is there is a potential for vapours from chemicals appropriate exclusion zones
must be set up.
(ii)
If required air analysis monitors will be used to monitor vapour levels.
Hazardous Waste
a)
Hazardous waste products for site include but is not limited to the following:
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17.10
(i)
Corrosives;
(ii)
Fabric filter bags;
(iii)
Toxic inorganic materials such as soluble salts;
(iv)
Liquid waste;
(v)
Enviro Lube;
(vi)
Oily sludges and oil filter debris;
(vii)
Oils and drums with oil;
(viii)
Toxic organic material such as pesticides;
(ix)
PCB contaminated materials;
(x)
Poisons;
(xi)
Radioactive waste;
(xii)
Solvents; and
(xiii)
Any substances of unknown composition.
b)
Appropriate disposal of hazardous waste must be in accordance with relevant
Environmental legislation and statutory requirements.
c)
Contractors will implement recycling procedures where appropriate.
Flora and Fauna
a)
Except to the extent necessary for the carrying out of the Works, flora must not be
removed, damaged or disturbed nor shall any vegetation be planted. Trapping,
poisoning and/ or shooting of animals is strictly forbidden. No domestic pets or livestock
are permitted on Site. Where the use of herbicides, pesticides and other poisonous
substances has been specified, The Contractor will submit a Method Statement.
b)
Approval from the Environment Manager/Contract Representative must be sought
before the clearance of any native vegetation.
c)
Marine Life
Fishing and/or prawning activities are forbidden at all times on Power Station
property with the following exceptions:
17.11
(i)
Commercial/experimental ventures that have the express permission of The
Principal; and
(ii)
Contractors, who in the course of their duties, are required to clear blockages at
the CW screens are advised that all marine life and refuse is to be either
returned to the natural environment or stored in an approved manner for later
disposal.
Noise and Air Pollution
Contractors are to carry out their work in such a way that noise and air pollution is minimised.
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This includes proper enclosure of work involving excessive noise or the release of dust or grit
(eg. grit blasting), or using dust suppressant methods when working with coal fines or fly-ash.
Special precautions may be necessary during windy conditions.
17.12
Environment Risk Assessments
Environment risks should be considered when carrying out tasks and adequate control
measures put in place to protect the environment.
17.13
Finding of Minerals, Fossils and Relics
Valuable minerals, fossils, articles or objects of antiquity or of anthropological or archaeological
interest, treasure trove, coins and articles of value found on the Site will, as between the parties
be and remain the property of The Principal. Immediately upon the discovery of these things
The Contractor must take precautions to prevent the loss or removal or damage and shall notify
The Principal of the discovery.
18.0
Site Establishment
18.1
Contractor to supply
18.2
a)
The Contractor must provide in the area(s) allocated by The Principal at the Site, all
sanitary and all other accommodation for the personnel employed by The Contractor
and Subcontractors on the Contract, except where otherwise stated in Part 1 of the
Specification. Each building or structure must have its exact location approved. Use of
other areas requires special approval. The Contractor is responsible for compliance by
its Subcontractors.
b)
The Contractor must supply, erect, maintain and remove within 14 days after the Date
of Practical Completion, any temporary structures such as The Contractor's site office,
store shed, workshop, tool shed and employees' amenities shed, change room,
sanitary accommodation, hot water boilers, etc., all as required by the relevant
industrial arrangements/agreements and Authorities. The buildings and associated
services must be maintained in a clean and sanitary condition, all subject to the
approval of The Principal and Authorities concerned. The Contractor will give all
notices to the Authorities and pay all fees.
Site accommodation standards and rules
a)
Site accommodation and amenities must be of a standard that complies with the
requirements of The Principal and any applicable WHS Laws and NSW Workplace
Health and Safety Statutory requirements. Adequate facilities must be provided before
any work under the Contract at Site commences. All site buildings and containers must
be identified with the company name.
b)
No residential accommodation required for personnel will be allowed on The Principal's
property and the provision of any accommodation away from Site, such as by operation
of accommodation schemes, etc., will be the responsibility of The Contractor.
c)
The Contractor will provide all drainage and surface preparation required in the area
allocated. The Contractor will be responsible for the maintenance of the allocated area,
road access and other installed services.
d)
Access into the Site will normally be by road only and the Tenderer must ascertain
before tendering what road and rail facilities will be available for the transport of
materials. No claims for reimbursement of The Contractor's extra costs which have
been incurred by neglect of this requirement will be considered by The Principal.
e)
Connection of temporary services to The Principal’s electrical, water, sewerage and
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telecommunications supplies and or terminal points must be carried out by suitably
qualified and trained personnel. Proof of trade and appropriate training qualifications
must be provided to The Principal prior to any work being carried out. Personnel
undertaking this work are to be suitably inducted to the site prior to any work being
carried out.
f)
18.3
Contractors are to enclose the underside of all site sheds, containers or buildings to
stop under entry, except for repairs, when an opening is greater than 150mm. This may
be achieved by positioning F81 galvanised mesh securely fixed against the site facility
wall and buried 150mm into the ground with the trench backfilled.
Costs
The Contractor must pay all costs, including demurrage charges, incurred in the delivery to Site
and receipt, handling and storage at the Site of all materials forming part of the Works.
a)
The Contractor will be responsible for the receipt of all material and equipment and
must ensure that, for all deliveries to Site under this Contract, the material and/or
equipment is addressed to The Contractor's Site Manager and adequate arrangements
are made for the receipt of the materials and/or equipment.
b)
The Contractor will also be responsible for off-loading, safe-keeping, handling and
storage of all plant and materials including the handling of all plant and material to and
from the storage area allocated at the Site.
c)
For the purposes of this Clause, materials or plant items issued by The Principal to The
Contractor will be deemed to be materials forming part of the Works from the time of
issue. All costs associated with delivery and handling from the time of issue will be
borne by The Contractor, including the cost of transport from the point of issue to the
Site.
19.0
Spares, Disposal and Return of Plant
19.1
Disposal and Return of Plant
Any dangerous good or hazardous substances must be disposed of in accordance with
Legislative Requirements current State and Federal Regulations. Proper disposal of the items
is the responsibility of The Contractor. The Principal will require evidence that all such items
have been correctly and safely disposed of.
19.2
Supply of Spare Parts
Spare parts available from The Principal stores will be free issued. All other spares as approved
by The Principal will be purchased by The Contractor under the Cost Plus provision of the
Pricing Schedules contained in Part 3.
19.3
Items of equipment to be delivered to The Principal's Store must comply with the following:
a)
A tag of non-ferrous metal or plastic material with punched lettering must be attached to
each item. It must carry a serial or part number and a brief but accurate description in
English so that the item can be identified accurately without reference to any other
information. If a number of items are included in a package the tag must show the
number and quantity of each item included;
b)
Small electrical items such as coils, contacts, springs, brushes and such other
equipment must be supplied in transparent moisture-proof packages with
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Rev: 7 December 2016
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identification tags inside the packages, and the tags must be legible without unsealing
the packages. Each package must contain only items of sub-assemblies of identical
design;
c)
To permit accurate and convenient checking of delivery of spare parts each item as
listed in the delivery manifesto must be given an individual serial number distinct and
separate from any other number allotted to it. These separate numbers must
correspond with the number on the tags which will be attached to the individual parts or
packages as described in Clause 19.3 (a); and
d)
Particulars of the parts must be such that they can be easily related to the items
included in the Contract.
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
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TABLES
TABLE A – TABLE OF KEY DATES
Table A will be located in Part 3 – Returnable Schedules and will contain the following as a
minimum:
Refer
Period From Date Of
Item
Description
Clause No
Possession Of Site
No
Portion Number 1
DRAWINGS AND INFORMATION
1.
Contractor to Supply:
Detailed program for all inspections and
surveys, works high lighting critical path
activities, Contract Quality Management Plan
and inspection and Test Plans
OHS Management System and the completed
Schedule 3-4 – Site OHS Management –
Assessment Criteria
OHS Management System Audit Report
Findings
Site Specific Safety Management Plan
8.5h) &
4.23
1 week prior to Possession of
Site
8.1
Attached to Tenderer’s
Quotation
8.1
Attached to Tenderer’s
Quotation
2 weeks prior to Possession of
Site
1 week prior to Possession of
Site
As per Table E
Environmental and Waste Management Plans
8.1
8.4
Quality Documentation
8.3
Final Summary Report and Quality Assurance
documentation
Document and Drawings for Design Review
8.3
4.28 & 8.10
4 weeks after Practical
Completion
Within 4 weeks of Date of Issue
of the Letter of Acceptance.
The Principal to Supply;
Comments on design, drawings, manuals,
procedures and equipment submitted by the
Contractor
SITE WORKS
Possession of Site
2
Completion of erection ready for commissioning
Practical Completion
Within 7 days of receiving of all
the information requested for the
review
Within 2 weeks of Date of Issue
of the Letter of Acceptance
As per the Contractors Works
Program
30 June 2017
NOTES:
1.
Dates shown in the Table of Key Dates are based on an anticipated Date of Issue of the Letter
of Acceptance no later than 7 February 2017, however, The Principal cannot guarantee this
date. 2 weeks written notice of the Date of Possession of Site will be forwarded to The
Contractor.
2.
If The Principal grants Possession of Site prior to the Possession of Site Date shown in the
Table of Key Dates, any happenings occurring during the period between the date possession
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Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
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was granted and the nominated Possession of Site Date, will not be considered as grounds for
an extension of time for Practical Completion.
3.
Completion to a stage of Practical Completion prior to the Date for Practical Completion fixed
under or pursuant to the Contract must not be effected without the prior approval in writing of
The Principal.
4.
The failure to achieve approval of the Specific OHS and Environment Management plans will not
be considered as grounds for an Extension of Time for Practical Completion.
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
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TABLE B - DRAWINGS AND DOCUMENTS FOR TENDERING PURPOSES
Following is a list of indicative drawings; these drawings do not cover all work included in the
specification and are for tendering purposes only.
Drawing No.
VX801300
VX807320
VX827544
VX837356
VX837357
VX837371_1
VX837371_2
VX837382_1
VX837382_2
VX837390
VX837414
DES324846
DES324847
DES431762
DES647067
DES647175
DES917006
VX837362_2
VX837395_2
VX837912
Title
Vales Point Main & Auxiliary Power System Electrical System Diagram Disaster
Recovery
Power Supplies 11kV Transmission Lines 680, 690 Route Plans
Energy Australia - ZONE NO 133 11KV NETWORK SINGLE LINE DIAGRAM
Units 5 & 6 - 6.6kV Station Switchboard 5 Single Line Diagram
Units 5 & 6 - 6.6kV Station Switchboards 3 & 4 Single Line Diagram
SWITCHBOARD 5, 6.6KV_415V OIL&GRIT TRAP TRANSF (PANEL 7) 671
SCHEMATIC DIAGRAM
SWITCHBOARD 5, 6.6KV_415V OIL&GRIT TRAP TRANSF (PANEL 7) 671
SCHEMATIC DIAGRAM LEGEND
SWITCHBOARD 3 & 4, COAL BUNKERING SUBSTATIN(PANEL 8) 689
SCHEMATIC DIAGRAM
SWITCHBOARD 3 & 4, COAL BUNKERING SUBSTATIN(PANEL 8) 689
SCHEMATIC DIAGRAM LEGEND
6.6KV STATION SWITCHBOARD DC RING MAIN PANEL SCHEMATIC
DIAGRAM
SWITCHBOARD 5 COMMUNICATION BLOCK DIAGRAM & TERMINATION
DIAGRAM
CATU Earth Ball.pdf
Cost Sub B Conduits.pdf
FENCES AND GATES TUBULAR FENCE GATES DETAILS
73A,STANDARD FENCE FOR HIGH VOLTAGE AREAS, METRIC
ECNSW STANDARD - ELECTRICAL ELECTRICAL WIRING STANDARD
NUMBERING & COLOURS SCHEDULE
SUBSTATIONS STANDARD EARTHING EARTHING TERMINALS FOR STEEL
STRUCTURES STUB CLAMP ATTACHMENT DETAILS
SUBSTATIONS STANDARD EARTHING PORTABLE EARTHING EQUIPMENT
CATU MT815S SCREW ACTION CLAMP ASSEMBLY
SUBSTATIONS STANDARD EARTHING PORTABLE EARTHING EQUIPMENT
CATU MT 701 SNAP ACTION EARTHING CLAMP ASSEMBLY
Proposed 11kV Feeder Parameters.pdf
Single Line Diagram for Proposed Power and Protection Circuits.pdf
Substation Earth Stub.pdf
VX 807320 - 680 and 690 Feeder Connection Options.pdf
VX306408 - Proposed 6.6kV Cable Routes.pdf
VX807320 - With Legend and Explanatory Notes
6.6KV SWITCHBOARD 5 GENERAL ARRANGEMENT SIDE VIEW
6.6KV SWITCHBOARD 3 & 4 GENERAL ARRANGEMENT SIDE VIEW
Bolting Arrangements For High Current Connections
GIS 12 resin cast CT.pdf
Station Board 3 Coal Bunkering Duty Substation Protection Settings.pdf
Station Board 5 Oil and Grit Standby Transformer Protection Settings.pdf
Pole disc 680 Feeder Pole 224.jpeg
680 Feeder Pole 277.jpeg
Cable connection at Ash Dam Substation.jpeg
Objective ID No. D1385418
Rev: 7 December 2016
Part 1 - Particulars of Work and Special Commercial Requirements
680/690 Line Repowering
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Cable connection at Return Water Substation.jpeg
Typical substation requiring lightning modification.jpeg
TABLE C - DRAWINGS TO BE PROVIDED BY THE CONTRACTOR
The following list of drawings is to be provided by The Contractor within the periods stated in Table A
Table of Key Dates. These drawings are to be provided in accordance with clause 8.5 Documentation
and Drawings.
Drawing Type
Foundation Drawings
Arrangement Drawings
Drawings For Supporting
Services
Logic Diagrams
Electrical System And Circuit
Diagrams
Wiring Diagrams
Schematic Diagrams
Maintenance Drawings
Cable Schedules
Specifics
For substation
For supplied equipment including substation, transformer,
auto-recloser, HV link boxes, marshalling cubicles, protection
panels
For protection systems
Single line diagrams and route plans for new and modified
electrical systems
For all high voltage, low voltage, control (including protection)
and instrumentation systems
For all high voltage, low voltage, control (including protection)
and instrumentation systems
For supplied equipment including transformer, auto-recloser,
switchgear
For all high voltage, low voltage, control (including protection)
and instrumentation cables. Cable numbers to be provided by
The Principal
TABLE D - FIRE FIGHTING EQUIPMENT
The firefighting equipment to be provided will be extinguishers and hoses within the areas allocated to
The Contractor on Site for erection, storage and any other purposes. The type, number and location
of the extinguishers and hoses must be nominated from time to time by The Principal.
In addition to above, the following firefighting equipment must be provided:
Extinguisher
Number Required
portable water type fire extinguisher(s) for use in Site
1
accommodation;
portable foam type fire extinguisher(s) for use on erection 2
Site;
portable foam type fire extinguisher(s) for use in the Site
1
storage area.
Objective ID No. D1385418
Rev: 7 December 2016
Litres Capacity
9
9
9
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TABLE E - QA DOCUMENT SUBMISSION MATRIX
DOCUMENT DESCRIPTION
Quality Assurance
Questionnaire Schedule No.
3-6
Company Quality Manual
Contract Specific Quality Plan
WITH QUOTATION
Copy to be Submitted
Sample to be Submitted
The Questionnaire is to be
completed and returned
with the Tender
One uncontrolled copy
A sample of a Contract
Specific Quality Plan for
similar works
Sample Inspection an Test
Plans used on similar
works
Inspection and Test Plan
Schedule of Proposed
Subcontractor's Schedule 3-4
Schedule of Special
Processes
Objective ID No. D1385418
Rev: 7 December 2016
DURING CONTRACT
To be submitted for review
To be submitted for review
and acceptance by The
and use by The Principal on
Principal
request
The Schedule is to be
completed and returned
with the Tender
One controlled copy within
four weeks of the award of
the Contract
Progressive submission of
controlled ITPs. Each ITP is
to be submitted two weeks
before the commencement
of the relevant phase of the
Work
The Schedule is to be
updated if there are
changes from the Tender
Within two weeks of award
of Contract
ANNEXURE 1 - REQUEST TO ATTEND PRE TENDER MEETING
Tender Details
Pre Tender
Date:
Location:
Pre Tender
Time:
Vales Point
Description:
Contract
Number:
Phone:
Delta Contact:
Tenderer Details
Company
Name:
Company
Contact Person
Email:
Phone:
Number of Staff to attend:
(Please keep to a Maximum of 2- If more required contact the Contact The
Principal Contract Representative to request permission.)
Employee
Details
Name
WorkCover
Position
OHS
General
Induction
Card
Number
Inducted to The
Principal
Yes/No Expiry
Date
Note: Please email listing to The Principal Contract Representative 24 hours prior to the Pre
Tender Meeting.
Objective ID No. D1385418
Rev: 7 December 2016
ANNEXURE 2 – GENERAL CONSTRUCTION REQUIREMENTS
A2.1
Labels and Nameplates
Labels and Nameplates are critical for the safe operation of plant and must not be considered a minor
outstanding item. Nameplates must be supplied and fitted to all items of supplied plant that require
identification or operation. The weight of any item of plant above 1000 kg must be included on the nameplate.
Nameplates must be fitted to all items of plant for which it is reasonable that identification of that equipment
will be required during operation or maintenance.
Engraved labels must be provided for the following applications:
a)
To indicate the service of all instruments, signal transmitters and transducers, controls, relays,
indicating lights, fuses, control panels etc. In these cases the labels must be mounted on or
immediately adjacent to the respective items of equipment
b)
To indicate the function of selector switches, control / switches etc. This may be achieved by
engraving the escutcheon plates of the control equipment.
c)
To identify instruments, controls and equipment generally mounted within panels, consoles and
cubicles which otherwise could only be identified from the front of the panels, consoles and cubicles.
d)
To identify nominated accessories associated with instruments. To identify groups of terminals on
rows of terminal blocks associated with the various particular circuits.
e)
To identify those cabinets (and equipment mounted within the cabinets) associated with analog
control systems and the computer system.
f)
To provide warning in those locations where normal isolation procedures may not ensure that the
equipment is 'dead', e.g. anti-condensation heaters.
g)
To provide warning on all transmitters, transducers and associated isolating equipment used for the
analog control system to warn personnel against unauthorised interference with such devices.
h)
To identify all modulating actuators; such labels are to be located on or adjacent to each actuator
and should identify controlled device.
Engraved labels must not be fitted to any items of equipment, doors or covers which are readily removable or
interchangeable.
Labels for transmitters and pressure and level switches must include in mimic diagram form, details of piping
and valving arrangements.
In general, individual labels must be sized to suit the inscription which will be in 5 mm characters. Labels must
be either engraved or photo-etched anodised aluminium, suitable supporting stands and backing plates must
be provided.
Warning labels must present white lettering on a red background. All other labels must present white lettering
on a black background.
Labels must be secured in position on a fixed portion of the equipment (i.e. not on removable covers) by
nickel-plated brass screws. A combination of screws and glue may be used. Glue only may be used if there is
no practicable alternative.
A2.2
Earthing
Accessible metallic items, and any metallic reinforcement or construction must be effectively earthed.
Particular attention is drawn to the Australian Standard requirements for earthing a high voltage substation
Objective ID No. D1385418
Rev: 7 December 2016
which must be applied to all construction and installation within a power station site.
Earth connections to sensitive equipment such as instrumentation and computer panels must be distributed
radially from the common earth bar. Each connection must be terminated at a different point on the earth bar.
For Motors and other free standing items of plant at least one earth terminal for each item of electrical
equipment (e.g. cubicle, motor) is required. The terminal point must consist of a 10 mm diameter (or larger)
brass bolt or stud with brass washers and nuts, suitable for termination a copper strap 25 mm x 1.5 mm or
accepting a cable terminating lug. For very small items of equipment smaller bolts may be provided, subject to
the approval of The Principal.
Equipment on which the Tenderer provides the incoming power cables must be earthed by the Tenderer to
The Principal's earth grid. Attaching an Earth at mounting fastenings is not permitted, nor may an item be
earthed by mounting on an earthed metal panel;
A2.3
Fasteners
Standard Metric designation fasteners must be used.
Fasteners exposed to weather or corrosion must be of 316 grade Stainless steel or better.
A2.4
Cabling (General)
Unless otherwise approved or required by design, conductor material for all cables must be copper. Only
cables made to Australian Standards and Assured to Australian Standards will be accepted. Conductors of
power and control cables must consist of seven or more strands. Cables must be suitable for use in unearthed
systems
Cabling must be consistent with the requirements of The Principal Standard Drawing DES431762.
Control and power conductors must not be in the same cable unless the cables are supplying movable plant
such as trippers and submersible pumps.
The cross sectional area of the cable must be suitable to withstand the maximum through fault for the
maximum duration. To provide phase segregation, all cables for
3.3 kV system or higher must use single core cables.
Paper insulated lead alloy sheathed cables must not be used.
Cables must be installed in neat and workmanlike manner free from kinks and unnecessary bends. Cable
installation in pits must be installed without impeding access inside such pits
Lubrication must be applied to cables during the installation of PVC sheathed cables in PVC conduits to
prevent the welding and scuffing of the cable sheaths.
Where cables enter or leave conduits, or pass through an opening in a wall, floor or ceiling and cable risers
the conduits and the openings must be fireproof sealed.
In all locations within two metres of the floor and in any location where cables may be exposed to mechanical
damage, guards must be provided.
Where cables pass under or adjacent to pipes containing fluids, stainless steel covers must be provided to
divert any leaking fluid.
Cables must be provided with supports located as close as is practicable to the point of termination of the
cable. Cables run on trays must be clamped to them. Cables in vertical risers must be adequately supported
throughout the run at intervals not exceeding 2 m to prevent undue strain where the cables leave the riser.
Cables must be clamped at the point where they enter or leave a cable tray. At most two layers of cable may
be carried on a tray.
The bending radius of a cable must be greater than that recommended by the manufacturer.
All power cables above 6mm2 must be individually supported. Power cables less than 6mm2 and control
cables may be supported in groups of up to ten cables.
Objective ID No. D1385418
Rev: 7 December 2016
Single core power cables forming part of a three phase system must be rigidly held in trefoil formation every
metre, the installation must be suitable to withstand the maximum short circuit forces for the maximum
duration without damage to itself or other nearby cables, structures or personnel.
Cables must be identified at each end both above and below each gland by identification tags of 13 mm wide
stainless steel strips stamped with 7 mm letters and figures representing the cable number. The strips must
have a fold over tab at each end of at least 10 mm, crimped and must be fixed longitudinally along the cable
by binding with annealed stainless steel wire at the tabs.
The identification tags for cables of trefoil groups must include a suffix consisting of a letter to represent the
phase of the cable. A further suffix consisting of a number must also be used when more than one cable per
phase is used. EG, the first trefoil group of a cable No. 700001 would consist of cables numbered 700001R1,
700001Y1 and 700001B1; the second trefoil group, 700001R2, 700001Y2 and 700001B2 etc.
Cables must be identified at either end and at either side of all penetrations.
The power cable installation at motor terminal boxes must include a suitable support system for the cable and
terminal box while the motor is removed for maintenance.
The use of cable changing boxes for power cables is permitted adjacent to associated motors or
switchboards.
Cables must only be joined at a terminal unless approved by The Principal.
At areas subject to fire hazard and where it is possible to accumulate rubbish or such like material to cause
fire hazard, the cable installation must be protected against damage by fire. Stainless steel sheet of 1.6 mm
thickness is considered as adequate material for the fabrication of fire protective covers. A minimum
clearance distance of 50mm must be maintained for all protective system and for vertical protective systems
fire stopping must be sectionalised at approximately 3 m intervals to prevent chimney effect.
Direct laid cables must not be used unless approved by The Principal.
Stainless steel cable glands must be used on all metallic switchboards, all cable glands must be suitable for
maintaining IP 67 integrity.
Signal cables connected to R.T.D. devices must use the three or four-wire method of connection.
The loop impedance of any cable core pair must not exceed 200 ohms.
A2.5
Cabling (Crimping)
The Crimping tool must be so designed as to prevent release until the correct degree of crimping has been
attained, all lugs must be double crimped.
The correct die for each size of crimp lug must be used. Hexagonal crimps must be used on cables 25 mm2
cross sectional area and larger, and the die identification code must be impressed onto these crimp lugs.
A2.6
Terminations of Cables
Signal cable screens must be bought out at one end of the cable and terminated. When the pigtail of screen is
longer than 15 mm, an insulating sleeve must be placed over the bared wire before termination. The signal
cable screens must be bonded to an appropriate earth at the control system end.
Control cables must be terminated in using heavy duty pre insulated ring type crimp lugs or lip lugs.
Terminated cores must be left sufficiently long and neatly looped to allow a fresh termination should the
original termination device break off. Spare cores which are not required to be terminated must be left long
enough to reach the further most terminal of the row if the cable is terminated.
Low voltage power cables must be terminated using shrinkable sleeves or self amalgamating tape to the
approval of The Principal. The shank of the lug must be insulated.
Only screw type spring loaded (such as SAK type) or stud terminals are allowed for terminating. Insulation
displacement, or push in terminals must not be used.
Objective ID No. D1385418
Rev: 7 December 2016
A2.7
Plugs and Sockets
The connectors of both plug and socket must be of the high contact pressure type with hard gold-plated
contact surfaces, conservatively rated for the duty.
The plug connectors must incorporate a permanent shroud to provide physical protection for the withdrawn
plug. The plug must be capable of insertion into its mating socket one way only.
Multiple cables terminated on the one plug will only be acceptable if each cable comes from the same source
and all cables of the loom are taped together. Each plug must be provided with a means of clamping its
cables to ensure stress is not transmitted to the individual pins from the cable.
After insertion of the plug into its mating socket, a positive method of securing the union must be provided.
A simple numbering system must be used to identify plugs and mating sockets. Individual cores of the
multicore cable to multi-pin connectors need not be identified.
Where a cable is suppling a 3 phase outlet, a neutral must be included.
A2.8
Ferruling
Both ends of every wire must be fitted with approved white non-flammable plastic ferrules having recessed
identifying numerals and/or letters filled with black paint to correspond with the numbering of wiring diagrams.
The ferrules must encircle the wire and insulation. Stamped number tags, plain ferrules marked on the surface
only with ink or paint and similar methods will not be accepted. The numbering system used must comply with
The Principal's numbering scheme, details of which will be given to the Tenderer. All ferrules must be fitted so
as to read from left to right and be the correct way up irrespective of the side from which the wire approaches
the terminal. Where the wire approaches the terminal from above or below, the ferrule marking must read
from bottom to top.
A2.9
Ferruling
Where a control or instrument cable is installed, at least 20% of the core must be spares.
Olex brand Dekoron cable must be used for all instrument cabling installations.
Cable cross section must be such that voltage drops for an instrument of control cable must be less than 5%
of the nominal voltage.
Signal cable screens and drain wires must not be used as a zero voltage or signal return wire.
The cable screen must be continuous and electrically isolated from earth throughout its length. Where the
cable meets a termination, the screen must be regarded as a third isolated conductor and must be terminated
in the same way as the signal wires. The screen must be earthed furthest from the field device and identified
by the cable number.
Instrumentation or control cables may only be terminated to spring loaded terminals using lip lugs.
All wires must be terminated using a lug.
Cores that have Trip functionality must have an additional red ferrule clearly marked trip.
A2.10
Extent of Cable Supply
The Contractor must provide all power, control, indication alarm etc., cables between any two items of plant,
which are to be supplied and installed by him and which would normally have cabling between them.
The Contractor must provide all necessary terminals, cable glands, clamps, cable boxes, jointing and
terminating facilities and supporting steelwork and conduits for the installation of the specified cables. The
installation must be carried out so as to ensure the installation against mechanical or electrical failure under
ordinary use, wear and tear, and any abnormal conditions which may be reasonably anticipated.
A2.11
Setting out of Cabling
Objective ID No. D1385418
Rev: 7 December 2016
The Tenderer must be responsible for the planning and setting out of all cabling work.
Unless approved by The Principal, areas adjacent to the plant having a temperature too high for normal cable
types and/or subject to fire hazards must be avoided. If high temperature regions cannot be avoided, cables
with heat resistant insulation must be used and/or approved heat shields provided
Where duplicate power supplies to the one switchboard parallel, standby and/or emergency plant is involved,
the cables must be routed so that a fire or other prospective source of damage to cables to one item of plant
will not damage the duplicate power supply or those cables to the alternative item of plant. Routing errors
must be rectified by the Tenderer to the satisfaction of The Principal.
Unless approved by The Principal, power cables and control cables must be separated physically. (e.g., on
separate cable trays)
Cable marshalling boxes must be installed in protected positions to the approval of The Principal. For rotating
drives, control signal marshalling boxes must be installed next to the motor start and emergency stop stations.
A2.12
Cable Trays and Racking
Supports must be provided throughout the length of cables to minimise sag and to prevent undue strain on the
cable. The spacing of the supports must not exceed 500 mm. Supports maybe in the form of brackets, ladder
trays or perforated sheet steel trays.
Cable trays must be of welded construction and so constructed that there is no surface which cannot be
galvanised. The supports must be at maximum centres of 2
m. Cable trays must not deflect more than 10 mm when loaded with cables. Intermittent rungs must have an
effective support width of 25 mm at a maximum of 300 mm centres. Cable trays for the support of single core
power cables of a three phase power system must also be capable of withstanding the forces due to the
maximum through fault for the maximum duration without damage. Adjoining cable ladder rack sections must
be electrically bonded at the splice. The cable ladder rack must be electrically bonded to earth grid at intervals
not greater than thirty (30) metres. Perforated cable trays must be electrically bonded to the cable ladder
racks at two points (minimum) for each separate section of cable tray.
A2.13
Conduits
All conduits used on site must be suitable for underground use, and sealed to IP67.
All metal conduits must be earthed at the distribution board by means of an earth clip and a direct connection
to the main earthing conductor. Metal conduit terminating underground for future extension must be provided
with galvanised screw caps on the ends. Goosenecks or other means must be used in long conduit runs to
accommodate relative expansion between conduits and support steelwork etc.
A2.14
Cable Selection
The minimum conductor size for high voltage applications is 120mm2. Insulation rating must be must be 20%
in excess of the rated voltage.
Cables must be sized to have a 20% greater load capacity than the calculated maximum current.
Insulation must be minimum V90 temperature rated. Calculations must take into account DOL motor start
loadings.
The voltage drop, due to motor starting currents, must be limited to ensure satisfactory starting conditions
when the supply voltage is 6% below nominal. Acceptable conditions are 80% voltage at motor terminals.
The power factor of the starting current must be taken as 0.2, if actual power factor is not known.
A2.15
Fault and Impedance Rating
The cross sectional area of the cable (or sheath) must be suitable to withstand the maximum through fault for
the maximum duration.
A2.16
Setting Out of Terminal Strips
Terminal strips must be arranged in vertical rows. In the case of floor-mounted equipment, they must be at
least 200 mm above floor level. Sufficient terminals must be provided on each item of equipment to permit the
Objective ID No. D1385418
Rev: 7 December 2016
connection of all incoming cores. 10% spare terminals must be provided. A minimum of every tenth terminal
must be identified to facilitate terminal locations.
Transparent shrouds must be provided to stop inadvertent access to live conductors designated as above
extra low voltage within Australian standards. Terminals must be grouped and their function identified.
A2.17
Enclosures for Electrical and Control Equipment
It must not be possible to open a door unless any isolator fitted is open.
Where an enclosure is mounted outdoors, a sloped 316 stainless steel roof must be provided, with a minimum
50mm extension past the sides of the cubicle. Standing 50mm above the top of the cubicle.
Protective shrouding will be provided to prevent inadvertent access to any voltage above Extra Low Voltage.
No equipment must be mounted below the level of bottom opening of the door.
Any manual control switches must be mounted between 750mm and 1850mm in height.
All outgoing control circuits must be wired to spring loaded terminal blocks.
Components must be arranged such that there is unrestricted access to terminals and fixing bolts once
protective shrouding is removed.
Cables must be able to be installed without the need to dismantle any part of the enclosure.
Anti-condensation and light circuits must be separate from other circuits within a cubicle, terminals for these
circuits must be clearly labelled with a warning that voltages may be present and identifying the circuit.
Where a DC supply is fed into a switchboard, it will be in the form of a ring main, switches and terminals must
be installed.
A2.18
Power Supply Systems
Power supply systems must be arranged so that under all possible circumstances (except under fault
conditions) the voltage will be sufficient for satisfactory starting, running and stopping of the connected plant
and the requirements of AS 3000 are met.
The systems must also be arranged so that in the event of a fault, damage due to
excessive currents and voltages will be confined to the item of plant in which the fault occurred.
For relay protected systems the fault duration must be taken as the operating time of the back up relay. For
systems protected by fuses the duration must be taken as the operation of time the fuse. In all other cases
unless otherwise nominated or approved by The Principal, the duration of the short must be taken as three
seconds.
Low Voltage systems must have their neutral points earthed effectively. High voltage systems must be
impedance earthed so that the prospective earth fault current will not exceed the rated current of the
transformer supplying the system.
A2.19
Voltage and Frequency Limits
Electrical systems must be designed as a minimum to meet National Electricity Automatic Connection ride
through requirements and to work within the following voltage tolerances.
a) AC Systems
(i)
Frequency: 47 – 51Hz
(ii)
Voltage: +/- 6% nominal sustained, 75% for 5 minutes
b) DC Systems
(i)
Objective ID No. D1385418
Rev: 7 December 2016
240V: 205 - 320VDC - normally 266V DC
(ii)
110V: 95 - 146VDC - normally 122VDC
(iii)
50V: 42 - 65VDC - normally 51VDC
Under heavy load conditions up to 0.06 pu AC V ripple may be expected.
A2.20
Current Transformers
Measurement current transformers must have a rated secondary current of 1A. Protection current
transformers must have a rated secondary current as specified in Part 1 or shown on drawings.
The thermal limit of the current transformers must be not less than the circuit rating.
The rated short time current of the current transformers must be not less than the switchboard fault rating.
Current transformers must be provided complete with all necessary mounting clamps, core earthing bolts and
similar equipment. They must be clamped rigidly to prevent deformation and damage under short circuit
conditions, and mounted in such a way as to allow easy access to secondary terminals and so that the rating
plate is visible without removing equipment other than enclosure doors or covers.
Bar primary current transformers must be mounted on bushings which are supported independently from the
primary conductor, unless otherwise approved.
A rating plate must be fixed to the outside of the enclosure as well as to the current transformer.
Current transformers with wound primaries must have their primary terminals and all connections fully
insulated.
If current transformers of the encapsulated type are used the core and coils must be coated with semi-fluid or
flexible plastic material before encapsulation. Where current transformers for more than one circuit are
included in the same compartment they must be of the encapsulated type.
The final tapping of the coils of non-encapsulated current transformers must consist of at least three layers of
an approved tape, applied half lap, and the surface must then be given two coats of an approved air drying
insulating varnish. The external finish of all toroids or secondary windings must be smooth.
Objective ID No. D1385418
Rev: 7 December 2016