ESKOM HOLDINGS LIMITED
CONTRACT NUMBER
Rev 0
CEP Motor Refurbishment Project
PART 3: SCOPE OF WORK
Document reference
KENDAL MILL MOTOR REFURBISHMENT PROJECT
No of pages
This cover page C3.1
1
Employer’s Works Information
2- 22
Total number of pages
PART C3: SCOPE OF WORK
1
22
C3 ECC3 COVER PAGE
ESKOM HOLDINGS LIMITED
CONTRACT NUMBER
Rev 0
CEP Motor Refurbishment Project
C3.1 EMPLOYER’S WORKS INFORMATION CONTENTS 1. SECTION 1 – DESCRIPTION OF THE WORKS ......................................................................................... 4 1.1
EXECUTIVE OVERVIEW ..................................................................................................................... 4
1.2
ABBREVIATIONS ................................................................................................................................. 5
1.3
DETAILED WORKS DESCRIPTION .................................................................................................... 5
1.4
SPECIFICATIONS FOR THE WORKS ................................................................................................ 7
2. SECTION 2 – MANAGEMENT AND START-UP ......................................................................................... 7 2.1
MANAGEMENT MEETINGS ................................................................................................................ 7
2.2
PROJECT DOCUMENTATION CONTROL ......................................................................................... 8
2.2.1 2.3
COMMUNICATION AND CORRESPONDENCE ........................................................................ 8
HEALTH, SAFETY AND RISK MANAGEMENT .................................................................................. 8
2.3.1
GENERAL .................................................................................................................................... 8
2.3.2
SAFETY OF WORKERS ............................................................................................................. 9
2.3.3
FIRE PROTECTION .................................................................................................................... 9
2.3.4
ASBESTOS .................................................................................................................................. 9
2.3.5
FIRST AID .................................................................................................................................. 10
2.3.6
HOUSEKEEPING ...................................................................................................................... 10
2.3.7
BARRICADING .......................................................................................................................... 10
2.3.8
RADIOGRAPHIC EXAMINATIONS ........................................................................................... 10
2.3.9
HAZARDOUS SUBSTANCES ................................................................................................... 10
2.3.10
RADIATION PROTECTION ....................................................................................................... 10
2.3.11
PLANT SAFETY REGULATIONS ............................................................................................. 11
2.4
ENVIRONMENTAL CONSTRAINTS MANAGEMENT ....................................................................... 11
3. SECTION 3 ................................................................................................................................................. 11 3.1
TRANSPORTATION........................................................................................................................... 11
3.2
DISMANTLING AND REASSEMBLING OF MOTORS ...................................................................... 11
3.3
PLANT AND MATERIAL .................................................................................................................... 12
3.3.1
GENERAL .................................................................................................................................. 12
3.3.2
MATERIALS ............................................................................................................................... 12
3.3.3
LABOUR .................................................................................................................................... 12
3.4
WORKS AND EQUIPMENT FOR THE WORKS SUPPLIED BY THE EMPLOYER ......................... 12
3.4.1
GENERAL .................................................................................................................................. 12
3.4.2
EQUIPMENT SUPPLIED BY THE EMPLOYER........................................................................ 12
3.4.3
CRANES .................................................................................................................................... 12
3.4.4
TELEPHONES ........................................................................................................................... 12
PART C3: SCOPE OF WORK
PAGE 2
C3.1 ECC3: EMPLOYER’S WORKS INFORMATION
ESKOM HOLDINGS LIMITED
CONTRACT NUMBER
Rev 0
CEP Motor Refurbishment Project 3.5
PROCUREMENT, FABRICATION AND DELIVERY .......................................................................... 13
3.5.1
GENERAL .................................................................................................................................. 13
3.5.2
STORAGE MATERIALS ............................................................................................................ 13
4. SECTION 4 ................................................................................................................................................. 13 4.1
WORK TO BE PERFORMED BY THE CONTRACTOR FOR THE WORKS .................................... 13
4.1.1
GENERAL .................................................................................................................................. 13
4.1.2
SCOPE OF WARRANTY ........................................................................................................... 13
4.2
DOCUMENTATION REQUIREMENTS .............................................................................................. 14
4.2.1
GENERAL .................................................................................................................................. 14
5. SECTION 5 - COMPLETION ...................................................................................................................... 14 5.1
GENERAL ........................................................................................................................................... 14
5.2
DOCUMENTATION REQUIRED ........................................................................................................ 15
5.3
COMPLETION TO DEFECT DATE PHASE ...................................................................................... 15
6. SECTION 6 - PROGRAMME AND PLANNING ......................................................................................... 15 6.1
OVERHAUL PROJECT ...................................................................................................................... 15
7. SECTION 7 - SUBCONTRACTING ............................................................................................................ 16 7.1
GENERAL ........................................................................................................................................... 16
8. SECTION 8 - TESTS AND QUALITY CRITERIA ....................................................................................... 16 8.1
COMMISSIONING, TESTING AND HAND-OVER ............................................................................. 16
8.1.1
QUALITY REQUIREMENTS...................................................................................................... 16
8.1.2
ELECTRICAL TESTS REQUIRED ............................................................................................ 17
8.1.3
TESTS DURING WINDING AND FINAL ASSEMBLY ............................................................... 17
8.1.4
TESTS AFTER WINDING AND FINAL ASSEMBLY ................................................................. 17
8.1.5
TESTS ON THE FULLY ASSEMBLED MOTOR ....................................................................... 17
8.1.6
QUALITY HOLD ......................................................................................................................... 18
9. SECTION 9 ................................................................................................................................................. 19 9.1
PRICE LIST (6.6 KV SQUIRREL CAGE INDUCTION MOTORS) ..................................................... 19
10. SECTION 10 - ESCALATION ................................................................................................................... 20
PART C3: SCOPE OF WORK
PAGE 3
C3.1 ECC3: EMPLOYER’S WORKS INFORMATION
ESKOM HOLDINGS LIMITED
CONTRACT NUMBER
Rev 0
CEP Motor Refurbishment Project
1
DESCRIPTION OF THE WORKS 1.1
EXECUTIVE OVERVIEW
The “Works” that will be done on the 6.6 kV CEP motors of Kendal Power Station cover:
Transportation from Kendal Power Station to the contractor’s premises.
Stripping and marking of all parts with a unique and relevant job number.
Performing a complete mechanical & electrical assessment of the motors in the form of a full assessment report to determine the scope of work.
The scope of work must be approved by the employer before any repair work can commence on the motor.
Overhauling, assembling and testing of motors as specified by the Employer’s representative (for routine tests as well as final acceptance tests) including test certificates.
Supplying of motor spares as per OEM specification.
Delivery of the motor, including data pack, to Kendal Power Station.
The Employer has very limited information on the motors. The Contractor must obtain all the design and manufacturing details required for the Works. Upon completion of the Works, motors must be delivered to Kendal Power Station Main stores (or any other location preferred by the employer). The data pack must be delivered to the motors system engineer.
Should the motor be found to be beyond repair, the contractor will be required to return the motor to Kendal Power Station.
Whenever additional testing or work, which is not covered by the contract, may be required for assessment, an approval from the Employer’s representative must be obtained and a quotation must be submitted to Kendal Power Station before commencement of such tests or activities.
PART C3: SCOPE OF WORK
PAGE 4
C3.1 ECC3: EMPLOYER’S WORKS INFORMATION
ESKOM HOLDINGS LIMITED
CONTRACT NUMBER
Rev 0
CEP Motor Refurbishment Project
1.2
ABBREVIATIONS
Abbreviation
Meaning given to the abbreviation
MV
Medium Voltage
CEP
Condensate Extraction Pump
kV
Kilo Volt
OEM
Original Equipment Manufacturer
NDT
Non Destructive Testing
MPI
Magnetic Particle Inspection
UT
Ultrasonic Testing
CACA
Closed Air Circuit Air
CACW
Closed Air Circuit Water
TEFC
Totally Enclosed Fan Cooled
CT
Current Transformers
RTD
Resistance Temperature Detectors
IR
Insulation Resistance
PI
Polarization Index
DE
Drive End
NDE
Non Drive End
El-Cid
Electromagnetic Core Imperfection Detection
VPI
Vacuum Pressure Impregnation
1.3
DETAILED WORKS DESCRIPTION
This section outlines the work to be done on the CEP motors. The Contractor must utilize the listed items as the minimum scope for the quotations and provide the employer with a detailed breakdown of costs.
General
Cost (R)
1. Transport 1.1 Transport motor from Kendal Power Station to Repairer workshop and back. 1.2 On-site transport. (Failed motor to Stores, Coupling swap, Spare motor to site)
PART C3: SCOPE OF WORK
PAGE 5
C3.1 ECC3: EMPLOYER’S WORKS INFORMATION
ESKOM HOLDINGS LIMITED
CONTRACT NUMBER
Rev 0
CEP Motor Refurbishment Project 2. Strip and Assess 2.1 Disassemble motor. 2.2 Wash and dry stator and clean all parts. 2.3 Core-flux test. 2.4 Watt-loss test. 2.5 IR and PI test. 2.6 Tan-delta test. 2.7 El-Cid test. 2.8 Bar-to-bar test. 2.9 Winding resistance test. 2.10 NDT tests on Rotor, cooling fans and shaft journals. (UT, MPI, and Dye-Pen) 2.11 Check for concentricity of rotor. 2.12 Test all instrumentation. (RTD’s, Thermocouples, CT’s, Space-heaters) 2.13 Assess bearings, oil-rings, labyrinths and bearing insulation, bearing housings. 2.14 Inspect and assess motor cooler. 3. Stator 3.1 New gasket to be installed on terminal box as well as auxiliary terminal boxes. (cork packing). 3.2 Supply & fit new flag connectors for main terminal box. 3.3 Supply and fit new desiccators. 3.4 Replace stator leads. (Leave enough slack to swop MTB with star-point if necessary) 3.5 Replace star-point. 3.6 Replace main terminals. 3.7 Stator Rewind and VPI. 3.8 Complete new stator core. (Supply and Stack) 3.9 Re-stack core. 3.10 Complete re-wedge. 3.11 Replace CT’s. 3.12 Replace auxiliary terminals. (CT’s, RTD’s, space heaters)
PART C3: SCOPE OF WORK
PAGE 6
C3.1 ECC3: EMPLOYER’S WORKS INFORMATION
ESKOM HOLDINGS LIMITED
CONTRACT NUMBER
Rev 0
CEP Motor Refurbishment Project 3.13 Duplicate auxiliary terminal boxes. 3.14 Replace space heater if necessary. 3.15 Replace space heater wiring with silicon wiring if necessary. 3.16 Skim feet. 4. Coolers 4.1 Remove water boxes and replace gaskets (for CACW) 4.2 Clean and Repair cooler tubes. (for CACA and CACW) 4.3 Replace all neoprene seals. (for CACA and CACW) 4.4 Pressure test cooler. (for CACW) 5. Rotor 5.1 Re-bar rotor. 5.2 Complete new rotor-core. (Supply and Stack) 5.3 New short-circuit rings. 5.4 Micro-welding on shaft journals. 5.5 Micro-welding on seal-landings. 5.6 Micro-welding on shaft extensions. 5.7 Rotor light skim. 5.8 Rotor balancing at full-speed with fans and coupling (if no coupling then half-key) 5.9 Inspect condition of cooling fans. 5.10 Repair external cooling fans. (TEFC and CACA) 5.11 Repair internal cooling fans. (CACW and CACA) 5.12 Replace external cooling fans. (TEFC and CACA) 5.13 Replace internal cooling fans. (CACW and CACA) 6.
Bearing and seals
6.1 Replace labyrinth seals. 6.2 Replace oil seals. 6.3 Repair thrust pads (NDE).
PART C3: SCOPE OF WORK
PAGE 7
C3.1 ECC3: EMPLOYER’S WORKS INFORMATION
ESKOM HOLDINGS LIMITED
CONTRACT NUMBER
Rev 0
CEP Motor Refurbishment Project 6.4 Repair thrust and guide journal. 6.4 Supply & fit new DE & NDE inner and outer bearing caps. 6.5 Re-metal bearings. (NDE & DE) 6.6 Replace guide bearing. (DE) 6.7 Replace bearing insulation. 6.8 Replace type K thermocouple. 6.9 Replace weir. (Mechanical seal) 6.10 Replace sump-cover gasket, sight glasses and filler cap. 6.11 Replace oil drain valves. (each) 7.
Assembly
7.1 Assemble all parts. 8.
Final tests
8.1 Bearing run, including vibration tests. 8.2 Full-load test. 9. Other 9.1 Supply and Stack complete Stator- and Rotor-core.
1.4
SPECIFICATIONS FOR THE WORKS
The repair should never adversely affect motor performance.
The motors must be refurbished to OEM specifications. No deviations or modifications are allowed.
The Contractor shall comply with the ESKOM standard for “Refurbishment of Power Station Electric Motors” GGS0389.
The Contractor shall comply with the Eskom standard for ‘’ Transportation of Power Station Electric motors’’ 36-397.
The Contractor shall comply with the ESKOM specification for “Power Station Electric Motor Procurement” GGS0802.
The Contractor shall be expected to keep one set of stator- and rotor-core laminations in stock for the duration of the project.
PART C3: SCOPE OF WORK
PAGE 8
C3.1 ECC3: EMPLOYER’S WORKS INFORMATION
ESKOM HOLDINGS LIMITED
CONTRACT NUMBER
Rev 0
CEP Motor Refurbishment Project
2. SECTION 2 – MANAGEMENT AND START-UP 2.1 MANAGEMENT MEETINGS Meetings must be held biweekly (or weekly if necessary) between the Project Manager and the Contractor (and any other co-opted members). The Contractor must be represented by a Project Manager at each meeting. The venue for these meetings must be determined by the Project Managers at the inaugural meeting. The Employer’s Project Manager will write the minutes of the meetings.
Meetings of a specialist nature may be convened as described above, or can be arranged at a time and location that suits both Parties.
The Contractor reports the overall progress to the Project Manager when notified as a minimum requirement and the following must be included.
Contractor’s progress on current activities.
Contractor’s planned start and finish dates for the works.
Contractor’s and Employer’s project programs to be aligned.
The progress of any other relevant activities.
To discuss any technical or commercial issues related to the works.
To discuss any interfacing requirements related to the works.
2.2 PROJECT DOCUMENTATION CONTROL 2.2.1
COMMUNICATION AND CORRESPONDENCE
All correspondence must include:
Employer Contract number.
Contract description i.e. Kendal Power Station CEP Motor Refurbishment Project.
Correspondence subject matter.
Where appropriate the correspondence includes the Project Manager’s reference.
All communications from the Contractor are numbered sequentially with a prefix as advised by the Project Manager. The Project Manager responds in like manner to a maximum of two address formats provided in writing by the Contractor. The prefix is decided upon at the inaugural meeting.
PART C3: SCOPE OF WORK
PAGE 9
C3.1 ECC3: EMPLOYER’S WORKS INFORMATION
ESKOM HOLDINGS LIMITED
CONTRACT NUMBER
Rev 0
CEP Motor Refurbishment Project 2.3 HEALTH, SAFETY AND RISK MANAGEMENT
The Contractor shall provide a health and safety plan based on Employer’s Safety, Health and Environmental (SHE) Specification. 2.3.1
GENERAL
The Contractor complies with the Occupational Health and Safety Act no 85 of 1993 and its regulations, Eskom SHEQ Policy, Standards, Procedures, Guidelines, Specifications and Regulations.
The Contractor ensures safety awareness at all times through continuous training.
The Contractor, at all times is responsible for the supervision of his employees, agents, Sub-Contractors and takes full responsibility and accountability for ensuring they are competent, compliant and aware of the legal requirements and other requirements and execute the works accordingly
The Contractor ensures that all statutory appointments and appointments required by any Eskom Regulations are made in writing and that all appointees fully understand their responsibilities and are trained and competent to execute their duties.
The Employer, or any person appointed by the Employer, may, at any stage during the term of contract:
Conduct health and safety audits by a competent person regarding all aspects of compliance with the SHEQ Requirements, at any off-site place of work, or the site establishment of the Contractor;
Refuse any employee, Sub-Contractor or agent of the Contractor access to the premises if such person has been found to commit an unsafe act or any unsafe working practice or is found not to be competent or authorised.
Issue the Contractor with a stop order should the Employer become aware of any unsafe working procedure or condition or any non-compliance.
The Contractor immediately reports any incidents, disabling injury, near miss, first aid incident as well as any threat to health or safety of which it becomes aware at the works or on the Site to the Project Manager.
The Contractor agrees that the Employer is relieved of any and all of its responsibilities and liabilities in terms of Occupational Health and Safety Act no 85 of 1993 in respect of any acts or omissions of the Contractor, and the Contractor’s employees, agents or Sub-Contractors, to the extent permitted by the Occupational Health and Safety Act no 85 of 1993.
2.3.2
SAFETY OF WORKERS
The Contractor ensures the safety of all persons working in the Site. Any hot work including welding will be applied for in accordance with a permit to work system. No welding will be allowed on site unless permission is granted in writing by the Project Manager.
All welding, flame cutting and grinding work is properly screened to protect persons from arc flashes or eye injuries. Fire blankets are fitted over the scaffolding planks and platforms. Precautions are taken to prevent any objects welding or grinding splatter from falling.
PART C3: SCOPE OF WORK
PAGE 10
C3.1 ECC3: EMPLOYER’S WORKS INFORMATION
ESKOM HOLDINGS LIMITED
CONTRACT NUMBER
Rev 0
CEP Motor Refurbishment Project 2.3.3
FIRE PROTECTION
The Contractor ensures that adequate fire fighting apparatus is provided at all his work sites, and that his personnel are trained in the use of this apparatus.
The Contractor takes precautions to prevent any occurrence of fires or explosions while carrying out any work near flammable gas and liquid systems. Any tampering with the Employer’s fire equipment is strictly forbidden.
All exit doors, fire escape routes, walkways, stairways, stair landings and access to electrical distribution boards must be kept free of obstruction, and not be used for work or storage at any time. Fire fighting equipment remains accessible at all times.
In case of a fire, report the location and extent of the fire to the Electrical Operating Desk at extension 6796. 2.3.4
ASBESTOS
The Contractor does not disturb any thermal insulating material on the plant until it has been positively identified as not containing asbestos. Approval is obtained from the Supervisor before any thermal insulation is disturbed.
The Contractor is obliged to ascertain from the Project Manager in advance whether areas required to be stripped, are non-asbestos. 2.3.5
FIRST AID
The Contractor provides a First Aid service to his employees and Sub-Contractors. In the case where these prove to be inadequate, like in the event of a serious injury, the Employer’s Medical Centre and facilities will be available.
Outside the Employer’s office hours, the Employer’s First Aid Services are only available for serious injuries and life threatening situations.
The Employer recovers the costs incurred, in the use of the above Employer’s facilities, from the Contractor.
2.3.6
HOUSEKEEPING
The Site is cleaned daily. All electrical cables and hoses are routed so as not to cross over floors and walkways. All Equipment is packed neatly without interference to access. All excess scaffolding material is removed from Site after the scaffolding has been erected. Contractor is responsible for their removal to the designated scrap area on a daily basis. 2.3.7
BARRICADING
Access to danger zones is restricted using handrail type guards of at least 1, 2 meters high and able to block access to the danger zone. Symbolic safety signs depicting 'Danger' and 'No entry' are attached to the guards. This includes access during the taking of X-rays.
PART C3: SCOPE OF WORK
PAGE 11
C3.1 ECC3: EMPLOYER’S WORKS INFORMATION
ESKOM HOLDINGS LIMITED
CONTRACT NUMBER
Rev 0
CEP Motor Refurbishment Project 2.3.8
RADIOGRAPHIC EXAMINATIONS
When radiographic tests are carried out in the plant by Others the danger area is evacuated with the exception only of authorized radiographic workers, and thereafter barricaded. Compliance is with the Kendal Power Station Site Regulation.
The relevant warning signs at the lockout gates are bolt secured and not by wire or any other means, which could be removed while radiographic tests are in progress.
The radiographic technicians ensure that all the lockout gates are opened on completion of the tests. 2.3.9
HAZARDOUS SUBSTANCES
The Contractor manages hazardous substances in accordance with the requirements of Occupational Health and Safety Act no 85 of 1993 and NEMWA Act. The Contractor declares all hazardous chemical substances brought to site to the Employer.
2.3.10 RADIATION PROTECTION
The Contractor conforms to Kendal procedure 55/15-PA-004 (Industrial Radiography Procedure) and legislative requirements when performing any industrial radiography.
2.3.11 PLANT SAFETY REGULATIONS
The Contractor complies with the Employer’s Plant Safety Regulations.
The Contractor ensures that all Supervisors attend Employer’s Plant Safety Regulations training and are authorised as Responsible Person.
2.4 ENVIRONMENTAL CONSTRAINTS AND MANAGEMENT The contractor ensures that all goods, services or works comply with the relevant Kendal Power Station environmental procedure for contractors, environment policy, Environmental risk assessment procedure, Waste management procedure and Nonconformity, corrective and preventative action procedure.
The Contractor ensures that all goods, services or works supplied in terms of the Contract comply with all applicable environmental legislation.
The Contractor is responsible to keep the work area clean of any rubble. All waste introduced and/or produced on the Employer’s premises by the Contractor for this contract, is handled in accordance with the minimum requirements for the Handling and Disposal of Hazardous Waste in terms of Government Legislation as proclaimed by the Department of Water Affairs and Forestry Act 1994 and Eskom environmental requirements.
The Contractor must comply to the following Kendal Power Station Procedures: o
1015682 – Environmental Policy.
o
1015684 – Environmental Non-conformities, corrective and preventative actions.
o
55-PC-010 – Waste Management Procedure.
PART C3: SCOPE OF WORK
PAGE 12
C3.1 ECC3: EMPLOYER’S WORKS INFORMATION
ESKOM HOLDINGS LIMITED
CONTRACT NUMBER
Rev 0
CEP Motor Refurbishment Project
3. SECTION 3 3.1 TRANSPORTATION The rotor shaft must be locked using a clamp to prevent axial shaft movement during transit. The motor should be placed on rubber blocks. The contractor must comply with Standard 36-397 i.e. Transportation of Power Station Electric Motors.
During transportation to and from Kendal motors must be covered using tarpaulin.
3.2 DISMANTLING AND REASSEMBLING OF MOTORS Precautions must be taken to ensure that no damage is imposed to the motor during the dismantling phase. Ensure that:
Motors and motor covers are lifted using “D” shackles for lifting purposes.
Tubes do not damage the shaft.
Slings are not placed on either the bearing or seal surfaces.
The end windings are protected from damage by the rotor and slings.
Extra care is taken to ensure that the rotor does not touch the stator during dismantling.
3.3 PLANT AND MATERIAL 3.3.1
GENERAL
The following are a list of standard specifications as referred to in the Works information. The Contractor must ensure that he obtains the latest revision of the below standards.
Specification
Description :
GGS 0389
Refurbishment of Power Station Electric Motors
GGS 0802
Power Station Electric Motor Procurement
QM 58
Supplier Contract Quality Requirements Specification
GGR 0992
Plant Safety Regulations
36-397
Transportation of Power Station Electric motors
ISO 9001
Quality Management Systems
ISO 14001
Environmental Management Systems
IEC 60034
Rotating Electrical Machines
1015682
Kendal Power Station Environmental Policy
1015684
Environmental Non-conformities, corrective and preventative actions
55-PC-010
Kendal Power Station Waste Management Procedure
PART C3: SCOPE OF WORK
PAGE 13
C3.1 ECC3: EMPLOYER’S WORKS INFORMATION
ESKOM HOLDINGS LIMITED
CONTRACT NUMBER
Rev 0
CEP Motor Refurbishment Project 3.3.2
MATERIALS
Except where specified otherwise by the Employer, the Contractor provides, manufactures, delivers and stores all material, tools, and test equipment to implement the Works. Only ESKOM approved material to be used in refurbishing and repairing of the MV the motors.
3.3.3
LABOUR
The Contractor provides appropriate personnel to supervise and perform the Works, in accordance with this contract.
3.4 WORKS AND EQUIPMENT FOR THE WORKS SUPPLIED BY THE EMPLOYER 3.4.1
GENERAL
This section describes what the Employer is to supply specifically for the purpose of the Works. The Contractor is to supply everything else required to provide the Works.
3.4.2
EQUIPMENT SUPPLIED BY THE EMPLOYER
All motors mentioned under the scope of work. Motors, listed as per the price list, located at Kendal Power Station.
3.4.3
CRANES
A mobile crane will be supplied by the Employer on request of the Contractor. The Contractor must indicate the exact date, time and duration when the crane will be needed. This must be done five days prior to loading and unloading of motors. Failing to do so might lead to unnecessary delay.
3.5 PROCUREMENT, FABRICATION AND DELIVERY 3.5.1
GENERAL
The Employer reserves the right to appoint a representative or representatives to inspect all parts during erection and to be present at any of the tests specified. Such witnessing of tests by Eskom does not relieve the Contractor of his contractual responsibilities. 3.5.2
STORAGE OF MATERIAL
The Contractor shall ensure that during the period between motor arrivals at the contractor’s workshop, all motors are stored in acceptable and approved manner as to prevent damage by fire, manhandling, corrosion and/or theft, etc.
PART C3: SCOPE OF WORK
PAGE 14
C3.1 ECC3: EMPLOYER’S WORKS INFORMATION
ESKOM HOLDINGS LIMITED
CONTRACT NUMBER
Rev 0
CEP Motor Refurbishment Project 4. SECTION 4 4.1 WORK TO BE PERFORMED BY THE CONTRACTOR FOR THE WORKS 4.1.1
GENERAL
It is not the intention of this scope of work to specify in detail all the activities to be performed by the Contractor. The Contractor is responsible for carrying out all activities and supplying everything necessary to complete the Works in all respect, irrespective whether such an activity or item of plant is specifically listed in the contract document or not. For any additional work, a quotation must be sent to the employer for approval prior to commencement of the work. The contractor must ensure that all motors that are still in a running condition are tested prior to dismantling. These tests will be used as a base for the final tests after the repairs. Such test result must be witnessed by the Employer.
4.1.2
SCOPE OF WARRANTY
The scope of the warranty provided by the Contractor includes, but is not limited to:
All workmanship, new materials and any modifications or deviations from the original design;
All re-used components;
The identification of the full extent of defects in the motor, and the completion of all necessary refurbishment work;
The compliance of the motor with the agreed acceptance criteria for the following site tests carried out by the Employer;
Contractor to provide the material specification and dimensions for all new bearing components. Approval from Employer is required before new materials are made part of the machine. Employer has the right to inspect all new components before use.
The Contractor is responsible for, but not limited to the refurbishment of the following motors: Plant OEM Power (kW) Speed (rpm) Power Factor Voltage (kV) Current (A) Frame Size Duty cycle Mass (kg) Frequency (Hz) Cooling IP rating Class Insulation Lubricant DE bearing NDE bearing Motor orientation Mounting PART C3: SCOPE OF WORK
Mill Motor GEC 1,550 993 0.83 6.6 172 UDV500 S1 9,810 50 CACA 55 F ISO-VG46 Glacier BP 3997 sleeve bearing Glacier BP 3996 sleeve bearing Vertical Flange mounted PAGE 15
C3.1 ECC3: EMPLOYER’S WORKS INFORMATION
ESKOM HOLDINGS LIMITED
CONTRACT NUMBER
Rev 0
CEP Motor Refurbishment Project 4.2 DOCUMENTATION REQUIREMENTS 4.2.1
GENERAL
The Contractor shall supply all documentation including test certificates, related to servicing, overhauling and of the systems and equipment supplied under this Contract. The format, content, layout and quality of all documentation shall be to the Employer’s approval.
5. SECTION 5 – COMPLETION Completion is after factory acceptance tests were passed in accordance with the acceptance criteria or to the employer’s satisfaction. If at any point there are deviations from the acceptance criteria, the employer may request that an on-site load-run of at least 72-hours has to be performed before motor is accepted.
5.1 GENERAL It is the Contractor’s responsibility to issue the certificate of completion of the Works to the Employer. If, in the opinion of the Employer, the Works have been completed, satisfactorily passes all tests that have been prescribed and has been satisfactorily operated by the Contractor during the commissioning period, in the manner and to the required levels of efficiency and output prescribed by the Employer, the Employer will issue a certificate of actual completion in respect of the Works.
The plant will only be taken over once the tests certificate including additional documentation has been issued to the Employer.
5.2 DOCUMENTATION REQUIRED Upon completion of the works the Contractor shall supply the Employer with a full data pack consisting of the following:
Assessment or fault report.
Core Flux / Watt Loss test certificates.
Tan Delta test certificate.
Rotor bar continuity / El-Cid test certificate.
Run-out test certificate.
Rotor NDT, MPI and balancing certificate.
White metal bearing, material and bonding certificates.
Build list.
Bearing insulation measurement.
Bearing run until temperature has stabilized.
Vibration Spectrum report.
No- load run report.
Heat-run. (if requested)
PART C3: SCOPE OF WORK
PAGE 16
C3.1 ECC3: EMPLOYER’S WORKS INFORMATION
ESKOM HOLDINGS LIMITED
CONTRACT NUMBER
Rev 0
CEP Motor Refurbishment Project
5.3 COMPLETION TO DEFECT DATE PHASE The defect date phase will commence immediately once the motor has been installed in the plant. It is the responsibility of the Employer to inform the Contractor about this date. During the defects date phase the Employer shall be responsible for the operation of plant and routine maintenance. The Contractor shall be responsible for the rectification or repair of all defects arising from normal operation or inadequate workmanship.
6. SECTION 6 - PROGRAM AND PLANNING
6.1 OVERHAUL PROJECT The project program and any possible changes thereto will be communicated to the contractor by the employer. The contractor has 7 working days to collect, strip and assess (including providing assessment reports) as well as to develop a proposed SOW and project program for each specific motor from receiving a request to collect that motor from Kendal Power Station.
7. SECTION 7 – SUBCONTRACTING
7.1 GENERAL The Contractor is to provide a list of all his Sub-Contractors and detail which activities are to be performed by each Sub-Contractor. Any delay in the program caused by a Sub-Contractor of the Contractor is to the account of the Contractor.
PART C3: SCOPE OF WORK
PAGE 17
C3.1 ECC3: EMPLOYER’S WORKS INFORMATION
ESKOM HOLDINGS LIMITED
CONTRACT NUMBER
Rev 0
CEP Motor Refurbishment Project 8. SECTION 8 – TESTS AND QUALITY CRITERIA 8.1 COMMISSIONING, TESTING AND HAND-OVER
8.1.1
QUALITY REQUIREMENTS
The Contractor shall comply with all requirements of Employer Standard QM 58 – Supplier Contract Quality Requirements Specification. Before the motor is removed from site a motor component check sheet should be filled by both the contractor and the Employer. Any additional information should be noted and the check sheet updated accordingly.
Once the motors are stripped the contractor should involve the Employer. The Contractor must develop a check sheet indicating all motor components. This will be used to assess the motor – component by component – and also to cost the work by component during inspection. This is done to ensure that the scope of work is done as per assessment finding. Should any additional repair work be required on the motor the contractor must inform the Employer about such activities prior to commencement. Written approval for additional work is to be provided by the Employer.
It is the responsibility of the Contractor to ensure that the Employer and others required by the Employer are present during dismantling to inspect any evidence of failure, or aspects of defective design or workmanship uncovered. The contractor is also to ensure that correct photographic records are made; identifying and reporting to the Employer any weaknesses that would have caused failure or might cause future failure. All tests results, investigations and calculations required for these purposes are to be carried out by the Contractor.
The Contractor is to develop a full quality program (QCP) which complies with the ISO 9001 standard. This quality plan is to be approved by the Employer. The Contractor shall comply with all requirements contained in the ESKOM Standard QM 58 – Supplier Contract Quality Requirements Specification and any amendments thereto, which the Employer considers necessary or expedient during the contract.
On submitting the tender the Contractor shall supply the employer with a QCP for the overhauling process. Before commencing with the overhaul the Contractor must supply a bar chart detailing start date, activities, duration and completion date of works including the quality hold points, to the Employer.
8.1.2
ELECTRICAL TESTS REQUIRED
The following tests will form part of the acceptance criteria. See section 1.3 – Detailed works description.
8.1.3
TESTS DURING WINDING AND FINAL ASSEMBLY
Dielectric tests are carried out to the agreed quality plan submitted by the Contractor.
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C3.1 ECC3: EMPLOYER’S WORKS INFORMATION
ESKOM HOLDINGS LIMITED
CONTRACT NUMBER
Rev 0
CEP Motor Refurbishment Project 8.1.4
TESTS AFTER WINDING AND FINAL ASSEMBLY
Insulation resistance is measured before and after high-voltage dielectric tests. The temperature at which the readings are taken is recorded in each case. The results are shown to meet the approved requirements after correction to standard temperatures.
Dielectric tests must be carried out in accordance with SANS 60034.
Stator winding resistance is measured and recorded with the winding temperature at the time. The resistance is shown to agree with the design value within agreed limits. 8.1.5
TEST ON THE FULLY ASSEMBLED MOTOR
No-load and locked rotor test results are measured and recorded, and shown to be as specified.
8.1.6
QUALITY HOLD
Inspections are to be carried out by the Employers representative in conjunction with the Contractor, during assessment and testing.
The following are some of the hold points included in the program
Stator Winding Resistance.
Winding Insulation Resistance.
Polarisation Index.
Tan-Delta.
HV test.
Locked rotor test. (Voltage or Current balance)
Rotor. (Bar to bar & El-Cid)
Bearing temperature DE & NDE.
Air gap measurements before and after strip.
Insulation resistance.
Full-load test.
Vibration analysis.
No load test.
Locked rotor test.
Temperature rise, efficiency, power factor (duty point, full load)
Torque/speed characteristic.
The acceptance criteria for all tests performed shall be as per GGS0389.
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C3.1 ECC3: EMPLOYER’S WORKS INFORMATION
ESKOM HOLDINGS LIMITED
CONTRACT NUMBER
Rev 0
CEP Motor Refurbishment Project
9. SECTION 9 9.1 PRICE LIST (6.6 KV SQUIRREL CAGE INDUCTION MOTORS)
Motor Details
Rands
kW
Pole
Frame size
Assessment
Refurbishment
Total Cost
1550
6
UDV500
R
R
R
Skill
Rate (R/hr)
Fitter Winder Labourer Supervisor Engineer
Tendered prices are to be excluded of Value Added Tax, but inclusive of all costs related to this project.
An additional 25% will apply to labour costs for any emergency work done. If this does not cover all labour expenses overtime rates may be used to defray costs.
No additional costs will be paid for spare parts during emergency work.
…………………………. Tenderer’s Name
……………………………… Signature
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C3.1 ECC3: EMPLOYER’S WORKS INFORMATION
ESKOM HOLDINGS LIMITED
CONTRACT NUMBER
Rev 0
CEP Motor Refurbishment Project
10. SECTION 10 - ESCALATION
Fixed prices/rates are preferred for the full contractual period. However, should the tenderers be unable to offer fixed prices/rates for full contractual period of five (5) years, the only escalation acceptable to Eskom will be as follows: FIXED:
YEAR 1:
01/04/2014 - 31/03/2015
ESCALATION:
YEAR 2:
01/04/2015 - 31/03/2016
YEAR 3:
01/04/2016 - 31/03/2017
Year two and three will be subject to escalation on an annual basis, and will be linked to SEIFSA indices table c 3 (a) Labour cost base date March 2014. 10% of the value will remain fixed and the remaining 90% will be subject to escalation. PRICES/RATES FIXED FOR FULL CONTRACTUAL PERIOD?
YES
NO
PRICE/RATES SUBJECT TO ESCALATION CLAUSE ABOVE?
YES
NO
OR ANNUAL INCREASE FOR THE SECOND YEAR: …………..% AND THIRD YEAR: …………….
………………………………… NAME OF TENDERER
PART C3: SCOPE OF WORK
……………………………….. TENDERER'S SIGNATURE
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C3.1 ECC3: EMPLOYER’S WORKS INFORMATION
