TABLE OF CONTENTS FOREWORD...2 INTRODUCTION SCOPE NORMATIVE REFERENCES DEFINITIONS AND ABBREVIATIONS...3

Transcription

1 TITLE SPECIFICATION FOR AN EXOTHERMIC DATE: JUNE 2006 PAGE: 1 OF 15 TABLE OF CONTENTS Page FOREWORD...2 INTRODUCTION SCOPE NORMATIVE S DEFINITIONS AND ABBIATIONS REQUIREMENTS General Tool Kits Moulds Consumables TESTS MARKING AND PACKAGING DOCUMENTATION TRAINING QUALITY ASSURANCE...6 Annex A - Bibliography...7 Annex B - Revision information...8 Annex C - Technical schedules A and B...9 Annex D Stock Items...15

2 PAGE 2 OF 15 FOREWORD Recommendations for corrections, additions or deletions should be addressed to the: Technology Services Manager City Power Johannesburg (Pty) Ltd P O Box Booysens 2016

3 PAGE 3 OF 15 INTRODUCTION Earthing of power systems is an essential and integral part of City Power s electrical infrastructure. Failure of any part of the earthing system results in serious and potentially catastrophic consequences. It has been determined that an exothermic welding system is the most reliable method of bonding and connecting earthing conductors. It is therefore important to ensure that all earthing components comply with the required specifications and are of acceptable quality. As this is difficult to manage within the present City Power business structures it has been decided that SABS support structures will be relied upon to manage compliance to specification as well as quality. The implication to suppliers is that City Power will only purchase an exothermic welding system that complies with the relevant IEEE standard. 1 SCOPE This specification covers City Power s requirements for an exothermic welding system in accordance with IEEE NORMATIVE S The following documents contain provisions that, through reference in the text, constitute requirements of this specification. At the time of publication, the editions indicated were valid. All standards and specifications are subject to revision, and parties to agreements based on this specification are encouraged to investigate the possibility of applying the most recent editions of the documents listed below. CP_TSSPEC_056, Specification for earth rods, couplers and copper-clad steel conductors IEEE 80: 1986, Guide for safety in AC substation grounding SCSASACH1: 2001, ESKOM Standard for utilizing copper clad steel as earth tails for distribution substations in high copper theft areas 3 DEFINITIONS AND ABBIATIONS The definitions and abbreviations in the above documents shall apply to this specification.

4 PAGE 4 OF 15 4 REQUIREMENTS 4.1 General The exothermic welding system shall be galvanically compatible with copper-clad steel conductors and earth rods complying with CP_TSSPEC_ The components shall be designed for use in a system that may be either solidly or resistively earthed, and subject to frequent high intensity lightning storms The exothermic welding system shall be easy to use The exothermic welding system shall be as described in IEEE Tool Kits The tool kits shall contain all the items necessary to correctly and safely perform the exothermic welding process Each tool kit shall contain the following items: a) At least two sets of mould handles or clamps; b) Mould cleaning equipment (scrapers, wire and bristle brushes); c) Safety equipment (gloves, apron and goggles or face shield); d) At least three driving caps (for driving earth rods described in CP_TSSPEC_056); e) Sealing putty or similar for worn moulds; f) A flint gun for powder ignition; and g) Spare flints for the flint gun The items listed above shall be supplied in a sturdy metal or plastic toolbox Extra sets of mould handles or clamps shall be supplied on request. 4.3 Moulds The moulds shall be capable of being used for a minimum of 200 welds and shall be constructed of graphite or similar material The moulds shall be supplied in the following configurations (all references to earth rods shall mean 14,2 mm i.e. M16 earth rods complying with CP_TSSPEC_056): a) EES M16 earth rod to M16 earth rod in a side by side configuration (parallel); b) E7S 70 mm 2 stranded copper conductor to M16 earth rod in a side by side configuration (parallel); c) E7T 70 mm 2 stranded copper conductor to M16 earth rod in a T configuration; and

5 PAGE 5 OF 15 d) S-P M12 stud to steel plate configuration. The steel plate will be vertical, and may be either flat or curved (e.g. a steel pole or the side of a transformer tank). 4.4 Consumables Weld metal and ignition powder shall be supplied in suitable containers for use with moulds having the configurations detailed in clause of this specification Each container shall contain sufficient weld metal and ignition powder for one weld. The container shall be marked with its capacity in order to ensure that the correct amount of weld metal is used with a particular mould. Note: A copper M12 stud is required to be provided with each weld metal for item 8 (SAP code 508) Each container shall also be supplied with a suitable metal retaining disc, the purpose of which is to prevent the weld metal from falling into the mould before ignition In order to restore corrosion protection that may have been removed prior to the welding process, zinc spray in an aerosol form is required. Aerosol spray is preferred to paint because of the ease of application and the lack of cleaning up required in comparison to traditional paint and brush methods. 5 TESTS The manufacturer shall submit detailed test reports that it may be in possession of. In particular, Eskom test reports relating to the product offered will result in that product being viewed in a favourable light. 6 MARKING AND PACKAGING 6.1 All equipment offered shall bear the name of the manufacturer, as well as a manufacturer s reference number. 6.2 In addition, containers of weld metal shall be marked with the appropriate capacity and mould reference number of the manufacturer. 6.3 Tool kits shall be delivered individually, but all other items and consumables shall be delivered in suitable cardboard boxes. 7 DOCUMENTATION 7.1 Detailed test reports (if available) confirming compliance with IEEE 80 shall be provided. 7.2 In addition to the documentation required above, full technical information relating to the performance of the exothermic welding system shall be supplied. 8 TRAINING 8.1 The following certified training courses shall be offered for City Power s staff:

6 PAGE 6 OF 15 Correct procedure for performing welds using the exothermic welding system, with particular emphasis on safety and performance. 8.2 The associated costs for the certified training courses in 8.1 shall be given per person and shall be fixed for the period of the contract. 9 QUALITY ASSURANCE A quality management system shall be set up in order to assure the quality of the exothermic welding system during design, development, production, installation and servicing. Guidance on the requirements for a quality management system may be found in the following standards: SANS 9000, SANS 9001, and SANS The details shall be subject to agreement between the purchaser and supplier.

7 PAGE 7 OF 15 Annex A - Bibliography SCSASACH1: 2001, ESKOM STANDARD FOR UTILIZING COPPER CLAD STEEL AS EARTH TAILS FOR DISTRIBUTION SUBSTATIONS IN HIGH COPPER THEFT AREAS.

8 PAGE 8 OF 15 Annex B - Revision information DATE. NO. NOTES Mar First issue June General editing Change of copper stud from M16 to M12. Update of Annex D.

9 PAGE 9 OF 15 Annex C - Technical schedules A and B for Tool Kits Schedule A: Purchaser's specific requirements Schedule B: Guarantees and technical particulars of equipment offered Item Sub-clause of CP_TSSPEC_055 Description Schedule A Schedule B Name of manufacturer XXXX Place of manufacture XXXX Manufacturer s identification reference XXXX & 4.4 Specification to which tool kit complies XXXX Does the toolkit contain all the items Yes/No Yes required in clause 4.2.2? 6 6 Marking as per clause 6 Yes/No Yes 7 6 Packaging as per clause 6 Yes/No Yes 8 7 Is all the information requested in clause 7 supplied? Yes/No Yes Tender Number: Tenderer s Authorised Signatory: Name in block letters Signature Full name of company:

10 PAGE 10 OF 15 Technical schedules A and B Deviation schedule Any deviations offered to this specification shall be listed below with reasons for deviation. In addition, evidence shall be provided that the proposed deviation will at least be more costeffective than that specified by City Power. Item Sub-clause of CP_TSSPEC_055 Proposed deviation Tender Number: Tenderer s Authorised Signatory: Name in block letters Signature Full name of company:

11 PAGE 11 OF 15 Technical schedules A and B for Moulds Schedule A: Purchaser's specific requirements Schedule B: Guarantees and technical particulars of equipment offered Item Sub-clause of CP_TSSPEC_055 Description Schedule A Schedule B Name of manufacturer XXXX Place of manufacture XXXX Manufacturer s identification reference XXXX & 4.4 Specification to which moulds comply XXXX Are the moulds supplied in the configurations required in clause 4.3.2? Yes/No Material of mould Graphite or similar 7 6 Marking as per clause 6 Yes/No Yes 8 6 Packaging as per clause 6 Yes/No Yes Yes 9 7 Is all the information requested in clause 7 supplied? Yes/No Yes Tender Number: Tenderer s Authorised Signatory: Name in block letters Signature Full name of company:

12 PAGE 12 OF 15 Technical schedules A and B Deviation schedule Any deviations offered to this specification shall be listed below with reasons for deviation. In addition, evidence shall be provided that the proposed deviation will at least be more costeffective than that specified by City Power. Item Sub-clause of CP_TSSPEC_055 Proposed deviation Tender Number: Tenderer s Authorised Signatory: Name in block letters Signature Full name of company:

13 PAGE 13 OF 15 Technical schedules A and B for Consumables Schedule A: Purchaser's specific requirements Schedule B: Guarantees and technical particulars of equipment offered Item Sub-clause of CP_TSSPEC_055 Description Schedule A Schedule B Name of manufacturer XXXX Place of manufacture XXXX Manufacturer s identification reference XXXX & 4.4 Specification to which consumables comply Are the weld metal containers supplied with a retaining disc? Yes/No XXXX Are the weld metal containers marked with the capacity of the contents and the mould reference number? Yes/No Yes Is the zinc spray supplied in an aerosol Yes/No form? Yes 8 N/A Is the spray nozzle non-clogging? Yes/No Yes Is a copper M12 stud provided? Yes/No Yes Yes Is a handle suitable for all moulds provided? Yes/No Yes 11 6 Marking as per clause 6 Yes/No Yes 12 6 Packaging as per clause 6 Yes/No Yes 13 7 Is all the information requested in clause 7 supplied? Yes/No Yes Tender Number: Tenderer s Authorised Signatory: Name in block letters Signature Full name of company:

14 PAGE 14 OF 15 Technical schedules A and B Deviation schedule Any deviations offered to this specification shall be listed below with reasons for deviation. In addition, evidence shall be provided that the proposed deviation will at least be more costeffective than that specified by City Power. Item Sub-clause of CP_TSSPEC_055 Proposed deviation Tender Number: Tenderer s Authorised Signatory: Name in block letters Signature Full name of company:

15 PAGE 15 OF 15 Annex D Stock Items Material Group: NET-ACCS Item SAP N o. SAP Short Description SAP Long Description MOULD REF EES MOULD, GRAPHITE, EES, FOR USE WITH EXOTHERMIC, M16 EARTH ROD TO M16 EARTH ROD IN A SIDE BY SIDE (PARALLEL) CONFIGURATION. ITEM SPECIFICATION NO. CP_TSSPEC_ MOULD REF E7S MOULD, GRAPHITE, E7S, FOR USE WITH EXOTHERMIC, 70 MM2 COPPER TO M16 EARTH ROD IN A SIDE BY SIDE (PARALLEL) CONFIGURATION. ITEM SPECIFICATION NO. CP_TSSPEC_ MOULD REF E7T MOULD, GRAPHITE, E7T, FOR USE WITH EXOTHERMIC, 70 MM2 COPPER TO M16 EARTH ROD IN A T CONFIGURATION. ITEM SPECIFICATION NO. CP_TSSPEC_ MOULD REF S-P MOULD, GRAPHITE, S-P, FOR USE WITH EXOTHERMIC, M12 COPPER STUD TO PLATE CONFIGURATION. ITEM SPECIFICATION NO. CP_TSSPEC_ WELD METAL REF EES WELD METAL SUITABLE FOR USE WITH MOULD EES (EXOWELD REF WM200). ITEM SPECIFICATION NO. CP_TSSPEC_ WELD METAL REF E7S WELD METAL SUITABLE FOR USE WITH MOULD E7S. ITEM SPECIFICATION NO. CP_TSSPEC_ WELD METAL REF E7T WELD METAL SUITABLE FOR USE WITH MOULD E7T. ITEM SPECIFICATION NO. CP_TSSPEC_ WELD METAL REF S-P WELD METAL SUITABLE FOR USE WITH MOULD S-P, COMPLETE WITH M12 COPPER STUD. ITEM SPECIFICATION NO. CP_TSSPEC_ MOULD HANDLE MOULD HANDLE, SUITABLE FOR USE WITH ANY MOULD USED FOR EXOTHERMIC. ITEM SPECIFICATION NO. CP_TSSPEC_ ZINC SPRAY SPRAY, ZINC, FOR USE IN CONJUNCTION WITH EXOTHERMIC FOR THE PENTION OF CORROSION. ITEM SPECIFICATION NO. CP_TSSPEC_ EXOTHERMIC TOOL KIT TOOL KIT FOR EXOTHERMIC WELDING, COMPLETE WITH TOOL BOX AND ACCESSORIES. ITEM SPECIFICATION NO. CP_TSSPEC_055.