Template Project No.

Identifier: P181
DETAIL DESIGN DOCUMENT Purchase
1000782389
Order:
The design and implementation of back- Authorisation
2022.02.19
Date:
up Generators and upgrade of the Revision
LO937 existing MLV distribution board at CSIR Date:

STAGE 1 - CONCEPT DESIGN REPORT

BUILDING 9 DC GENERATOR INSTALLATIONS
REVISION 00 - FEBRUARY 2022

PREPARED FOR: SUBMITTED BY:

Contact Person: Mr Abongile Gobeni PLP Consulting Engineers (PTY) Ltd.

CSIR Pretoria - Building 9 P.O. Box 2931
Meiring Naude Rd, Brummeria BROOKLYN
Pretoria, 0001 0075
South Africa
Contact Person: Victor Sambokwe (Pr.Tech.)

Tel: 012 – 807 6437

Fax: 086 656 9604
Email: [email protected]
 DETAIL DESIGN DOCUMENT
The design and implementation of back-up
Generator and upgrade of the existing MLV Page 2 of 35
distribution board at CSIR

PROJECT NAME: Back-up Generator and upgrade of the existing MLV distribution board
PURCHASE ORDER NUMBER: 1000782389
1. Executive Summary

PLP Consulting Engineers (Pty) Ltd has been appointed by CSIR, Pretoria, as Professional Electrical Consulting
Engineers to prepare the Concept Design report for this project.

The existing 1 MVA generator will be removed from the data center IT load, and two new generators will
be installed as data center back up electrical supplies in an N+1 redundancy scenario.

The existing MLV board will be replaced with a new Board, CSIR envision an almost maintenance free
MLV board where the board will have online thermal scanning and some of the MCCB’s will have micro
logics to enable CSIR to monitor power quality and consumption alike further the new MLV board will
feed the whole of building 9 and the data center.
All infrastructure will have early warning using the most appropriate technology where notification will be
sent to CSIR maintenance personnel using SMS, messaging service, and or e-mails.

PLP Consulting Engineers (Pty)Ltd objective is to assist the CSIR Team with the Assessment and Redesigning
of the existing MLV Boards and the Generator installations, construction monitoring and handover of the new
propose installation. The task will be executed according to the Standard Scope of Professional Services
associated with the delivery of a package for CSIR.

2. Stake holders:

 Employer: CSIR.

 Projects Manager: Mokete Sekiba, Cell: (064) 536 1749, [email protected])

3. Authorisation
Compiled By: Approved By:
Name: P.V Sambokwe (Pr. Tech) Name: F.P. Pieterse (Pr. Eng.)
Tel: (012) 807 6437 Tel: (013) 741 4499
Date: 2019.12.06 Date: 2019.12.06
ECSA No: 200770044 ECSA No: 770358

Design Engineer (Director) : PLP Consulting

Director: PLP Consulting Engineers (Pty) Ltd
Engineers (Pty)ltd
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Generator and upgrade of the existing MLV Page 3 of 35
distribution board at CSIR

QUALITY MANAGEMENT
ISSUE/REVISION FIRST ISSUE REVISION 1 REVISION 2 REVISION 3

Remarks Issued for Approval

Date 2022.02.24

Prepared by V.Sambokwe

Signature

Quality Checked by P.J Cronje

Signature

Authorised by F.P Pieterse

Signature

Project number

CLIENT APPROVALS

REVIEWED BY

JACO Theron
Senior Electrical Engineer (Principal Associate)

REVIEWED BY

ABONGI LE

TABLE OF CONTENTS
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Generator and upgrade of the existing MLV Page 4 of 35
distribution board at CSIR

1. EXECUTIVE SUMMARY
2. STAKEHOLDERS
3. AUTHORISATION
4. INTRODUTION
4.1 MV SYTEM
4.2 LV NETWORK
4.3 EMERGENCY POWER
4.3.1 DESIGN CRITERIA
5. PROJECT DESIGN
6. SITE LOCATION
7. LV RETICULATION
8. BILL OF QUANTITIES
9. GENERAL SPECIFICATION
10. CIVIL WORKS
11. CABLE TERMINATIONS
12. TESTING AND EARTHING OF INSTALLATION
13. EARTHING OF INSTALLATION
14. INSTALLATION DETAILS
15. POWER CABLES
16. DECOMMISSIONING
17. QUALITY ASSURANCE
18. ENVIRONMENTAL

ANNEXURE A - MDB 9 DB SINGLE LINE DIAGRAM

ANNEXURE B - DATA CENTRE DB SINGLE LINE DIAGRAM
ANNEXURE C - GENERATOR PLINTH DETAIL AND LAYOUT
ANNEXURE D - GENERATOR EARTH GRID LAYOUT
ANNEXURE E - GENERATOR PLINTH DRAINAGE & CONTAIMENT DETAILS
ANNEXURE F - BILL OF MATERIAL
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distribution board at CSIR

4. Introduction

PLP Consulting Engineers (Pty)Ltd has been appointed by CSIR, Pretoria, as Professional
Electrical Consulting Engineers to prepare the Preliminary Design for this project.

The data center up-stream existing electrical infrastructure consists of the following:

 1 x 1000kVA transformer
 1 x 1000kVA generator

 1 x 25kA MLV board with change over MMCB’s located in this board

The project aims at upgrading this infrastructure where the proposed arrangement will be as
follows:

 Existing 1 MVA generator will be removed from the Data Center IT load, and two new
generators will be installed as data center back up electrical supplies in an (N+1)
redundancy scenario.
 Existing MLV board will be replaced with new, CSIR envision an almost maintenance free
MLV board where the board will have online thermal scanning and some of the MCCB’s
will have micro logics to enable CSIR to monitor power quality and consumption alike
further the new MLV board will feed the whole of Building 9 and the data center will have
its own Distribution Board.

 All infrastructure will have early warning using the most appropriate technology where
notification will be sent to CSIR maintenance personnel using SMS, messaging service,
and or e-mails.

The Electrical Engineer from PLP Consulting will assist with broad planning, conceptualising and
co-ordination of electrical engineering activities, including communicating with CSIR, other services
providers (Contractors) and stakeholders, as and when appropriate.

The purpose of this Preliminary Design Report is to:

• Provides an overview of the electrical installations to be designed and installed for Building 9.

• To provide an overview of:

 Proposed Infrastructure,
 Site Condition,

• Proposed Technology to be applied for the LV Networks,

• The report evaluates the design parameters and design assumption,

• Detailed BOQ’s and Cost estimate.

SUMMARY OF ELECTRICAL INSTALLATIONS

The Electrical installation includes the following major elements:

• 2 x Generators (N + 1) scenario,
• 2 x ATS Systems,
• MLV Distribution Board
 LV Cable reticulation to new MLV Board
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distribution board at CSIR

ITEM DESCRIPTION COMMENTS

1.1 DEMOGRAPHIC INFORMATION
Generator Co-ordinates:
 Building - 9
Geo-graphical site  MV Supply Point Existing

Layout

MV Reticulation Existing
Proposed Infrastructure LV Reticulation Underground & LV Boards

Soil type Soft

Site Conditions
Climate Temp: 0 to 35oC
1.2 NETWORK INFORMATION
1.2.1 MV Source Existing 1 MVA Substation
1.2.2 Load for area (New Development) Final phase: 350kVA
1.2.3 MV Cable and size (Existing) PILC (70sq.mm)
1.2.4 LV Cable and Size (New) 2 x 95mm² 4 core XLPE cable
New LV Board Replacements
Associated Projects LV Infrastructure and ATS (Automatic
Transmission Switch)
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distribution board at CSIR

4.1 MV SYSTEM

The building is current supplied with an existing 1 x 1000kVA, 11kV/400V Transformer and a
1 x 1MVA Generator that feed through a changeover panel to an existing LV Distribution Board
(MDB9)

4.2 LV Network

The building is supplied via 6 x 70mm² PILC (70sq.mm) cables from the transformer to the existing
Distribution Board (MDB 9). The existing MLV 9 Board will be replaced with a new one.

4.3. EMERGENCY POWER (DATA CENTRE)

New generators (N + 1) scenario located near the existing building will supply emergency power to
the existing Data center only. The rest of the building will utilize their own existing generator for
back-up.

The Normal supply will be fed from the existing 1000kVA Transformer to the Generator 1 ground
mounted Change over panel (ATS). The output of Generator 1 Automatic Transfer Switch (ATS)
will then feed Generator 2 Automatic Transfer Switch (ATS). The output of Generator 2 will then
feed onto the new Data Center Distribution Board.

The standby diesel-driven generator will automatically start in the event of a power failure, the
ground mounted automatic transfer switch (ATS) will automatically switch to generator supply to
make live the Data Centre section only and take load. When the mains power returns the control
system shall monitor the mains supply and once stable initiate the changeover back to mains
supply. The Generator specialist will enable the generator to return to normal power with no-break.
The generator shall then cool down and switch off and remain in
‘Auto’ mode.

Only critical alarms will shut down the generator sets, non-critical alarms will allow connection to a
BMS system for action by the facilities department.

Prior to handover, the emergency power system will be fully tested for the automatic transfer and
operation of equipment supplied. A training session and instructions will be provided to the
appropriate facilities management staff.

See attached drawings for Single Line Diagrams

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Generator and upgrade of the existing MLV Page 8 of 35
distribution board at CSIR

4.3.1 Total Data Centre Load

Base on information received through the metering load profile, the total load for the Data Centre is:

The current Total Load for Data Centre

Total kVA (S) = 132kVA

Load for additional equipment to be relocated to Data Centre Main Distribution Board

Fire Suppression system = 40A

Sunren server room = 60A
Computer Room Aircon DB( as per meetring) = 63kVA

Total kVA (S) = √3 x Vx I

= (1.732 x 60 x 400) + 63kVA
= 104.56kVA

TOTAL KVA REQUIRED FOR BUILDING 9

Based on anticipated Load for Data Centre UPS System of 250kVA (N+1) scenario

The total required Load is)

= (250 + 104.56)
= 354.56kVA

Total kVA (S) @ 1.25% Full load = S x 1.25

= 354.56 x 1.25
= 443.20kVA

Total kVA (S) with Diversity factor of 0.7 = S x 0.7

= 443.20 x 0.7
= 310kVA

Therefore, required kVA Load = 350kVA

The total parameters for the Generator set will be as follows:

kVA Rating = 350kVA

Voltage = 230/400V

kW Rating = 332.5kW

Power Factor = 0.95

Silent canopy which can stand outside with lockable doors

The fuel tank will have to form part of the main Generator base to avoid separate plinths for the
unit. The tank shall have sufficient capacity to run the engine on full load for a period of 12 hours
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Generator and upgrade of the existing MLV Page 9 of 35
distribution board at CSIR

4.3.2 EXISTING EMERGENCY POWER

The existing 1000kVA Emergency Generator will be used to supply the entire building 9
offices and lights excluding the Data Centre, Colling system, Fire suppression system and
Sunren room.

The existing control gear for the generator will be upgraded and new drawings produces.

4.4 Distribution Boards

4.4.1 DISTRIBUTION PANELS

Distribution panels shall be manufactured according to the drawings and the General
specification in this document. Panels shall be provided in the following locations:

The Distribution Boards to be maintenance free MLV board where the board will have
online thermal scanning and some of the MCCB’s will have micro logics to enable Client to
monitor power quality and consumption alike further the new MLV board will feed the whole
of building 9 excluding the Data center which will have a separate DB with similar
requirements.

All infrastructure will have early warning using the most appropriate technology where
notification will be sent to CSIR maintenance personnel using SMS, messaging service,
and or e-mails.

 1 x Main LV Distribution Board (MDB 9)

 1 x DATA CENTRE Distribution Board

Drawings of DB’s, showing the proposed lay-out of equipment, must be submitted to the
Engineer for approval, before manufacturing commences.

Busbars must be positioned to allow for cable entry from the Top and bottom. All bus bars
must be tinned and rated according to the main circuit breaker and allows for 25% load
increase.

Positions for spare equipment must be blanked off with blank clip-in cover or blank clip-in
circuit breakers.

All boards must be inspected in the factory by the engineer before delivery.

All distribution panels and kiosks are to comply with the requirements of clause 6.6 of
SANS 10142-1 (previously SABS 0124-1).

4.4.2 DOORS

Doors shall be of smooth flat finish suitably braced to ensure stiffness and recessed flush
in the architrave. Catches shall be flush mounted.
Single doors shall not exceed the width of 0,6m.
All internal steelwork to be rust proofed, Powder coated, smooth finished and of colour as
specified in the general specification.
All Exterior Steelwork to be of 3CR12 steel.
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Generator and upgrade of the existing MLV Page 10 of 35
distribution board at CSIR

4.4.3 BUSBARS

Copper bus bars provided for each phase and neutral and marked in phase colours shall
be mounted on insulators. Boards shall be suitably sized to accommodate, without undue
cramping, all equipment.
A substantial brass earth bar, solidly bonded to the metalwork of the board, is to be
provided with connectors for the incoming earth conductor and the earth wires of outgoing
circuits.

4.4.5 MARKING AND LABELLING

Clearly engraved labels are to be mounted on or below every switch. The wording of the
labels in one official language is to be according to the lay-out drawings or as directed by
the engineer’s representative and must be confirmed on site. Flush mounted board 2,0m
above the finished floor level. Where relevant, 2,0m above the finished floor level. Where
relevant, distribution boards shall conform to SABS 1180.

4.5 EQUIPMENT FOR DISTRIBUTION BOARDS

4.5.1 EARTH LEAKAGE RELAY (30mA): SINGLE OR THREE PHASE WITH ASSOCIATED
CIRCUIT BREAKER.

The unit shall withstand fault currents (in accordance with SABS 156 of 2,5 kA or 6 kA, as
required, between phase and earth, between phase and phase, or between phase and
neutral without sustaining damage.

The circuit breakers shall be provided with overload trip coils and shall have a rupturing
capacity of 2,5 kA or 6 kA as required, when tested in accordance with SABS 156.

The earth leakage unit must comply fully with SABS 767, as revised, and bear the SABS
mark, equivalent to the ABB make.

4.5.2 MOULDED CASE CIRCUIT BREAKERS: (1A - 600A)

Circuit breakers shall be three pole housed in an insulating moulded chase and suitable for
panel mounting. The circuit breakers shall comply with IEC 157-1 and SABS 156 and shall
be similar or equivalent to the ABB compact systems suitable for standard performance
levels (type N).

Circuit breakers shall be suitable for operation on supply voltages of 380/220V to 440/250V
50Hz, and the rupturing capacity at these voltages when the circuit breakers are tested in
accordance with clause 7.10 of SABS 156 shall be as listed below for the various
categories of circuit breakers.

The overload and short circuit trips of the circuit breaker may be of the following type:

(a) Combined thermal/magnetic trips with interchangeable trip units, the magnetic trip setting
being adjustable.

(b) Combined thermal/magnetic trips with fixed and sealed trip units, the magnetic trip setting
being adjustable.

The tripping times of the circuit breakers shall be in accordance with SABS 156.

The circuit breaker contacts are to be of silver alloy, and arc chutes or magnetic blow-outs
must be provided.
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Generator and upgrade of the existing MLV Page 11 of 35
distribution board at CSIR

The continuous current rating, trip rating and rupturing capacity of the circuit breaker shall
be as stated in the directions for the service, and shall be one of the following categories
covered by this specification: -
-----------------------------------------------------------------

Normal Rupturing capacity Equal and

(@ 380/400V, AC) Similar to

Current Symmetrical
(current)

-----------------------------------------------------------------

500 - 1000 A 35kA ABB

250 - 500 A 10kA ABB

250A and less 15kA ABB

4.5.3 TRIPLE POLE ON LOAD ISOLATORS WITHOUT TRIPS

The switches shall be of the triple pole, hand operated panel mounting, air break type,
having continuous current ratings as indicated below, and suitable for operation on 330 -
440V, 50Hz systems.

The contacts are to be of silver alloy, and the switch mechanism shall be of the quick make
quick break type.

The switches are required to open and close circuits carrying currents up to the full current
rating of the switch.

The switches shall further be capable of being closed against faults and shall temporarily
withstand the following system fault currents, until the associated circuit breakers operate:

Isolator rating 60A : Fault current 2 500A

Isolator rating 100A : Fault current 10 000A
Isolator rating 100A : Fault current 15 000A
Isolator rating 150A : Fault current 15 000A
Isolator rating 250A : Fault current 25 000A
Isolator rating 450A : Fault current 25 000A
Isolator rating 600A : Fault current 25 000A
Isolator rating 1000A : Fault current 25 000A

The switches are to be housed in moulded bakelite cases and are to be suitable for back of
panel mounting.

To distinguish the switches from circuit breakers, to operating handles shall have a
distinctive colour, preferably red and shall be indelibly marked “Isolator”.
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Generator and upgrade of the existing MLV Page 12 of 35
distribution board at CSIR

5 Project Design

5.1 Complete Development Reticulation Diagrams

Annexure A - Proposed MDB 9 Single Line diagram

Annexure B - Data Centre Main DB Single Line diagram.
Annexure C - Generator Platform Layout Drawings

5.2 Building 9 - The spare capacity for the newly installed Generator and supply cable:

CSIR Supply 350kVA/415V Free-Standing Generator, 486.94A TP

Main Circuit LV Breaker 500A TP, 15kA
Existing LV Supply Cable before de- 2 x 95mm2 4 Core XLPE Copper with 2 x 95mm2
ration BCEW, Current-Carrying Capacity = 2 x 258A = 516A

De-ration Factors: 2 x horizontal touching cables at

Existing LV Supply after de-ration 500mm deep = 0.81
Ground thermal resistivity (K.m/W) = 1.2
Depth of a cables = 0
Ground Temperature at 250C = 1.00

The total de-ration factor = 1.2 x 0.81 = 0.972

Total Calculated De-Ration
De-rated cable capacity = 0.972 x 486.94A = 473.31A
De-rated MV cable capacity

The Fault current for the Main distribution boards is less than 10kA and therefore the rating
of the isolators and circuit breakers will have 5kA rating.

5.2.1 Voltage Drop Calculations for the Generator 95mm² Cable

METHOD A:

Cable Impedance = (Given Ω per km)/1000 x Cable length

Where cable impedance/km can be obtained from cable properties provided by

manufacturers

Voltage Drop = Full Load Current x Cable Impedance

Where Full-Load current is obtained from Load Estimation

Percentage Voltage Drop = Voltage Drop /230V x 100

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distribution board at CSIR

METHOD B:

Voltage Drop = 3ø or 1ø Volt Drop per Amp per metre

Where cable mV/A/m can be obtained from cable properties provided by manufacturers;
Three-phase and Single-Phase figures can be chosen depending on the application

Percentage Voltage Drop = Voltage Drop /400V x 100

5.2.2 Volt Drop Calculations – Building 9 LV Cable

Voltage Drop Calculations building 9 Method Method Total Volt Drop

A B
Generator to LV Panel in Bld 9:
From Generator (2 x 95mm2 4 core XLPE V
cable)
impedance 0.000246 Ω
Voltage drop for 95mm2 0.016 0.260 From
book
Full load Current 250 250 A
Length of cable 65 65 m
% Volt Drop 0.007 0.106 % 0.007% 0.106%

All Calculated Voltage drop are within the maximum voltage drop allowed by SANS 10142-1-
2017 of 5%
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Generator and upgrade of the existing MLV Page 14 of 35
distribution board at CSIR

6 SITE LOCATION AND DETAIL

SITE LOCATION

The site is located within the Tshwane Metropolitan Municipal area, adjacent the N1 and along
Meiring Naude road situated in the Gauteng Province.

The following parameters are used in the design of the power supply system:

 Medium voltage three phase : 11kV

 Low voltage three phase : 415V

 Low voltage single voltage : 230V

 Mains power frequency : 50HZ

6.1 CONSTRUCTION PROGRAMME

The Contractor’s programme shall be co-ordinated with the Engineer and CSIR and shall
include allowance for adverse weather conditions, builders holidays and public holidays
as specified by the PMT.

6.2 STORAGE

The Contractor shall provide adequate and safe storage for all materials. All materials
shall be stored or stacked in positions that will not interfere with other work in progress
in the area.

6.3 QUALITY OF MATERIALS

6.3.1 All materials supplied or utilised under this shall be new and unused. Only materials of
first class quality and finish shall be utilised. All materials shall be subject to prior
approval by the Engineer. The Engineer may in some cases require factory acceptance
tests before delivery of material to site

6.3.2 All materials shall comply with the relevant SABS specifications.

All materials shall be unconditionally guaranteed for a period of 12 months from the date
of practical completion, which is first hand over. Where Supplier's guarantees are of a
shorter duration than 12 months, the Contractor shall unreservedly agree to the extension
and cession of all warranties and guarantees.

6.3.4 The Contractor shall replace any materials that are found to be defective during the 12
months defects liability period.
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distribution board at CSIR

6.4 COMPETENCE OF PERSONNEL, WORKMANSHIP AND STAFF

6.4.1 All work shall be executed and supervised by suitably qualified staff. Only “ACCREDITED
PERSONS” shall be permitted to carry out and supervise work.

The Contractor shall at all times have an adequate number of employees available during
the construction period to ensure that the work does not delay the construction programme.

6.4.2 The works shall be supervised by a full time registered “THREE PHASE ELECTRICIAN”.

6.5 CO-ORDINATION OF SERVICES

The Contractor shall be responsible for the onsite co-ordination with the CSIR and other
relevant Contractors. Allowance shall be made for this liaison and on-site co-ordination in
the tender price.

6.6 FINISHING AND TIDYING

6.6.1 In view of the concentration of construction and other activities likely to be experienced
during the Contract period, progressive and systematic finishing and tidying will form an
essential part of this Contract. On no account will soil, rubble, materials, equipment or
unfinished operations be allowed to accumulate in such a manner as to unnecessarily
impede the activities of others. In the event of this occurring the Employer (CSIR) will have
the right to withhold payment for as long as may be necessary in respect of the relevant
Works in the area(s) concerned, without thereby prejudicing the rights of others to institute
claims against the Contractor on the ground of unnecessary obstruction.

6.6.2 Finishing and tidying shall therefore not be left to the end of the Contract, but shall be a
continuous operation.

6.7 EXISTING WORKS AND SERVICES

The Contractor is responsible for obtaining information regarding services and the existing
works which may be affected by the new works. Before the Contractor commences
operations, he must discuss with and have the approval of the Project manager (CSIR)
concerned regarding the method he proposes to use for the safeguarding of any services
and existing works he may encounter during construction. The cost of all precautionary
measures, which may be necessary to ensure the safety of such services and existing
works, as well as the protection of all persons, shall be borne by the Contractor. Any
alteration to services, which may be required, shall be carried out by the Authority
concerned at the expense of the Contractor. The Contractor shall be held responsible for
any damage, injury or accident caused as a result of his failure to take the necessary
precautionary measures.
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distribution board at CSIR

6.8 SUPERVISION

Work shall at all times be subject to full time supervision by a qualified and experienced
Site Agent. This representative must be authorised and competent to receive instructions
on behalf of the Contractor.

6.9 PROTECTION OF OTHER SERVICES AND STRUCTURES

The Contractor shall take all the necessary precautions to protect existing services,
finishes and structures during the execution of the Contract, and shall be fully responsible
for all repairs and damages thereto. The costs for any repairs or damages shall be
recovered from the Contractor.

The Contractor shall also exercise extreme care when excavations are made, to avoid
damage to existing or newly installed services. Any damages to other services shall be
rectified and the costs for the rectification will therefore be recovered from the
contractor/subcontractor.

7 LV Reticulation Design

7.1 LV Internal Reticulation:

New LV Cables will be installed from the Transformer room to the new Generator plant position. All
cables will be installed directly underground on a river sand bedding which will be suitable for this
type of development.

 4 x LV Cable specification: 600/1000V; XLPE Insulated PVC; SWA; Cu. complete with BCE
wire as per specification.
 LV Cable sizes will be standardized as per CSIR requirement: 185sq.mm

All LV cables and earthing will be provided in accordance with the latest standards and
specifications. The complete LV supply installation shall be handed over CSIR before the date of
commissioning.

7.2 Design Parameters and Assumptions:

 Diversity factor : Three Phase, Single Phase – Balanced Network.

The following design parameters are applicable:

a) Medium Voltage:

 Supply voltage: - 0.415kV, 3-phase

b) Low Voltage:

 Loading (Building 9 MDB 9) - 230kVA

 Loading (Building 9 Data Center) - 132kVA
 Supply voltage - 415 Volt
 Regulation - +- 10%
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Generator and upgrade of the existing MLV Page 17 of 35
distribution board at CSIR

7.3 Design Criteria

The Electrical Services will fulfil the following design criteria and configuration of all electrical
networks and services:

 Adequate Capacity: load handling capabilities to meet present and future power
requirements,

 Stability: the power supply must provide the necessary quality of supply under all
environmental and power supply conditions, i.e. stability, voltage and frequency tolerances,
interference free, etc.

 Reliability: under all circumstances,

 Adaptability: ability to cater for changes in future technology and without infrastructure
modifications,

 Flexibility: simplicity of operation and ability to cater for changes in occupancy,

 Maintainability: ease of maintenance and totally serviceable with locally available

components,

 Cost Effectiveness: minimized capital and long-term operational costs,

7.4 Earth Resistivity and Earthing

All MV and LV earthing will be provided in accordance with the Municipalities latest standard and
specifications or similar.

As no earth resistivity tests have been carried out as yet, we are unable to give a clear picture on
what earthing configuration will be used, but we expect that the Standard earthing configuration as
per Local Municipality urban and CSIR reticulation (Underground cable networks) will be used

The contractor shall obtain the service of a specialist to do a complete survey on the site to obtain
the resistivity readings for the different areas. From this the specialist shall do a detail design for
the earthing and lightning protection installation which shall first be approved by the Consultant
before installation. For this purpose a provisional amount is allowed in the bill of quantities.

7.5 Commissioning and Handing Over

All electrical internal services installed shall be handed over to the CSIR before the date of
commissioning.
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Generator and upgrade of the existing MLV Page 18 of 35
distribution board at CSIR

8. Bill of Quantities

Annexure F - Bill of Quantities and Cost estimate.

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distribution board at CSIR

9. Generator and General Specification

9.1 Design standards and specification

Any relevant bulletins, specifications of material and standards required for successful completion
of the project are also applicable:

The following parts of SANS 2001 and associated specification data are applicable:

 SANS 2001- BE1 Earthworks (general)

 SANS 2001- BS1 Site Clearance

Where the required information is not provided in the SANS 2001 documents, the following parts of
SANS 1200 and associated specification data are applicable:

 SANS 1200 A - 1986 : General

 SANS 1200 C - 1980 (Amended 1982) : Site Clearance
 SANS 1200 D - 1988 (Amended 1982) : Earthworks

9.2 Applicable SANS Standards

Applicable SANS 10198 Standardised Specifications for the purpose of this Contract the latest
issues of the following Standard Specifications for Electrical Engineering Construction, applicable
at the date of Contract advertisement, shall apply –

 SANS 110198 (1 – 13) LV Cable selection, handling and installation

 SANS 10292 Earthing of low voltage distribution systems
 SANS 61238-1
 SANS 97
 SANS 0200
 SANS 1339
 SANS 97
 SANS 10198 (1 – 13)
 IEC 60298:1990
 NRS 003-1:1994 (3)
 Compression and mechanical connectors for power cables
 Electric cables
 Neutral earthing in MV systems
 Electric cables – XLPE
 Electric cables - PILC
 MV Cable selection, handling and installation
 AC Metal Clad – enclosed switchgear and control gear
 Metal Clad Switchgear
 VC 8075
 Compulsory specification for the safety of electrical cables
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THE FOLLOWING STANDARDS OR EQUIVALENT RSA OR INTERNATIONAL STANDARDS SHALL

APPLY AS APPROPRIATE:

 The National building regulations as amended

 SANS 10142-1 Wiring of premises

 SANS 10313 Earthing of structures
 SANS 10199 The design and installation of earth electrodes
 SANS 10313 The protection of structures against lightning
 SANS 10400 The application of the National Building Regulations
 SANS 1063 Earth rods and couplers
 SANS 1411 Materials of insulated electric cables and flexible cords
 SANS 1507 Electric cables with extruded solid dielectric insulation for fixed
installations (300/500 V to 1 900/3 300 V)
 SANS 1574 Electric cables - Flexible cords and flexible cables
 SANS 61558 Safety of power transformers, power supply units and similar
 SANS 767 Earth leakage protection units
 NRS 016:1995, Electricity distribution — Code of practice for the earthing of low-voltage
distribution systems.

OHS ACT

All legal requirements as stated in the OHS-act must be adhered to apart from the exemptions
as in part 0 of the Distribution Standard.

 OHS Act Occupational Health and Safety Act 85 of 1993

9.3 GENERATOR – SPECIFICATION

SEE ATTACHED EMERGENCY GENERATOR SPECIFICATION

9.3.1 Chromadek Shelter and Paving surround Generators

The Contractor to excavate and build a Pitched Chromadek covered steel structures over the
Generators to match existing on site and paving around the generator plinths positions. The shelter
to be as indicated in the BOQ.
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10. CIVIL WORKS

10.1 Generator Platform

The Contract shall construct the Generator plinths will Bund wall as indicated on drawings

10.1.1 SITE CLEARANCE

Clear and Grub

The area designated by the Engineer and cleared and grubbed will be measured to the nearest m².
The grubbing of trees and tree stumps cutting of trunks and branches exceeding 0, 5m in girth in to
transportable lengths, backfilling of cavities, transporting, and disposing of material thus cleared,
grubbed, cut, and demolished.

10.1.2 EARTHWORKS

Remove topsoil to nominal depth 300mm, stockpile, and maintain

The rate shall cover the cost of removing topsoil to a nominal depth of 300mm, stockpiling, and
preventing dust nuisance.

10.1.3 Restricted Excavation

All excavations will be considered as soft excavations (intermediate included). Hard rock
excavations will only be if blasting, spilling, or wedging is required. Before commencing with hard
rock excavations, the Contractor shall take levels of the rock profile of the entire area to be
worked upon. For this purpose, the Contractor shall inform the Engineer at least forty-eight (48)
hours before commencing with such work, of his intention to perform such work
Excavation rates will include shoring or battering of trenches which might be required for deep
Excavations. Before commencing with hard rock excavations, the Contractor shall take levels of the
rock profile of the entire area to be worked upon. For this purpose, the Contractor shall inform the
Engineer at least forty-eight (48) hours before commencing with such work, of his intention to
perform such work
Hard rock excavations will only be applicable if blasting, wedging and splitting is implemented

Excavations will be neat and clear of rubble, organic and inorganic material and excessive
water will be pumped/removed or allowed to subside before backfilling and compaction
commences
The founding layer of backfilled excavations will be in-situ material ripped and compacted
to at least 90% mod AASHTO

10.1.4 Brick Type

All bricks shall comply with SANS 227 and shall be engineering units of class Face Brick
Standards with a nominal compressive strength of 12 MPa

10.1.5 FOUNDATIONS :

To sizes and depths shown, 220 & 280 walls without adjacent trenches to have 700 x 250 conc.
foundations. Concrete to be 30MPa strength. Reinforcing for various soil types as indicated.
CABLE TRENCHES

Shall be constructed by the Contractor as indicated on drawings.

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10.2 SLEEVES

Shall be installed by the Contractor.

10.3 BRICK MANHOLES

Manholes shall be constructed by the Contractor as indicated on drawings.

11. CABLE TERMINATIONS & ENTRIES

(a) All cable entries shall be from below and cable terminals shall be provided with
lugs appropriate to the cable specified, including bolts, nuts, plain washers and
locknuts. These terminals shall be located within 150mm of the cable boxes or
gland plates and approved copper riser connections shall be provided between the
terminals and the associated fuse or circuit breaker.
(b) The armoring of all cables shall be earthed to the main earth busbar together with
the bare copper earth conductor specified with that cable. The armoring shall be
neatly bent back over the outer PVC sheath and clamped to the channel with a K-
clamp together with a short strand of bare copper earth conductor. This bare
copper conductor shall be of the same cross sectional areas as the one laid with
the cable and shall be connected to the earth busbar.

11. GENERAL TO THE INSTALLATION OF CABLES

11.1 INSPECTIONS

A logbook with three copies per page shall be kept by the Electrical Contractor on the site,
in which each part of the installation that has been inspected can be recorded after
inspection and approval.

11.2 DAMAGE TO OTHER SERVICES

Before commencement of trench digging activities on any section of the cable routes the
Contractor shall obtain plans from the Principal Contractor or from the Consulting
Engineers indicating the position of existing services along the route. The Contractor shall
exercise the utmost care when working in their vicinity. Machine excavation near existing
services will only be to the extent permitted by the Engineer, and no additional payment
will be made for the hand work entailed.

The Contractor shall assume full responsibility in case he or any person in his service is
directly or indirectly responsible for any damages caused to other services already
installed (water, sewerage, storm water, roads, surveyor's pegs, etc.) Any such damage
shall immediately be reported to the Engineer or his representative.
The Contractor shall be held fully responsible for the repair of such damage to the
satisfaction of the Engineer.
The cost for the repair of such damage shall be borne by the Contractor. Claims by the
Contractor in this connection will not be considered.
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11.3 MISCELLANEOUS

Cables shall be rolled off the cable drums in such a fashion that they do not turn, cannot be
damaged mechanically and are not exposed to too high tensile stress. All High Voltage
cables and the heavier Low Voltage cables shall be supported at sufficiently short
distances during the entire installation process. Cable rollers shall be used to lay cable and
suitable cable grips shall be used. Great care shall be taken that the cables are not grazed,
stretched, or deformed in any manner. The cables shall as far as possible always be
installed exactly straight and parallel to one another.

The terminations and through joints shall be capable of withstanding the same testing
voltage as the rest of the cable.

Connection of cables to the switchgear shall always be effected in such a way that the
various phases, seen from the front of the switchgear, are in the following positions.

No 1 conductor: left (red phase) [A]

No 2 conductor: centre (white phase) [B]
No 3 conductor: right (blue phase) [C]

The open end of each cable shall be sealed against the ingress of water by means of a
suitable heat shrinkable end cap.

12. TESTING AND COMMISSIONING

The Contractor shall make allowance in his tender for the complete testing and commissioning of
the installation. All tests shall be carried out in the presence of the Engineer or his representative
and notice of the envisaged testing date shall be given at least ten days beforehand.

The Contractor shall make allowance in his tender for the supply of all instruments, materials and
tests which will be required for the commissioning.

Should any part of the installation fail during a test, or should the equipment in the opinion of the
Engineer not meet with the requirements, the Contractor shall replace, repair or correct such
equipment at his expense, to the satisfaction of the Engineer.

The following tests shall be carried out:

12.1 LOW VOLTAGE INSTALLATION

Continuity tests to prove the correct connection and correct phase connection of all Low Voltage
cables.

Continuity test to prove the earthing of all cable armouring and earthing conductors.

Should the Engineer have reason to believe that cables may be damaged, a pressure test shall
be conducted on the armouring to determine the state of the PVC sheath.

Tests for 600/1000V cables as detailed in SABS 150 par. D-3 or equivalent for cables
manufactured according to BS specification

12.2. INSPECTIONS

Inspections shall be conducted as follows, unless other arrangements are made by the Engineer.

a) After a specific section of trenching has been excavated the Contractor shall give the
Engineer or his representative 24 hours’ notice that he wants to install cable in this specific area.
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The Engineer or his representative shall then inspect the trench and approve it in writing before
cable can be installed in the trench by the Contractor. This inspection shall be carried out as soon
as possible after receiving the mentioned notice from the Contractor.

b) After the trench has been approved, the Contractor can proceed to install cable in the trench.
Only after the cable installation has been approved in writing can the trench be backfilled.

12.3. CERTIFICATE OF COMPLIANCE

On completion of the service, a certificate of compliance must be issued to the Engineer’s

Representative/Agent in terms of the Occupational Health and Safety Act, 1993 (Act 85 of 1993).

13. EARTHING OF INSTALLATION

13.1. Main Earthing

The type of main earthing must be as required by the supply authority if other than the Engineers,
and in any event as directed by the Engineer’s representative, who may require additional earthing
to meet test standards.
Where required an earth mat shall be provided, the minimum size, unless otherwise specified,
being 1,0m x 1,0m and consisting of 4mm diameter hard-drawn bare copper wires at 250mm
centres, brazed at all intersections.

Alternatively or additionally earth rods or trench earths may be required as specified or directed by
the Engineer’s authorised representative.

Installations shall be effectively earthed in accordance with the “Wiring Code” and to the
requirements of the supply authority. All earth conductors shall be stranded copper with or without
green PVC installation.
Connection from the main earth bar on the main board must be made to the cold water main, the
incoming service earth conductor, if any and the earth mat or other local electrode by means of
12mm x 1,6mm solid copper strapping or 16mm² stranded (not solid) bare copper wire or such
conductor as the Engineer’s representative may direct. Main earth copper strapping where
installed below 3m from ground level, must be run in 20mm diameter conduit securely fixed to the
walls.

All other hot and cold water pipes shall be connected with 12mm x 0,8mm perforated for solid
copper strapping (not conductors) to the nearest switchboard. The strapping shall be fixed to the
pipework with brass nuts and bolts and against walls with brass screws at 150mm centres. In all
cases where metal water pipes, down pipes, flues, etc., are positioned within 1,6m of switchboards
an earth connection consisting of copper strapping shall be installed between the pipework and the
board. In vertical building ducts accommodating both metal water pipes and electrical cables, all
the pipes shall be earthed at each distribution board.

13.2. Connection

Under no circumstances shall any connection points, bolts, screws, etc., used for earthing be
utilised for any other clamps on equipment and materials that must be earthed where these are not
provided. Unless earth conductors are connected to proper terminals, the end shall be tinned and
lugged.
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14. INSTALLATION DETAILS

14.1 CABLE SLEEVE PIPES

Where cables cross under roadways or walk ways and other services and where cables enter
buildings, the cables shall be installed in suitable PVC sleeves.
The ends of all sleeves shall be sealed with a non-hardening watertight compound after the
installation of cables. All sleeves intended for future use shall likewise be sealed.

14.2 NOTICES

The Contractor shall issue all notices and make the necessary arrangements with Supply
Authorities and other authorities as may be required with respect to the installation.

14.3 ELECTRICAL EQUIPMENT

All equipment and fittings supplied must be in accordance with the attached quality specification,
suitable for the relevant supply voltage, and frequency and must be approved by the Engineer’s
representative.

14.4 DRAWINGS

The drawings generally show the scope and extent of the proposed work and shall not be held as
showing every minute detail of the work to be executed.

The position of street lights may be influenced and must be established on site, prior to these items
being built in.

14.5 SERVICE CONDITIONS

All plant shall be designed for the climatic conditions pertaining to the service.

14.6 EARTHING AND BONDING

The Contractor will be responsible for all earthing and bonding of the building and installation. The
earthing and bonding is to be carried out strictly as specification and to the satisfaction of the
Engineer’s representative.

14.7 MAINTENANCE OF ELECTRICAL SUPPLY

All interruptions of the electrical supply that may be necessary for the execution of the work, will be
subject to prior arrangement between the Contractor and the Engineer and the Engineer’s
representative.

14.8 EXTENT OF WORK

The work covered by this contract comprises the complete electrical installation, in working order,
as shown on the drawings and as per this specification, including the supply and installation of all
lamps and also the installation of such equipment.
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15 POWER CABLES

The Contractor shall supply and completely install all distribution cables as indicated on the
drawings, and listed in the Schedule of Cables.

The storage, transportation, handling and laying of the cables shall be according to first class
practice, and the contractor shall have adequate and suitable equipment and labour to ensure that
no damage is done to cables during such operations.

The cable-trenches shall be excavated to a depth of 1.2m deep below ground level and shall be
450mm wide for one to three cables, and the width shall be increased where more than three
cables are laid together so that the cables may be placed at least two cable diameters apart
throughout the run. The bottom of the trench shall be level and clean and the bottom and sites free
from rocks or stones liable to cause damage to the cable.

The Contractor must take all necessary precautions to prevent the trenching work being in any way
a hazard to the personnel and public and to safeguard all structures, roads, sewage works or other
property on the site from any risk of subsidence and damage.

In the trenches the cables shall be laid on a 75mm thick bed of earth and be covered with a 150mm
layer of earth before the trench is filled in.

All joints in underground cables and terminations shall be made either by means of compound filled
boxes according to the best established practice by competent cable jointers using first class
materials or by means of approved epoxy-resin pressure type jointing kits such as “Scotchcast”.
Epoxy-resin joints must be made entirely in accordance with the manufacturer’s instructions and
with materials stipulated in such instructions. Low tension PVCA cables are to be made off with
sealing glands and materials designed for this purpose which must be of an approved make.
Where cables are cut and not immediately made off, the ends are to be sealed without delay.

The laying of cables shall not be commenced until the trenches have been inspected and
approved. The cable shall be removed from the drum in such a way that no twisting, tension or
mechanical damage is caused and must be adequately supported at intervals during the whole
operation. Particular care must be exercised where it is necessary to draw cables through pipes
and ducts to avoid abrasion, elongation or distortion of any kind. The ends of such pipes and ducts
shall be sealed to approval after drawing in of the cables.

Backfilling (after bedding) of the trenches is to be carried out with a proper grading of the material
to ensure settling without voids, and the material is to be tamped down after the addition of every
150mm. The surface is to be made good as required.

On each completed section of the laid and jointed cable, the insulation resistance shall be tested to
approval with an approved “Meggar” type instrument of not less than 500V for low tension cables.

Earth continuity conductors are to be run with all underground cables constituting part of a low
tension distribution system. Such continuity conductors are to be stranded bare copper of a cross-
sectional are equal to at least half that of one live conductor of the cable, but shall not be less than
4mm² or more than 70mm². A single earth wire may be used as earth continuity conductor for two
or more cables run together, branch earth wire being brazed on where required.
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15.1 LAYING, JOINTING AND MAKING OFF OF ELECTRICAL CABLES

[The requirements specified hereafter, are aimed essentially at high tension cable but are
also valid for low tension cable, where applicable.]

1. The use of the term “Inspector”, includes the engineer or inspector of the Engineer or an
empowered person of the concerned supervising consulting engineer’s firm.

2. No cable is to be laid before the cable trench is approved and the soil qualification of the
excavation is agreed upon by the Contractor and inspector.

3. After the cable has been laid and before the cable trench is back-filled the inspector must
ensure that the cable is properly bedded and that there is no undesirable material included
in the bedding layer.

4. All cable jointing and the making off of the cables must only be carried out by qualified
experienced cable jointers. Helpers of the jointers may not saw, cut, solder, etc. The cable
and other work undertaken by them must be carried out under the strict and constant
supervision of the jointer.

5. Before the Contractor allows the jointer to commence with the jointing work or making off of
the cable (making off is recognised as half a joint) he must take care and ensure:

5.1 that he has adequate and suitable material available to complete the joint properly and
efficiently. Special attention must be given to ensure the cable ferrules and cable lugs are
of tinned copper and of sufficient size. The length of the jointing lugs must be at least six
times the diameter of the conductor,

5.2 that the joint pit is dry and that all loose stones and material are removed,

5.3 that the walls and banks of the joint pit are reasonable firm and free from loose material
which can fall into the pit.

5.4 that the necessary copper-dams or retaining walls are made to stop the flow of water into
the joint pit,

5.5 that the joint pit is provided with suitable groundsheets so that the jointing work is carried
out in clean conditions,

5.6 that the necessary tents or sails are installed over the joint pit to effectively avert
unexpected rainfall and that sufficient light or lighting is provided,

5.7 that the necessary means are available to efficiently seal the jointing or cable end when an
unexpected storm or cloudburst occurs, regardless of how far the work has progressed,
5.8 that the cables and other materials are dry, undamaged and in all respects are suitable for
the joint work or making off,

5.9 that the heating of cable oil, cable compound, plumbers metal and solder is arranged that
they are at the correct temperature when required so that the cable is not unnecessarily
exposed to the atmosphere and consequently the ingress of moisture (care must be taken
of overheating).

Flow temperatures of cable oil and compound must be determined with suitable
thermometers. Cable oil and compound must not be heated to exceed the temperatures
given on the containers and precaution must be taken to ensure that the tin is not
overheated in one position. The whole mass must be evenly and proportionally heated.
(Temperature of solder and plumbers metal may be tested with brown paper (testing time:
3 seconds). The paper must colour slightly - not black or burnt)
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6. Before the paper insulated cables are joined, they must be tested for the presence of
moisture by the cable jointers test. This consists of the insertion of a piece of unhandled
insulated impregnated paper tape in warm cable oil heated to a temperature of 130 ± 5° C.
Froth on the surface of the oil is an indication that moisture is present in the impregnated
insulation and the amount of the froth gives an indication of the moisture present.

7. If the cable contains moisture or is found to be otherwise unsuitable for jointing or making
of the inspector is to be notified immediately and he will issue the necessary instruction to
cope with the situation.

8. The joint or making off of paper insulated cables must not be commenced during rainy
weather.

9. Once a joint is in progress the jointer must proceed with the joint until it is
complete and before he leaves the site.

10. The jointer must ensure that the material and his tools are dry at all times, reasonably clean
and absolutely free from soil.

11. Relating to the jointing of the cable the following requirements apply:

11.1 all jointing must be carried out in accordance with recognised and tried techniques
and comply strictly with the instructions given by the supplier of the jointing kit.

11.2 The cables must be twisted by hand so that the cores can be joined according to
the core numbers. If necessary the cable is to be exposed for a short distance to
accomplish this. Under no circumstances may the cores in a joint be crossed so
as to enable cores to be joined according to the core numbers. If it is not possible
to twist the bales so that the preceding requirement can be met, then cores are to
be joined in the normal way without any consideration of the core numbers.

11.3 Normally the cables will have profile conductors. The conductors shall be pinched
with gas pliers to form a circular section, bound with binding wire so that they do
not spread, and then thinned before jointing.

11.4 Jointing ferrules, the length of which are at least 6 times the diameter of the
conductors, must be slid over the conductor ends to be joined and pinched tightly.
Then they are soldered by means of the ladle process whilst being pinched further
closed. Use resin only as a flux. The slot opening in the ferrule must be completely
filled, including all depressions. Remove all superfluous metal with a cloth dipped
in tallow. Work during the soldering process must be from top to bottom. Rub the
ferrule smooth and clean with aluminium oxide tape after it has cooled down to
ensure that there are not any sharp points or edges.

NB: The spaces between the conductor strands must be completely filled by soldering
process and must be carried out quick enough to present the paper insulation form
burning or drying out necessarily.

11.5 After the ferrules have been rubbed smooth and clean, they and the exposed
cores must be treated with hot cable oil (110°C) to remove all dust and moisture.
These parts are to be thoroughly basted with the oil.

11.6 The jointer must take care that his hands are dry and clean before the joint is
insulated. Also the insulating tape which is to be used must first be immersed in
warm cable oil (110°C) for a sufficient period to ensure that no moisture is present.
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11.7 After the individual cores have been installed they must be well basted with hot
cable oil and again after the applicable separator and/or belt insulation tape is
applied before the lead joint sleeve is placed in position.

11.8 The lead joint sleeve must be thoroughly cleaned and prepared before it is placed
on the cable and must be kept clean during the whole jointing process. Seal the
filling apertures of the sleeve with tape until the sleeve is ready for composed
filling.

11.9 The plumbing joints employed to solder the joint sleeve to the cable sheath, must
be cooled off with tallow and the joint sleeve is to be filled with compound while it
is still warm. Top up continuously until the joint is completely filled to compensate
for the compound shrinkage.

11.10 The outer joint box must be clean and free form corrosion. After it has been placed
in position it must be slightly heated before being filled with compound. Top up
until completely.

12. As far as cable and boxes are concerned the requirements as set out above are
valid where applicable.

16. DECOMMISSIONING

The Contractor will be responsible for the decommission and removal of all redundant equipment
relating to the Distribution Boards and as indicated in the BOQ after commissioning of the
Generators. The equipment will be sold as scrap to the Contractor.

17. QUALITY ASSURANCE

The supplier shall be listed as an ISO 9001 company. The product supplied shall have a certificate of
acceptance from the STS Association. All parts other than imported electronic components shall be
locally manufactured with local labor and proof thereof shall be submitted on request. Only offers who
are able to comply with the above requirements will be considered.

18. ENVIRONMENTAL

The equipment shall be designed to ensure satisfactory operation under the atmospheric conditions
prevailing at the site.
The ED offered shall operate normally at ambient temperatures in the range of -10 to 55 degrees
Celsius (IEC 62053-21). The ED shall operate in conditions of humidity of 0 to 95% below 35 degrees
Celsius and 0 to 75% above 35 degrees Celsius. It is expected that the environment will be corrosive.
The printed circuit board (PCB) of the ED shall be conformal coated as protection against insects, dust
and humidity.
The housing of the ED shall be made of stable insulating fire retardant material and shall comply with
classification IP51 but without suction in the meter (IEC 61036).
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ANNEXURE A

PROPOSED MDB 9 DB SINGLE LINE DIAGRAM

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ANNEXURE B

PROPOSED DATA CENTRE MAIN DB SINGLE LINE DIAGRAM

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ANNEXURE C

GENERATOR PLINTH DETAILS AND LAYOUT

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ANNEXURE D

GENERATOR EARHGRID LAYOUT

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ANNEXURE E

GENERATOR PLINTH, DRAINAGE & CONTAIMENT DETAILS

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ANNEXURE F

BILL OF QUANTITIES