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Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 1 of 116 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 4 of 116 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 5 of 116 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 6 of 116 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 7 of 116 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 8 of 116 (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 9 of 116 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 Rev: 7 December 2016 Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 10 of 116 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 C5288 11 of 116 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 12 of 116 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); Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 13 of 116 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 Rev: 7 December 2016 Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 14 of 116 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); Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 15 of 116 (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 Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 16 of 116 (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 Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 17 of 116 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: Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 18 of 116 (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. Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 19 of 116 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. Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 20 of 116 (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 Rev: 7 December 2016 Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 21 of 116 (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; Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 22 of 116 (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 Rev: 7 December 2016 Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 23 of 116 (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 C5288 24 of 116 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 C5288 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. Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 35 of 116 (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 Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 36 of 116 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 Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 37 of 116 (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 680/690 Line Repowering Vales Point Power Station C5288 38 of 116 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 Vales Point Power Station C5288 39 of 116 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 Vales Point Power Station C5288 40 of 116 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 Vales Point Power Station C5288 41 of 116 (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 Vales Point Power Station C5288 42 of 116 (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. Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 43 of 116 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 Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 44 of 116 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 680/690 Line Repowering Vales Point Power Station C5288 45 of 116 (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; Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 46 of 116 (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 Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 47 of 116 (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; Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 48 of 116 (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. Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 49 of 116 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 Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 50 of 116 (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 Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 51 of 116 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 Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 52 of 116 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 680/690 Line Repowering Vales Point Power Station C5288 53 of 116 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 Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 54 of 116 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 Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 55 of 116 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 Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 56 of 116 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 Objective ID No. D1385418 Rev: 7 December 2016 Schedule No Purpose Applicable Pricing Clauses 2-1.1 Firm Lump Sum Prices 5.1 ; 5.2 Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 57 of 116 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 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 58 of 116 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 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 59 of 116 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 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 60 of 116 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). 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 61 of 116 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; 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 62 of 116 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 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 63 of 116 (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; 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 64 of 116 (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; 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 65 of 116 (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). 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 66 of 116 (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: 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 67 of 116 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 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 68 of 116 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 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 69 of 116 (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 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 70 of 116 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. 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 71 of 116 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. 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 72 of 116 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. 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 73 of 116 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 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 74 of 116 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 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 75 of 116 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 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 76 of 116 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; 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 77 of 116 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 Objective ID No. D1385418 Rev: 7 December 2016 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 Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 78 of 116 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. 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 79 of 116 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] 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 80 of 116 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. 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 81 of 116 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 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 82 of 116 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. 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 83 of 116 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. 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 84 of 116 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; 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 85 of 116 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 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 86 of 116 (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; 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 87 of 116 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. 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 88 of 116 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 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 89 of 116 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. 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 90 of 116 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. 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 91 of 116 (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. 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 92 of 116 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) 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 93 of 116 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 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 94 of 116 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 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 95 of 116 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. 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 96 of 116 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 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 97 of 116 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; 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 98 of 116 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. 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 99 of 116 (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: 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 100 of 116 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. 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 101 of 116 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 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 102 of 116 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 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 103 of 116 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 680/690 Line Repowering Vales Point Power Station C5288 104 of 116 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 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 105 of 116 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 680/690 Line Repowering Vales Point Power Station C5288 106 of 116 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 Vales Point Power Station C5288 107 of 116 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 Part 1 - Particulars of Work and Special Commercial Requirements 680/690 Line Repowering Vales Point Power Station C5288 108 of 116 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