NATIONAL WATER RESOURCES INFRASTRUCTURE: NORTHERN OPERATIONS

HARTBEESPOORT AREA OFFICE

Refurbishment of Mokolo dam sleeve and

butterfly valves actuators.
 Refurbishment of Mokolo dam sleeve and butterfly valves actuators.

1 Table of Content

1 Table of Content..............................................................................................................2
2 Background..................................................................................................................... 3
3 Problem statement..........................................................................................................3
4 Scope of work.................................................................................................................. 3
4 Project Specifications......................................................................................................3
5 Occupational health and safety.......................................................................................4
6 Quality Control................................................................................................................4
7 Pre tender Requirements................................................................................................5
8 Pricing Activity Schedule.................................................................................................6
9 Rotork and Mastergear actuators....................................................................................8

Page 2
 Refurbishment of Mokolo dam sleeve and butterfly valves actuators.

2 Background

Mokolo Dam is a rock-fill type dam located about 40km south of Lephalale town, Limpopo, South
Africa. It was established in 1980 .The Malmanies River and the Bulspruit River, two tributaries of the
Mokolo, also enter the dam from its left side. The dam is classified as a Category III dam in
accordance with the Dam Safety Regulations. . The GPS coordinates for Mokolo dam are
Latitude : S24.08 and Longitude : E27.73
The dam supplies water requirements for Lephalale area, Exxaro mine, Matimba and Medupi Power
Stations. The outlet works at Mokolo dam consists of inlet tower with portal crane, service gate,
concrete trash racks, two outlet stack pipes with multi-level intake fitted with isolating butterfly valves,
downstream valve control room with river outlet sleeve valves, upstream spherical valve with
downstream jet flow gate valve and an off take from main river outlets to left bank pump station.

3 Problem statement
Butterfly valves actuators
A manual operated butterfly valve is installed on each of the four river outlet pipes upstream of sleeve
valves with the purpose to isolate the pipes in order to enable repairs or service of the sleeve valves.
Currently one of the sleeve valves cannot be isolated due to faulty isolating butterfly valve gearbox
actuator.
Sleeve valves actuators
At The downstream end of the outlet pipes terminate into four sleeve valves in the valve control room.
The main outlet pipes terminates in 2 hooded sleeve valves of 914mm in diameter and the 2 inner
pipes in hooded sleeve valves of 381mm in diameter. The sleeve valves are electrically operated but
can also be operated manually in the event of loss of electrical power. Currently the two main sleeve
valves cannot be operated either electrically or manually due to faulty actuators and drive
mechanisms.
The two sleeve valves were recently refurbished and because of the above mentioned defects they
cannot be commissioned .Unavailability of sleeves valves poses a serious threat to dam safety in the
event of flooding and also it interrupts normal downstream river compensation/releases activities.

Scope of work
The scope of work comprises inspection, refurbishment, repairs, replacement if necessary, operating
and testing(commissioning) of 2 sleeve valve actuators on river outlet lines 1 and 4, associated driving
mechanisms and 2 butterfly valve manual gearbox actuators also on river outlet lines 1 and 4.

4 Project specifications

Butterfly valve actuator specifications

Actuator make/manufacturer : Mastergear Co Ltd
Actuator type : M.B
Serial number : 4.753
Gearbox lubrication : Fully grease lubricated

Sleeve valve actuator specifications

Actuator make/manufacturer : Rotork syncropak
Actuator type : 16A/458
Output speed : 48RPM

Page 3
 Refurbishment of Mokolo dam sleeve and butterfly valves actuators.

Supply Voltage : 380/3/50

Motor rating : 8Hp
Auxiliary switch rating : 15A - 440VA
Wiring diagram number : 1411/40
Gearbox lubrication Oil : SAE80EP

5 Occupational health and safety

The Occupational Health and Safety and Regulations (Act number 85 of 1993) is applicable.
Construction Regulations, General Machinery Regulations and Driven Machinery Regulations have
particular reference. The DWS shall ensure that the provisions of the OHS are complied with for the
duration of the project. The contractor prior to commencing on with the project shall submit:
• A comprehensive OHS file in accordance with the OHS Act.
• A detailed site specific risk assessment for review and acceptance;
• A detailed method statement for approval by the Project Manager;
All work shall be done in accordance with relevant legislation(s) and regulation(s). The DWS reserves
the right to stop the contractor from executing work, which is not in accordance with the contractor’s
OHS plan for the site or which poses a threat to the health and safety of persons. The contractor may
not appoint a subcontractor unless the contractor is reasonable satisfied that the subcontractor has
necessary competencies and resources to perform work safely. Any subcontractor appointment shall
be approved by the Project Manager. Where a contractor appoints a subcontractor, all OHS Act
requirements shall be applicable to the subcontractor. The contractor shall appoint a full-time
competent employee in writing as the project supervisor, with the duty of supervising the project.

When the contractor and employees is found contravening OHS Act, the DWS shall stop the work
until such time that the contractor implemented corrective measures to the satisfaction of the DWS.

Risks Identified by the DWS

The following are the risks associated with this project as identified by the DWS:
• Flooding
• Drowning
• Falling
• Injury due to falling material
• Injury due to hand tools
• Snake bite
• Falling due to slippery surface
• Scaffold and climbing equipment collapse
• Electrocution
• Service gate or isolating equipment failure
• Back injuries from carrying heavy loads
• Confined spaces
 Eyes due to water spray jet

Notwithstanding the abovementioned risks the contractor shall formulate a risk management plan
which will include any additional risks identified by the contractor.

Isolations and Lock outs

Prior to decommissioning and commencement of any work, the contractor in conjunction with the
Project Manager shall isolate and lock out outlet lines, valves, actuators, electrical equipment and all
sources of energy relevant to the scope of work in accordance with the Occupational Health and
Safety Act (OHSA).The cost for OHS shall be included in the Tendered rates.

Page 4
 Refurbishment of Mokolo dam sleeve and butterfly valves actuators.

6 Quality control

The quality of the work shall be assured in accordance with the DWS Quality Control Specification,
that is, DWS 2020 were applicable. Prior to commencing with the project the Quality Control Plan
(QCP) shall be submitted to the DWS for review, acceptance and or approval.

All Plant shall be subject to inspection and testing by the Engineer at the Manufacturer's premises
before despatch. No material shall be delivered to the Site without inspection having being carried out
or waived by the Engineer in writing.

Inspection of equipment shall be carried out by the DWS representative or a nominated and approved
inspection authority.

The DWS may employ an independent, technically qualified organisation to carry out quality
surveillance of the work on his behalf. The inspection authority has the right to inspect any item
covered in the Contract at any stage of execution of the Project.

The Manufacturer's material test data certification and the Contractor's quality records shall be subject
to examination by the Engineer or his representative. For the purpose of carrying out quality
surveillance, the Engineer or his representative shall be granted access to any part of the Contractor's
premises and Site relevant to the work being carried out, at any reasonable time . The cost for quality
control shall be included in the Tendered rates. Plant, materials and services that do not conform to
the requirements of this Specification shall be rejected. Such rejected Plant shall be held at the cost
and risk of the Contractor who shall, when called upon, and at his own cost, repair the defects
according to the Contract.

Failing satisfactory repair of rejected equipment, the Plant shall be returned to the Contractor at his
cost and risk without any opportunity to substitute the rejected Plant. Alternative Plant may be
purchased at the Contractor's expense or an approved Contractor may be employed to do the repair.

Should the Contractor fail to comply with the provisions of this specification, the Certificate of
Commissioning shall not be issued.

7 Pre tender requirements

Before submitting a Tender, each Tenderer shall visit and examine the Site and its surroundings, and
shall obtain all the information that may be necessary for preparing the Tender. The date of the
official Pre-Tender Meeting and Site Visit, which will be organized by DWS, is stated in the Invitation
to Tender. Tenderers are at liberty to visit the Site at other times during the Tender Period subject to
making prior arrangements with the DWS.
The Tenderer and any of his personnel or agents who the Site or the Employer’s premises and lands
for the purpose of such inspection will release and indemnify the Employer and his personnel,
contractors and agents from and against all liability in respect thereof and in respect of entering and
being conveyed in any vehicle including airborne vehicles arranged by the Employer and will be
responsible for personal injury (whether fatal or otherwise), loss of or damage to property and any
other loss, damage, costs and expenses however caused, whether or not caused by the negligence of
the Employer. (Such indemnities shall be given to the Employer prior to the start of any Site visit in
the form attached to these Instructions to Attendance at the Pre-Tender Meeting and the Site Visit is a
compulsory precondition to submitting a Tender. Attendance will be confirmed by the Employer, by
means of the Tenderer’s completion of the Pre-Tender Meeting and Site Visit Inspection Certificate
(Annexure A). The Certificate will be signed during the Pre-Tender Meeting/Site Visit by the
Employer, the Engineer and the Tendering Contractors. The Pre-Tender Meeting with the Engineer
and the Employer will be arranged as part of the official Site Visit. The original signed Pre-Tender
Meeting and Site Visit Inspection Certificate (Annexure A) must be included in the documentation

Page 5
 Refurbishment of Mokolo dam sleeve and butterfly valves actuators.

submitted with the Tender. The Tenderer shall bear all costs associated with his visit or visits to the
Site and his attendance at the Pre-Tender Meeting.

8 Pricing activity schedule

SCHEDULE OF ACTIVITIES
ITE PAYMEN AMOUN
DESCRIPTION UNIT QTY RATE
M T T
          R c
1 Preliminary and general No 1

2 Outlet pipeline isolation and lockouts No 4

 
Rotork actuator s and driving mechanism, strip
3 No 2
and inspections.

Rotork actuators and driving mechanism

4 No 2
refurbishments/repairs or replacement

Rotork actuators and driving mechanism testing

5 No 2
and commissioning
 
6 Mastergear actuator strip and inspections No 2
 
Mastergear actuators refurbishments/repairs/
7 No 2
or replacement
 
8 Mastergear actuators testing and commissioning No 2
9 Outlet pipeline isolation and lockout removals No 4

TOTAL

SUB-TOTAL
Allow for : Contingencies (10 %)
Allow for : Escalation (0 % - rates fixed)
VAT (14 %)
TOTAL AMOUNT OF QUOTATION

__________________________ ____________________

Page 6
 Refurbishment of Mokolo dam sleeve and butterfly valves actuators.

TENDERER DATE

9 Rotork and Mastergear actuators

Sleeve valve rotork actuator

Rotork actuator nameplate

Page 7
 Refurbishment of Mokolo dam sleeve and butterfly valves actuators.

Butterfly valve Mastergear manual gearbox actuator

Mastergear actuator nameplate

___________________

Page 8
 Refurbishment of Mokolo dam sleeve and butterfly valves actuators.

PROJECT MANAGER
MR. TC MUTETWA
DATE:

_________________________________
HARTBEESPOORT: AREA MANAGER
MR. J. J. PRETORIUS
DATE:

___________________
FINANCE
MR. P. SENTLE
DATE:

_________________________________
SUPPLY CHAIN MANAGEMENT
MRS. WGJ LAMPRECHT
DATE:

Page 9