2014 C3.1 ECC3 Employers Works Information

ESKOM HOLDINGS LIMITED CONTRACT NUMBER _____________
PROJECT & CONTRACT TITLE ACTUATORS
PART 3: SCOPE OF WORK
Document Title No of
reference pages
This cover page 1
C3.1 Employers Works Information
C3.2 Contractors Works Information
Total number of pages
PART C3: SCOPE OF WORK 1 C3 ECC3 COVER PAGE

C3.1: EMPLOYERS WORKS INFORMATION
PART C3: SCOPE OF WORK PAGE 2 C3.2 ECC3 CONTRACTORS WORKS INFORMATION
1. Description of the Works

i. A twenty four hour, seven day a week call out service will be required from the Contractor to
repair any actuator / gearbox on any plant Boiler or Turbine.
ii. The Contractor is to ensure that all employees despatched to site has done the Project
Manager/Supervisors Induction presented on site before coming on the Plant.
iii. The Contractor is to provide all site and plant specific Personal Protective Equipment to all the
Contractors personnel before Contractors personnel comes to site. Signed declaration
required to this effect.
iv. Maximum travel time from Contractors workshop to site must allow a response time of less than
2 hours.
v. The Contractor will be required to have personnel trained within three months of the Contract
Start Date in Plant Safety Regulations as Responsible People to cover 24 hour, seven day a
week standby service.
vi. Immediate action on site where all tools required must be the responsibility of the Contractor.
vii. An actuator / gearbox repair request coming to site with the Contractors personnel filled in with
the following detail is required at all times for specific service payment to be made to the
Contractor:
The Contract agreement number

Date and time of call out
Date and time of the actuator / gearbox failure filled in by Project Manager/Supervisors
operating Power Plant Controller (ASS)
Project Manager/Supervisors employee who called out the Contractor. Name, department,
date and time.
Responsible person (RP) name, date and time and permit number
Responsible persons contact number, signature, date, time.
70.Order number if not 10notification number or Project Manager/Supervisors
Operating department reference number from ops log.
Unit number
Plant identification number (KKS)
Actuator / gearbox type and serial number.
Priority level in conjunction with expected return delivery time and date written in by Project
Manager/Supervisors Shift Manager or Contract Supervisor.
List of common faults with specific identified fault marked.
Additional text for notes.
Detailed report on failure to be faxed by Contractor to Project Manager/Supervisors
Representative as soon as repair is completed with reference to failure.
viii. The Contractor is required to go right up to the relevant control room where failed actuator /
gearbox is to apply for and accept the plant permit to work before actuator / gearbox is removed
and then keep the permit until return of the actuator. Permit must state that actuator is to be taken
off site if this is the case. Note attached documentation.
ix. All of the Contractors Responsible People must have completed the relevant flame / flash proof suit
training as well as having the required PPE for the proper implementation of it. The Contractor is
required to have done this training within three months from the Contract Start date.
x. All travelling to be the Contractors responsibility no matter what the requirement for transportation or
personnel to transport.
xi. The Contractor is to make sure that the laws regarding human rights and working conditions
towards their employees are exercised e.g. food, washing up facilities, lockers and safety.
xii. The Project Manager/Supervisor will not hold any resp0onsibility nor suffer from a contravention
against the Labour or safety laws of South Africa in place during the Contract Period.
xiii. The Contractor must be certified in writing to have personnel trained for the following electrically
driven actuators and actuator driven gearboxes. All certificates must be given through.
AMRI Actair 31R

AMRI SAPA 8
AMRI SAPA 15
AMRI Dynactair 3
Auma SAR AS50
Auma SAR 6
Auma SAR 6.1
Auma SAR 6A
Auma SAR 6AS
Auma SAR 6A-32
Auma SAR 7.1
Auma SAR 7.5
Auma SAR 07
Auma SAR 10
Auma SAR 10.1
Auma SAR 07.6
Auma SAR 10.2
Auma SAR 10.1-E22
Auma SAR 6.7
Auma SAR 0.2
Auma SAR 10.1-F10
Auma SAR 12 AS
Auma SAR 14.1
Auma SAR 14.1F14E22
Auma SAR 14.5G1/2
Auma SAR 16.1
Auma SAR 16.1F16E22
Auma SAR 07-5F07E22
Auma SAR 7.5F10E22
Auma SG 05
Auma SAR 50A
Auma gearbox GZ 14.1
Auma gearbox GZ 25.1
Auma gearbox GF 63.2
Auma gearbox GS 63.2
Auma gearbox GF 160
Auma gearbox GF 200

Auma gearbox GF 200R
Auma gearbox GF 200L
Auma gearbox GF 250
Auma gearbox GS 250
EMG Drehmo D60 E16
EMG Drehmo D60 E40
EMG Drehmo D60 E80
EMG Drehmo D120 E80
EMG Drehmo D250 E120
EMG Drehmo D250 E80
Rotork 7A
Rotork 11A
Rotork 14A
Rotork 16A
Rotork 30A
Rotork 40A
Rotork 90AR
Rotork gearbox IW3
Rotork gearbox IB13 6:1
Rotork gearbox W90
Automa Actuator (for a blow down sump quenching valve)
Compact 7 , C35SR-3-R1 net (for a blow down sump quenching valve)
Siemens M76342-E7547-J*38Z
Siemens 2SA1035-5ZZ90-5FZ0-Z BOO+KO3+J2C+LOC+CO2+QOE
Siemens 2SA1001-2GZ90-5F20-Z
Siemens 2SA3031-3GA19-OEF9-Z QOA+CO2+KOB+LOC+BOO
Siemens 2SA1005-2HB90-5FZ0-Z
Siemens 2SA1001-9GB00-5FZ0-Z
Siemens M76342-F7747-J*38Z
Siemens 2SA1001-9DB90-5FZ0-Z
Siemens 2SA1000-9GZ90-5F20-Z
Siemens 2SA3031-2HA19-OEF9-Z KO3+LOC+ROZ+CO2+BOO+YO1+YO2
Siemens 2SA3532-9FL19-OBF9-Z A40+A22+M05+BOO+NIA
Siemens 2SA3522-9EL19-OBF9-Z H4A+KO3+MO5+LOC+R4Y+CO2+BOO+HO1+YO1+YO2
Siemens 2SA3520-9FL19-ODF9-Z H4A+KO3+MO5+LOC+R4Y+HO1+CO2+BOO+YO1+YO2
Siemens 2SA1010-9JB91-1FZO-Z
Siemens 2SA1005-9CB91-3FZ0-Z
Siemens M76342-C7627-J*38Z
Siemens 2SA1001-9GB91-1FZ0-Z
Siemens 2SA1000-9AB01-3FZ0-Z
Siemens gearbox M77391-9+130-B-201
Limitorque 380V 2,3A 0,58 HP 1417 RPM
Centork 480 015
Geared motor Bauer 3 Phase bevel helical CFG15G32-117/D2A4-309K
Geared motor Bauer G81 CFG 17-117 SNH
Geared motor KDA400
Geared motor FAF40DT80K4-H6 TYPE: FAF40A
xiv. The Contractor will be required to come out to site, remove actuator from plant with plant safety
regulation permit and reinstall after repairs within a period of at most 24 hours if priority 1, at most 1
week if priority 2 and at most one month if priority 3.
xv. All motor direction checks must be done by the Contractor before and after repairs / overhauls /
refurbishing to ensure the direction is not altered and run in the same direction as before the repairs
that was required.
2. Work to be performed by the Contractor for the works

I. The Contractors must have the capability to carry out full maintenance, repair, testing and
servicing of all actuators / gearboxes listed within point 1 (Description of the works). The full
scope of General Overhauls and Interim Repairs must be done within a maximum period of 18
days which in turn calculates to 111 units to remove from plant, inspect, repair and test on test
bench. Normal running maintenance repairs must be according to priority as described within
point 1 (Description of the works) and will be on an as and when required basis.
II. The Contractor must have enough workshop space to strip, bench test, repair, overhaul and
service 111 actuators / gearboxes within a workshop environment, lockable for inspections to
be carried out in group hold points.
III. The Contractor must have in transit and at premises insurance to cover lost stolen or misplaced
equipment or actuator / gearbox units or parts.
Activity 1 (Complete overhaul). Performed by the Contractor.
Inspect actuator before removal, noting any missing parts, breakages, oil leaks etc. Note all
defects on relevant inspection sheet.
Identify by tagging actuators and power cables, hard stamp gear case, motor and mounting
flange with identifying numbers. Note all numbers and deviations on detailed inspection sheet
with reference to QCP.
Remove actuator, keep all nuts, bolts and keys safe in separately marked plastic bags
indicating actuator type and position on site. Note all loose spares on Spares sheet.
Electrical plugs must be properly wrapped in a plastic bag to prevent water and dust ingress.
Transport to workshop.
Steam clean and degrease actuator externally.
Remove all covers, including motor terminal box cover.
Test run actuator noting the following:
Check direction of motor before stripping.
Thermo switch fitted to motor open circuited healthy by OEM standards.
Any abnormal operational noises.
Operation of de-clutch mechanism plus output shaft by OEM standards.
Inspect limit switch drive assembly by OEM standards.
Ensure function of all limit switches by OEM standards.
Transmitter signal where fitted by OEM standards.
Operation of brake where fitted by OEM standards.
No load amps by OEM standards.
Check feedback OCB for correct operation by OEM standards.
Loosen all Harting plugs and inserts. Wash out plugs with approved SMDS submitted solvent.
Check and rectify all connections by OEM standards.
Remove and strip motor. Service motor as follows:
Remove and replace NDE and DE bearings, bushes and oil seals by OEM standards.
Check and repair brake (if fitted) by OEM standards.
Wash windings and terminals in approved SMDS submitted solvent.
Re-assemble and test run Check and reset air gap on brake if fitted.
Service gearbox by OEM standards.
Steam clean and degrease gearbox externally.
Check condition of grease nipples and replace if necessary.
Remove input shaft.
Remove and replace bearings on input shaft by OEM standards.
Check bellville washers for wear and correct assembly by OEM standards. Replace and rectify
where required.
Inspect all internals of gearbox and actuator by OEM specification.
Replace damaged and out of specification spares by OEM standards.
Replace all o-rings, oil seals and gaskets with OEM or approved parts.
Remove all limit switches and drives.
Wash limit switches and drives in approved SMDS submitted solvent except the electronics
which must be cleaned if required by an approved SMDS submitted electronic circuit solvent.
Clean out and remove any rust deposits and repair inside switch compartments where
necessary.
Re-fit all limit switches and drives and lubricate with pre approved SMDS submitted lubricant.
Re assemble gear case by OEM specification.
Fill with pre approved SMDS submitted lubricant.
Refit motor and motor flange seal by OEM specification.
Torque test actuator and or gearbox with pre approved Contractors test bench.
Issue test certificate to be attached to QCP.
Supply copy of job card to QCP filled in with all detail previously mentioned. Give full detail of all
used spares supplied and fitted to overhaul actuator electrically and mechanically, within seven
days of completion of job.
Repaint actuator with Project Manager/Supervisor approved colour coding.
Transport to site
Fit removed actuator on plant, ensuring that the limit assembly is accessible, the plugs can fit
and the cable glands face downwards.
Earth wires must be properly fitted with a ring lug.
Clear Plant Permit to Work.
Re-commission actuator and or gearbox.
Activity 2 (In-situ inspections on site). Performed by the Contractor.

Identify actuator by plant identification code (KKS) and tag. Record all information, including
type, make, size, etc. level and position (vertical or horisontal, motor on left or right hand side.
Visually inspect actuator, noting any obvious defects, leaks, missing parts, breakages. Take oil
samples and report findings with tribology report.
Remove limit switch covers. Check insulation on internal wiring. Check all limit switches and
connections. Check Harting plug connections. Replace o-ring or gasket where necessary by
OEM specification. Test CPT signals. Replace limit switch covers.
Remove motor cover. Check all connections. Remove Harting plug insert clean and check
connections. Replace gaskets when necessary by OEM specification. Replace motor cover.
Remove brake cover if fitted. Check air gap. Clean out. Replace dust cover where necessary.
Replace cover. Remove and replace any broken screws and re-tap where necessary.
Record any missing or broken parts by OEM specification.
Acti 3 (Scope of in-situ service). Performed by the Contractor.

Identify actuator by plant identification code (KKS) and tag. Record all information, including
type, make, size, etc. level and position (vertical or horizontal, motor on left or right hand side.
Visually inspect actuator, noting any obvious defects, leaks, missing parts, breakages. Take oil
samples and report findings with tribology report.
Remove limit switch covers. Check insulation on internal wiring. Check all limit switches and
connections. Check Harting plug connections. Replace o-ring or gasket where necessary by
OEM specification. Test CPT signals. Replace limit switch covers.
Remove motor and test run
Remove motor cover. Check all connections. Remove Harting plug insert clean and check
connections. Replace gaskets when necessary by OEM specification. Replace motor cover.
Remove brake cover (if fitted). Check air gap. Clean out. Replace dust cover where necessary.
Replace cover. Remove and replace any broken screws and re-tap where necessary.
Record any missing or broken parts by OEM specification.
Remove and replace lubricant with approved SMDS submitted lubricant.
Check and report on all gear case internals by OEM specification.
Refill with approved SMDS submitted lubricant and replace motor make sure motor is for correct
application.
After repairs re-commission actuator and or gearbox.
3. Work and things for the works supplied by the Project Manager/Supervisor
Site, potable water and electricity only given from one point on site.
Accessible space for the performance of the Works but subject to interfaced activities of other
contractors.
Scrap bins are available on site.
Parking of Contractors vehicles is allowed at designated areas at Units 1 and 6 only.
4. Programme
A daily strength sheet of the Contractors manpower used on each working day must be
submitted to the Project Manager on each and every working day on site before any work can
commence that day. The following detail is of importance; Name; ID number, Trade. The
strength sheet template can be obtained from the Project Manager.
A program must be submitted for each schedule in the Price List with tender document for each
activity to be performed by the Contractor in MS Projects with the required duration per task,
resources per task and grouped tasks per activity and function performed by the Contractor.
Similar activities in nature and time can be performed by using a generic program.
The Contractor must submit a program (in Microsoft Projects) to the Project Manager with each
task order. This will be a standard requirement before any work commences.
5. Quality Management
I. There must be a Master QCP drawn up by the Contractor for each actuator / gearbox specific
listed under point 1 of the Works Information containing the following:
Reference by the Contractor to on site inspection sheet where all visual defects must be
recorded for initial reporting.
Reference by the Contractor to detailed disassembled inspection sheet as by OEM drawings
for each actuator / gearbox.
Detailed disassembled OEM part list is required from the Contractor with every single
component, OEM part number and current Price for replacement of each part from the
Contractor with reference to the OEM.
Every replaced part required by the Contractor must be verified by the Project
Manager/Supervisor and must be referenced back to OEM supply such as an attached
delivery note from OEM dated as applicable.
Every machined component arranged by the Contractor, not available from the OEM must
have a material certificate, specification and tolerance sheet including the machining company
QCP with all sizes noted. Only Eskom approved reverse engineering companies may be used.
Every single item must be accepted by the Project Manager/Supervisor on a pre-approval
base, Contractors premises or on site before re-assembly of gearbox / actuator.
Each lubricant used by the Contractor must have an MSDS attached to QCP created by the
Contractor and must be accepted by the Project Manager/Supervisor before use.
Every torque value and limit set by the Contractor must be verified by the Project
Manager/Supervisor in writing and witnessed at the Contractors premises before delivery and
must correspond to the actuator / gearbox tag and tested on the specific bench testing
machine supplied by the Contractor applicable specific to application.
All serial numbers of every actuator / gearbox must be noted by the Contractor on the specific
QCP applicable, the invoice and delivery note, along with Type and make.
II. Master Quality Control Procedures and the hold points must be inspected and certified by the
Project Manager/Supervisors Representative prior to Contract award.
III. At the first hold point for each actuator / gearbox the Project Manager/Supervisors
Representative is to be notified once the actuator is stripped for an inspection at the Contractors
workshop. At this point a list of spares from OEM with prices required for the repair must be
presented to the Project Manager/Supervisors Representative. The Contractor may only
proceed with the replacement of spares once the Project Manager/Supervisors Representative
signs in agreement with name and date of costs to be incurred. A list of all above spares, per
actuator must be available in report format.
IV. At the second hold point for each actuator / gearbox the actuator is reassembled and ready for
use, the Project Manager/Supervisors Representative must witness the relevant torque test for
the specific allocation.
V. Regarding guarantee the Contractor will provide a twelve month guarantee on the workmanship
and on spares supplied by the Contractor with the exception of the AUMA SA 07.1-SA16.1
actuator declutch mechanism. Not guaranteed is rod type de-clutching, switching mechanism,
motor rotor shafts, limit switch mechanism and drive gear. The guarantee will be limited to the
cost of repairs including electrical components provided that fuses with the correct amperage are
installed in control panels and that the motor thermos switch at all times and that the torque
setting are not overridden.
VI. Spares quality determines that the Contractor will only install OEM parts certified and rubber
stamped. That all manufactured parts will be only if OEM has none available declared in writing
or is obsolete at which point the material certificate and machining company QCP and
tolerances is attached to repair QCP.
6. Safety Management
i. Before any work performed by the Contractor may commence on the plant, the plant must be
switched off completely and isolated against plant being alive or from any moving parts. Each
actuator / gearbox must be isolated and on Plant Permit to Work individually isolated before
performing any work with the exception of stroking. Unless the stroking of any valve or damper
may constitute a danger to the plant or personnel in that area.
ii. Before the Contractor removes the actuator and/or gearbox, it must be driven out of torque
before being isolated.
iii. Actuator electrical plugs may not be removed by the Contractor unless isolated and under
specific Plant Permit to Work.
iv. No Contractor employee will be allowed to stand on hand rails or work without a site approved
safety harness if working at heights. A scaffold will be required in terms of ergonomic access to
any plant where it is not at a comfortable height.
v. Safety file must be handed in by the Contractor on the Contract Start Date.
7. Title to site materials

The Project Manager/Supervisor must approve all materials and spares supplied by the Contractor.
8. Drawings / Documentation
Drawings will be made available on request.
9. Specifications
Title Date or revision Tick if publicly

available
Project Manager/Supervisors Health and Safety Requirements 14 June 2005
Safety Risk Management manual for Contractors (Ref.30/05) (Kendal) Internal
All equipment for use must by NOSA and SABS compliant Rev 1
Quality Control Plan and Program must meet the requirements of theRef 50/15-PA*006
code of practice for Quality Systems. KEN-AQ-003
Occupational Health and Safety Act (OHSA) 1994
ISO 5000 standards as described below
BS 13480 standards as described below
ISO Standards
ISO 5725-2:1994 Accuracy (trueness and precision) of measurement methods and results. Basic
methods for the determination of repeatability and reproducibility of a standard
measurement method
ISO 5725-3:1994 Accuracy (trueness and precision) of measurement methods and results.
Intermediate measures of the precision of a standard measurement method
ISO 5725-4:1994 Accuracy (trueness and precision) of measurement methods and results. Basic
methods for the determination of the trueness of a standard measurement method
ISO 5725-5:1998 Accuracy (trueness and precision) of measurement methods and results. Alternative
methods for the determination of the precision of a standard measurement method
ISO 5725-6:1994 Accuracy (trueness and precision) of measurement methods and results. Use in
practice of accuracy values
ISO 8995:2002 Lighting of indoor work places
ISO 9000:2000 Quality management systems. Fundamentals and vocabulary
ISO 9000-1:1994 Quality management and quality assurance standards. Guidelines for selection and
use
ISO 9000-2:1997 Quality management and quality assurance standards. Generic guidelines for the
application of ISO 9001, ISO 9002 and ISO 9003
ISO 9000-3:1997 Quality management and quality assurance standards. Guidelines for the application
of ISO 9001:1994 to the development, supply, installation and maintenance of
computer software
ISO 9001:1994 Quality systems. Model for quality assurance in design, development, production,
installation and servicing
ISO 9001:2000 Quality management systems. Requirements
ISO 9001:2000 Quality management systems. Requirements
ISO 9002:1994 Quality systems. Model for quality assurance in production, installation and servicing
ISO 9003:1994 Quality systems. Model for quality assurance in final inspection and test
ISO 9004:2000 Quality management systems. Guidelines for performance improvements
ISO 10005:1995 Quality management. Guidelines for quality plans

ISO 10006:2003 Quality management systems. Guidelines for quality management in projects
ISO 10007:2003 Quality management systems. Guidelines for configuration management
ISO 10012:2003 Measurement management systems. Requirements for measurement processes
and measuring equipment
ISO 10015:1999 Quality management. Guidelines for training
ISO 13849-2:2003 Safety of machinery. Safety-related parts of control systems. Validation
ISO 14001:1996 Environmental management systems. Specification with guidance for use
ISO 14004:1996 Environmental management systems. General guidelines on principles, systems and
supporting techniques
ISO 14015:2001 Environmental management. Environmental assessment of sites and organizations
BS Standards
BS EN 13480-1 2002 (Current) (formerly BS 806 - 1993) Metallic industrial piping. General
BS EN 13480-2 2002 (Current) (formerly BS 806 - 1993) Metallic industrial piping. Materials
BS EN 13480-3 2002 (Current) (formerly BS 806 - 1993) Metallic industrial piping. Design and calculation
BS EN 13480-4 2002 (Current) (formerly BS 806 - 1993) Metallic industrial piping. Fabrication and
installation
BS EN 13480-5 2002 (Current) (formerly BS 806 - 1993) Metallic industrial piping. Inspection and testing
Procedures
1. Relevant equipment to be made available by Contractor.
Rotary Test Bench must have firm support to accurately test any gearbox or actuator listed in this
Works Information between 20 Nm and 4000 Nm.
Linear Test Bench must have firm support to accurately test between 1000N and 500 000 N
Thrust base Test Bench to test thrust bases for control valves between 1000N and 7000N linear
thrust.
Gearbox end stop adjustment to within 0.5
Lockable workshop floor space of at least 1000 square meter to house 111 stripped actuators for
inspection.

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ESKOM HOLDINGS LIMITED CONTRACT NUMBER _____________

PROJECT & CONTRACT TITLE ACTUATORS

PART 3: SCOPE OF WORK

C3.2 Contractors Works Information

Total number of pages

PART C3: SCOPE OF WORK 1 C3 ECC3 COVER PAGE

C3.1: EMPLOYERS WORKS INFORMATION

1. Description of the Works

The Contract agreement number

AMRI Actair 31R

Auma gearbox GF 200

2. Work to be performed by the Contractor for the works

Activity 1 (Complete overhaul). Performed by the Contractor.

Activity 2 (In-situ inspections on site). Performed by the Contractor.

Acti 3 (Scope of in-situ service). Performed by the Contractor.

7. Title to site materials

Title Date or revision Tick if publicly

ISO 10005:1995 Quality management. Guidelines for quality plans

1. Relevant equipment to be made available by Contractor.

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