TENDER FOR THE UPGRADING OF THE

MEDIUM VOLTAGE DISTRIBUTION CENTRE

April 2022
Table of Contents

1. Introduction ..................................................................................................... 5
2. General Tender Information ........................................................................... 5
2.1 Scope of Works ................................................................................................................. 5
2.1.1 Works Description ......................................................................................................... 6
2.2 Tender Documents............................................................................................................ 7
2.3 Tendering schedule........................................................................................................... 7
2.4 Site visit ............................................................................................................................... 7
2.5 Clarifications ....................................................................................................................... 8
2.6 Submission of tender offers ............................................................................................. 8
2.7 Tenderer’s price offer ........................................................................................................ 8
2.8 Tender expenses ............................................................................................................... 9
2.9 Content of tender offers - documentation required .................................................... 10
2.9.1 Tenderer’s Information............................................................................................ 10
2.9.2 Technical Proposal .................................................................................................. 12
2.9.3 Project time frame ................................................................................................... 12
2.10 Joint venture and consortia ............................................................................................ 13
2.11 Opening of tender offers................................................................................................. 13
2.12 Award of tender ............................................................................................................... 13
2.13 Rejection of tenders ........................................................................................................ 14
3. Technical Specifications .............................................................................. 15
3.1 Electrical Standards and Codes ......................................................................................... 15
3.2 Materials, Work and Design ................................................................................................ 15
3.3 Contractor’s Warranties ....................................................................................................... 16
3.4 Existing HV/LV Services ...................................................................................................... 18
4. Lot 1 – MFC Building ..................................................................................... 20
4.1 Hermetically Sealing of the DC Building ........................................................................... 20
4.2 Air Conditioning Units........................................................................................................... 22
4.3 Fire Safety & CCTV System ............................................................................................... 22
4.4 Lighting System..................................................................................................................... 23
5. Lot 2 – New Switchgear ................................................................................ 24
5.1 Existing Switchgear Specification ...................................................................................... 24
5.2 New Switchgear ............................................................................................................... 24

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 5.2.1 Objective ................................................................................................................... 24
5.2.2 Standards and Electrical Specifications ............................................................... 25
5.2.3 Installation and Safety ............................................................................................ 27
5.2.4 Switchgear Features ............................................................................................... 28
5.3 Local Transformer ........................................................................................................... 58
5.4 General Installation Requirements ............................................................................... 60
5.5 Optional Maintenance ..................................................................................................... 65
6. Conditions of Contract .................................................................................. 66
6.1 General conditions .......................................................................................................... 66
6.2 Definitions ......................................................................................................................... 66
6.3 Language .......................................................................................................................... 66
6.4 Compliance with Laws and Regulations ...................................................................... 66
6.5 Obligations of the Contractor ......................................................................................... 67
6.6 Safety ................................................................................................................................ 67
6.7 Quality Assurance ........................................................................................................... 68
6.8 Compliance with the Law and Regulation ................................................................... 69
6.9 Payment and Price Conditions ...................................................................................... 69
6.9.1 Variations .................................................................................................................. 69
6.9.2 Increase or decrease of cost ................................................................................. 69
6.9.3 Tendered rates......................................................................................................... 69
6.9.4 Measurement of work ............................................................................................. 69
6.9.5 Payment to Contractor ............................................................................................ 70
6.10 Insurance .......................................................................................................................... 70
6.11 Dispute Settlement and Arbitration ............................................................................... 71
6.12 Completion Period ........................................................................................................... 71
6.13 Delay in Execution........................................................................................................... 72
6.14 Execution of Works ......................................................................................................... 72
6.14.1 Site Management .................................................................................................... 72
6.14.2 Materials and Workmanship .................................................................................. 73
6.14.3 Possession of Site and Limit of Site of Work ...................................................... 73
6.14.4 Drawings and specifications .................................................................................. 73
6.14.5 Working Hours ......................................................................................................... 74
6.14.6 Access to works ....................................................................................................... 74
6.14.7 Power of Engineer ................................................................................................... 74

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7. Attachments................................................................................................... 75

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 1. Introduction

The Malta Freeport Distribution Centre was commissioned in 1992 by the Malta
Freeport Corporation to feed Freeport Terminals (Malta) Limited, Oil Tanking Limited,
Medserv Limited and Malta Fish Farms Limited. After privatization the Malta Freeport
Authority, formerly the Corporation, no longer had a technical department and thus,
operation and maintenance are performed by Malta Freeport Terminals Limited on
their behalf. The Distribution Centre now only feeds Malta Freeport Terminals Limited
since in April 2019 all other private entities were transferred to Enemalta’s
Distribution Centre.

Throughout these years the switchgear performed quite well with respect to
insulation and fault clearance. The only occasional nuisance consisted in the failure
of certain breakers to close immediately when switched on. These are clear signs of
ageing and that the switchgear is nearing its life expectancy. Another issue is spares
are no longer available. In addition, since the time of commissioning there has been
significant improvements in the design, reliability, life expectancy and protection of
circuit breakers.

This distribution centre is crucial to Malta Freeport Terminals Limited, thus it is

issuing a call for its upgrade.

2. General Tender Information

2.1 Scope of Works

The tender shall be split into two separate lots, namely:

LOT 1: Hermetically Sealing of Distribution Centre (DC) to eliminate the

ingress of dust and humidity. Installing air conditioning units, fire alarm system and
CCTV.

LOT 2: Replacing all the switchgear: The design, manufacture, factory testing,
delivery, installation and commissioning of medium voltage switchgear at Malta
Freeport’s Distribution Centre.

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2.1.1 Works Description

The project has a number of interrelated elements which are to be undertaken by the
contractor as part of this contract:

a. Undertake a survey of the electrical installation at the terminal to establish the

status of:

i. 11 kV distribution network

ii. Protection systems

iii. Earthing system

iv. Battery charging system / UPS

v. Energy monitoring, recording, transmission and display storage system

b. Design, construct, deliver, install and commission the following systems

i. 11kV switchgear and all supporting infrastructure.

ii. Energy monitoring, recording, transmission and display storage system.

iii. HV testing after the installation of all cabling (including those installed by
others).

iv. Maintain the DC including all equipment and facilities for a period of 2
years. To be quoted separately as Optional Maintenance.

c. Design, implement, commission and maintain the 11 kV protection system

associated with the switchgear at the DC and the alternate supply
configurations and shedding options of the MFT 11kV network.

d. Design and install the necessary foundations and the required floor levelling
for the new switchgear opposite to existing ones (including all necessary civil
works).

e. Supply, lay in ducts, jointing and terminating of medium voltage cables from
existing switchgear to the new ones.

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2.2 Tender Documents

The Tenderer ca n o btain a complete set of the Tender Documents from Malta
Freeport Terminals Ltd. official website:

https://www.maltafreeport.com.mt/about-us/tenders/

2.3 Tendering schedule

Event Date

Issuing of tender 13th April 2022

Deadline for Submission of Tender offers 31st May 2022

Contract Award 60 days after tender submission

closes (Max)

Project Commencement Date Immediate from signing of

contract

2.4 Site visit

A technical clarification meeting and site visit for Tenderers shall be held on the
28th of April 2022.

Tenderers shall be asked to register by not later than one day prior
commencement of site visit by providing their full name, ID card number, vehicle
registration, and name of Company they represent and the contact details of the
nominated person present during the meeting. Only three (3) persons shall be
allowed to participate for each prospective Contractors. Registrations are to be
made to the following email address:
engineering.managers@maltafreeport.com.mt

Tenderers are advised, in their interest, to inspect the site of works, in order to
ascertain for themselves the conditions of the site itself in particular the
requirements of MFTL operations. No claims arising from lack of ascertaining the
site condition shall be entertained later.

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2.5 Clarifications

The Tenderer shall promptly notify the Engineer of any ambiguity upon
examination of the Tender Documents. Tenderers requiring clarification or
interpretations of the Tender Documents shall make a written request to the
Engineering department (as listed above) prior to the deadline set in the Tender
schedule.
The MFTL’s representative reserves the right to keep minutes of such clarification
meetings, which minutes shall be made available to all Tenderers through the
clarification process.
Any interpretation, correction or change of the Tender Documents will be made by
Addendum. Interpretations, corrections or changes of the Tender Documents
made in any other manner shall not be binding, and the Tenderer shall not rely
upon such interpretation, correction and changes.
Any addenda shall be communicated to the Tenderers which is expected that the
Addenda will be officially available at least a week before closure of tender.

2.6 Submission of tender offers

All Tenders and any other documents required to be submitted preferably through
a soft copy addressed to the Purchasing Manager:

purchasing.manager@maltafreeport.com.mt

For any other documentation / brochures etc. that cannot be sent in soft copy email
can be delivered at the front desk at the Malta Freeport Terminal Administration
block reception addressed to the Purchasing Manager.
The outer package enclosing the Tender offer shall be marked with the Tender
Name and the name of the Tenderer’s organization.
All offers must be received not later than the closing date and time indicated in the
Tendering Schedule.

2.7 Tenderer’s price offer

a) Prices shall be submitted in accordance with the items and requirements

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 indicated in the Bill of Quantities. Items of the Bill of Quantities against
which no price is entered could be deemed to invalidate the Tender.
Should any further work not specifically called up in the Bill of Quantity
but nominated in the Scope of Work be required, it is the Contractor's
responsibility to group the cost of this work under the appropriate general
heading nominated in the Schedule.
b) Alternatively, the Tenderer may set a pro rata based on other priced items
of the Bill of Quantities and the Tenderer shall be obliged to accept such
rate as established by the Company in order not to forfeit the Tender
Guarantee.
c) Prices shall only be submitted in Euro currency.
d) Tenderers must inspect the Tender Documents and shall satisfy
themselves before tendering as to the correctness, sufficiency and
applicability thereof. If the Tenderer finds any errors etc., during the
Tendering Period it shall not amend the Tender Documents. No claim will
be considered should there be any omission, inaccuracy or ambiguity
therein.
e) All rates and prices inserted by the Tenderer in the Schedule of Quantities
shall be firm fixed prices and rates for the duration of the Contract. No
adjustment will be allowed in the Contract Prices or Contract Rates in
respect of any changes which may take place in the cost of labour and
materials or of any other factors affecting such prices between the date of
submissions of Tenders and the date of Expiry of the Contract.
f) The tendered prices shall be the rate per complete item and the tender
value shall be the sum total of the items in the Bill of Quantities. The rates
tendered shall be considered as covering all the works as specified as well
as any other works which are contingent or of an indispensable nature for
completing the works in their entirety.

2.8 Tender expenses

a) Tenderers shall bear all costs and expenses associated with the
preparation and submission of their respective Tender offer.

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 b) The Client shall not be responsible nor shall it entertain any claims in
regard of any expenses, costs or losses incurred by any Tenderer in
relation to the preparation and submission of a Tender offer, attendance
at the Site Visits and the presentation or inspections or any other aspect
of the Tendering process.

2.9 Content of tender offers - documentation required

Tenderers are advised to ensure that all Submission Forms and information
submitted as part of their Tender offer should be presented in the same order and
sequence as they appear in the Tender Documents;

2.9.1 Tenderer’s Information

Tenderer’s Details

Tenderer shall include all contact details, name of the Authorized Representative,
addresses and contact numbers. Tenderer shall provide a detailed presentation
of its organisation and its activity.

Data on Joint Ventures and Consortia shall be supplied, including any supporting
documentation in accordance with the respective section.

The Tender shall include the legal name of the Tenderer and a statement that the
Tenderer is a sole proprietor, a Joint Venture and/or Consortia or a legal entity. A
Tender by a Joint Venture and/or Consortia shall give the place where this was
registered, its registration number and where it has its principal place of business
and have the company seal or other official certification affixed. A Tender
submitted by an agent shall have a valid power of attorney attached to the agent's
authority to bind the Tenderer.

Tenderer’s Organisation Outline

Tenderer shall identify the management structure and hierarchy of the Tenderer’s
organisation and with an Organigram (or organisation chart) of the said
organisation.

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Tenderers are to note that in the case of a Joint Venture or Consortium, a single
form must be filled and a single Organigram is submitted for the whole Consortium
or Joint Venture in the manner of a single organization.

Sub-Contracting Details

Each and every sub-contractor to be engaged on the works shall be identified,

regardless of the amount. The statement shall include, the name of each Sub-
Contractors’ organization, their address, contact numbers and e-mail address, a
description of the works to be carried out by each Sub-Contractor. The list must
include at least the following information:

Name of Sub- Description Address & Value of

Contractor of Works Phone No. Sub-
Contractor

Contractor’s experience

The Tenderer shall submit with their tender documents sufficient evidence that they
have carried out works of similar nature and maintenance as those now being
proposed in order that the Client may be in a position to assess whether they are
technically and financially capable of carrying out the proposed works. The
Tenderer shall provide a list of projects of similar size, value and complexity,
carried out in the last ten (10) years including the following details:

 Project Name, Value and Location

 Nature and Value of Tenderer’s involvement/works
 Project start date and completion date
 Client organisation and client references

In the case of a Joint Venture or Consortia, although any experience gained as a

single organisation is preferable, separate sheets giving details of the general
experience of each constituent may be submitted.

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 Technical Expertise

A list of the key experts to be engaged shall be given, including the years of
expertise in the said field and respective qualifications. The Project Coordinator
shall be specifically engaged full time upon the works and shall be present at all
times during the works.

Key experts’ positions to include:

 Project Coordinator
 Health and Safety Supervisor
 Quality Control Manager
 Mechanical and Electrical Engineer

Prior to the award of the Contract, the Client will notify the Tenderer in writing if the
Company, after due investigation, has reasonable objection to any such person or
entity. If the Company has a reasonable objection to any such person or entity,
the Tenderer must submit an acceptable substitute or entity with an adjustment in
his tender price to cover the difference in cost occasioned by such substitution.
The Company may at its discretion accept the adjusted Tender sum or it may
disqualify/ reject the Tender.

2.9.2 Technical Proposal

The Tenderer shall include a detailed technical proposal, including the Tender
technical specifications signed by the Tenderer.

Wherever possible, the Tenderer shall submit with his tender all possible
information such as descriptive literature, illustrations, pamphlets and any other
documents, the name of the manufacturers etc. regarding the materials which are
to be used.

2.9.3 Project time frame

The Tenderer shall include a detailed Gantt chart of the project.

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2.10 Joint venture and consortia

Tender offers submitted by organizations forming a Joint Venture or Consortium

shall be acceptable as long as the requirements listed hereunder are met in full.

Joint Ventures and Consortia must submit a single cohesive Tender offer with the
object of securing a single Contract as one organization and any information and/or
Forms required must be submitted accordingly. In this respect, any Joint Venture
or Consortium must submit only one set of documents, forms and other information
required under the Tender Documents except where otherwise specifically
indicated, in the same way as if the Tender offer is being submitted by a single
organization. Tender offers submitted in a piecemeal and fragmented manner with
repeated information and forms submitted separately by individual constituents of
a Consortium or Joint Venture except where otherwise specifically permitted under
the Tender Documents may result in the rejection of the Tender offer.

In the event that the Contract is awarded to a Joint Venture or Consortium, no

changes in the constituents of said Joint Venture or Consortium shall be
permissible for the entire duration of the Contract, other than as may be permitted
or required by Law.

Information regarding Joint Ventures or Consortia shall be submitted on the

Tenderer’s Details form and any supporting information or documentation outlined
above shall be attached to same.

2.11 Opening of tender offers

The Evaluation procedure is confidential in its entirety. The Evaluation Board’s

decisions shall be collective and all its deliberations shall be held in closed session
and its members shall be bound by secrecy.

2.12 Award of tender

It is the intent of the Company to award contracts on the basis of the most
favourable Tenders, provided that the Tender has been submitted in accordance
with the requirements of the Tender Documents. A tender is deemed to be the
most favourable not when considering solely the price quoted but also when
considering other factors which may deem appropriate to the Company such as

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but not limited to the technical solutions proposed, bidder’s experience and
references, project time schedule, etc..

Following the adjudication period, a Letter of Intent will be sent to the successful
Tenderer notifying same of the intention of the Client to enter into a Contractual
Agreement for the provision of the Works envisaged in this Tender.

The Company reserves the right to award Lot 1 or Lot 2 separately.

2.13 Rejection of tenders

The Company shall have the right to reject any or all Tenders and to reject a Tender
not accompanied by any data required by the Tender Documents or to reject a
Tender which is in any way incomplete or irregular. The Company is not bound to
accept any tender and shall not be bound to give any reason for rejecting any or
all tend

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 3. Technical Specifications

3.1 Electrical Standards and Codes

Enemalta is the electrical distribution company supplying the electrical energy to the
Terminal.

The high voltage switchgear and associated equipment to be supplied by the

Contractor in response to this tender must be compliant with the requirements of
Enemalta.

A statement of compliance with Enemalta requirements shall be submitted with tender.

The contractor shall liaise with Enemalta to ensure that the equipment supply including
the determination of the protection settings are in accordance with the Enemalta
requirements.

All Contract works shall be undertaken in accordance with the:

a. Maltese Government’s electrical and safety regulations and standards including

but not limited to: The Network Code - Approved by the Malta Resources
Authority -Version 1- October 2013 Issued by: Enemalta Corporation

b. European IEC Standards

c. Conform to the latest IEE Wiring Regulations.

d. All the electrical equipment complies with relevant product standards.

3.2 Materials, Work and Design

The Contractor shall design where required, manufacture, deliver, commission, test
and hand over the electrical equipment and systems using the design, materials and
standards of workmanship required by or specified in the Contract. All materials and
other items required to be supplied by the Contractor shall be new, in conformity with
their description, of Merchantable Quality and fit for the purpose for which they are
supplied in every respect.

The description in the Contract of any material or other items by a proprietary brand
name, model, number or other specific means shall not in any way relieve, limit or

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exclude any of the Contractor's obligations, responsibilities or liabilities under the
Contract in respect of the design, materials or items including, but not limited to, the
obligations under the last preceding paragraph as to quality and fitness for purpose.

3.3 Contractor’s Warranties

In addition to the requirements of the relevant Standards, the Contractor shall warrant
to the Customer that:

a. The Contractor has the skills, qualifications and experience necessary to,
design where required, install, commission and test and complete the work
under the Contract as required by the Contract; and can offer example of
previous works of a similar nature for inspection if deemed necessary.

b. The Contractor will, in the performance of the work under the Contract, comply
with all relevant Regulatory Requirements and with the lawful requirements of
local and other relevant authorities insofar as they affect or are applicable to
the work under the Contract.

c. The Contractor will install, commission and test the equipment so that when
commissioned at the Terminal will:

i. Meet proper standards of workmanship and be in accordance with the

requirements of the Contract, all relevant Regulations and Standards, the
requirements of the electrical inspector, electrical supply company
Enemalta, and be free of defects and omissions;

ii. Not infringe any patent, registered design, copyright or other intellectual
property right;

iii. Be fit for the intended purpose in all respects and will be capable of being
operated at their designed capacity;

iv. Comply with all of the requirements of the Contract, including, but not
limited to, the requirements of the Specification and the Drawings.

d. The Contractor has carried out a site visit and fully understood the
requirements.

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e. The electrical equipment and systems when commissioned will be capable of
being operated in conformity with the requirements of all authorities having
jurisdiction over the equipment.

f. The warranty shall cover the complete delivered products (include all electrical
components such as circuit breakers, bus sections, isolators, MCCBs and
RCDs, the DC itself, etc.), and requires that the Contractor provides all parts
and labour at his own expense to properly rectify any defect found in the system
up to the expiration of the warranty period.

The Customer shall in all cases first advice the Contractor of the defect and
give the Contractor the first opportunity to attend to it. Another Contractor will
be engaged only when the initial Contractor fails to rectify the matter
expeditiously, or in a satisfactory manner, and the reasonable costs thereof will
be to the initial Contractor’s account. If the Customer deems the defect critical
to the operation of the system, the defect will be attended to within four (4)
hours, otherwise the defect must be attended to within one (48) hours from the
time the defect is reported to the Contractor.

Such work by another Contractor shall not relieve the initial Contractor of his
obligations under the Contract.

g. The warranty shall also cover the DC refurbishment and its’ ancillaries.

h. The Contractor is to inform Customer of any Safe Operating Procedures

(SOPs) or bulletins issued by the original equipment manufacturer regarding
any of the equipment used in this project. Should the Contractor wind down his
company then the Contractor is to ensure that Customer continues to receive
such SOPs/bulletins.

The emergency breakdown service shall provide a guaranteed maximum four

(4) hour response to callout outside normal hours, and a guaranteed maximum
one (1) hour response to callout during normal hours. Any breakdown repair
work which, in the opinion of the Customer has been caused by negligence on
the part of the Contractor shall be rectified at no additional cost.

i. Contactor is liable for any work that is subcontracted to other contactors.

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 j. The Contractor shall ensure that all manufacturers' and sub suppliers'
warranties required under the Contract and all customary warranties from
manufacturers and suppliers who carry out work or supplied plant or equipment
in relation to the electrical equipment are provided to the Customer. The
provisions of such warranties shall not in any way modify or limit any of the
rights, powers or remedies of the Customer against the Contractor in contract,
tort or otherwise.
k. In case of latent defect the warranty shall be extended by 5 years on the faulty
component, identical or similar to it and others that can be affected.

3.4 Existing HV/LV Services

The present electrical installation at the Malta Freeport Terminal Limited is based on
an 11kV medium voltage supply from the Enemalta network.

Two Enemalta 11 kV feeders are connected to the Malta Freeport Terminal 11 kV

switchgear in the ‘Point of Supply’ Substation.

It is required that the contractor undertaking the works detailed in this specification
integrate and schedule the electrical installation and commissioning works so as to
ensure that there is

 No disruption to HV supplies to the Terminal operations.

 Agreed HV switching and energisation procedures of any circuit.

 Implemented the regulatory personnel safety permit system for the operation of
HV switchgear.

The terminal facilities and equipment include:

 Administration Offices

 Workshops

 Container Cranes.

 Refrigerated Container power supplies.

 IT Infrastructure

 Tower Lighting.

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It should be noted that:

There are currently 22 ship to shore container gantry cranes at the Terminal.

 Fourteen (14) cranes have ac drive systems incorporating Active Front Ends
and present to the electrical distribution network a power factor nominally 0.9
and harmonics. The rest are all DC type cranes.

 The AC type container cranes have a main transformer ranging from 2.25, 2
and 1.6MVA and all have an auxiliary transformer of 250kVA. The DC type
cranes have a main of 1.4MVA and an auxiliary of 250kVA.

 There are approx. 2064 refrigerated containers, with a possible expansion to

2544 connected to the terminals’ 400V system. The refrigerated containers are
a base load of approx. 5MVA. The refrigerated containers operate at a power
factor of approximately 0.6 lagging.

The planned redevelopment of the DC requires the upmost care and responsibility of
the contractor to ensure that:

 To perform a risk assessment and provide this to the Customer. Actions are
taken to ensure that there are no incidents and all necessary safety precautions
are taken. (Not all cables in the vicinity of the works can be powered off during
the works.)

 To provide the Customer with a method statement covering all the works to be
undertaken in this project.

 Any direct or associated electrical works do not impact on Terminal operations.

Prior to the contractor undertaking any Contract works, a detailed survey of the area
impacted by the planned development must be undertaken, identifying any potential
problems, means to protect other cables in the duct and existing electrical systems.

Prior to the commencement of the contract works the electrical survey results showing
the identification of electrical systems shall be brought to the attention of and
discussed with the Customer’s Project Manager prior to any works being undertaken.

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 4. Lot 1 – MFC Building

4.1 Hermetically Sealing of the DC Building

Hermetic sealing is required in the switchgear room and transformer room. The
present battery charger room require filtered ventilation thereby partition doors and
other works are required as described below. MFC DC Building drawings and
photographs referred to below are found in Attachment 2 Appendix 1. Photo 1 shows
an external view of the building.

a) Replacing the sealing of single leaf hinged Side Entrance door (Photo 2):

New Outdoor Type Class 4 Security Door

Removal and disposal of existing door

Installation of outdoor type security door Class 4 or better

b) Replacing the 4-leaf Main Entrance door to switchgear room (Photo 3a & 3b):

New Overhead door

Removal and disposal of existing door

Installation of overhead opening sectional door with sealing strips

on all 4 sides – Security Level RC2 minimum.

Manual opening, spring assisted.

Automatic/electric opening is not allowed.

c) Supply and install a hinged door between the Switchgear Room and
Transformer Room with the following specifications (Photo 4):

White aluminium

1 leaf opening

Seal around all 4 sides

Top half double glazed

Bottom 10mm white MDF

Latches to lock open

Opening handle without key lock

d) Replacing the 4-leaf entrance door to the transformer room (Photo 5a & 5b)

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 New Overhead door

Removal and disposal of existing door

Installation of overhead opening sectional door with sealing strips

on all 4 sides – Security Level RC2 minimum.

Manual opening, spring assisted.

Automatic/electric opening is not allowed.

e) Installation of a hinged door to seal the louvered opening above the side
entrance door with the following specifications (Photo 2):

Sandblast & hot dip galvanised louvered frame

White aluminium

1 Leaf opening

Seal around all 4 sides

Double glazed

Opening hand without key lock.

f) Removing, and closing off with brickwork the 2 louvered openings in

transformer room (Photo 5a)

g) (i) Removing the door leading to the existing battery room, sealing this opening
with brickwork and open a doorway from this room to the transformer room. (ii)
A door with same specification to ‘C’ above is to be supplied and installed. In
addition, the louvered window is to be removed sand blasted and hot dip
galvanised. A hinged aluminium window with same specifications as ‘e’ above
is to be supplied and installed (Photo 6).

h) All the building floor shall be thoroughly cleaned, and 1 layer of stabilizing
solution shall be applied. No opening shall be left unsecured during the
refurbishment works. A means of temporarily securing these are to be provided
by the contractor until the original fixture/door is re-installed. When all works are
completed the internal walls are all to be repaired from cracks and finish painted
in white.

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4.2 Air Conditioning Units

Installation of two split type Air conditions in the switchgear room with the following
specifications:

Capacity of 22,000 to 24,000 BTU

Wired remote controllers

Outdoor unit shall be placed on the roof of the building

Copper pipe insulation shall be outdoor type (foil wrapped)

Outdoor unit brackets, if any, shall be hot dipped galvanised

Installation of a split type Air Condition unit in transformer room sized to match the full
load loss of the transformer. Other specifications as above.

4.3 Fire Safety & CCTV System

Installation of fire alarm system with the following characteristics

 Three zones

o Zone 1 – four smoke and heat detector

o Zone 2 – two smoke and heat detectors

o Zone 3 – one smoke and heat detector

 SIM Dialler

 4-hour battery backup

 Outdoor siren

Sealing of all 5 cable ducts leading to the building with fire pillows of 4-hour fire rating
and fire retardant expanding foam.

In addition, the building perimeter and all the rooms inside the building are to be
monitored by CCTV cameras. Cameras are to be strategically placed to cover all
(indoor and outdoor) areas and system is capable to store footage from each camera
for a minimum of 1 week. The video recorder shall be located off site with fibre optic
communication access.

This fire system is to be integrated with the SCADA.

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4.4 Lighting System

All fluorescent lighting fittings are to be replaced with twin LED equivalent and all
emergency lighting fittings to be replaced too. Installation wiring, protection devices
and conduit to be retained if upon insulation testing and inspection are found to be
healthy.

23 | P a g e
 5. Lot 2 – New Switchgear

5.1 Existing Switchgear Specification

The existing switchgear has the following basic characteristics:

Manufacturer: Brush Switchgear of the United Kingdom who were the trading
name of Hawker Siddeley Switchgear at the time.

Type: VMV 12

Year of manufacture: 1992

Rated voltage: 12kV

Power Frequency withstand voltage: 28kV

Peak impulse withstand voltage: 75kV

Circuit breakers: Vacuum type

Insulation: Air insulated with resin encapsulated busbars.

Protection: Electro-mechanical GEC relays

Number of panels: 12 consisting of 2 x 2000A incomers from Enemalta, one

2000A bus section and nine 630A outgoers.

The existing configuration of the DC switchgear is shown in Photo 7 and in the network
drawing attached in Attachment 2 Appendix 1 and 2 respectively. The detailed
specifications of each cubicle to be replaced in Appendix 3.

5.2 New Switchgear

5.2.1 Objective

a) The Contractor shall be responsible for the supply, installation and

commissioning of an 11kV switchboards with a layout shown in the new single-
line diagram attached in Attachment 2 Appendix 4 and new set up details in
Appendix 5.

b) The switchgear shall be three-pole, metal enclosed, extensible, gas insulated

(GIS) (Option 1) or withdrawable air insulated (Option 2), primary switchgear
for indoor installation and of single busbar design. Switchgear and related

24 | P a g e
 equipment shall be designed to ensure service continuity and operating safety,
and to enable easy and minimum maintenance.

c) The switchgear shall be placed opposite to the existent switchgear and partially
over the cable flat below. The Contractor should give sufficient consideration
to the utilisation of space for installation and maintenance and to ensure easy
adaptation to future arrangements and extensions.

d) The existing configuration will be altered to include an additional bus section.

The outgoing feeders will be repositioned so that circuits can be ringed without
the risk of having the feeding transformers in parallel operation. Additionally,
the new set up will include two spare incoming feeders, at each end of the
busbar. Line diagram and the configuration arrangement in Attachment 2
Appendix 4 and 5 respectively show the current switchgear in the new setup.

5.2.2 Standards and Electrical Specifications

a) The switchgear shall be manufactured and tested in accordance to IEC 62271

or equivalent, particularly IEC 62271-200.

b) The Contractor shall be able to submit evidence of type testing by a recognised

short-circuit testing laboratory for each type of switchgear offered. The type
testing should include all current carrying parts such as busbars, circuit
breakers, disconnectors, earthing switches, CTs, VTs and cable compartments.

c) The main electrical requirements are shown in Table 01 below, and specific
technical requirements for the applications considered in this project are shown
in Table 02.

Standards

General IEC 62271-200

Capacitive Voltage Indication ICE 61243

Instrument Transformers IEC 60044

25 | P a g e
Low Voltage Switchgear &
IEC 61439
Control Gear

Plug-In Type Bushes EN50181

IEC 62271

SF6 IEC 60480

IEC 60376

Electrical Characteristics

Rated Voltage kV 12

Rated Power Frequency

kV(1min) 28
Withstand

Rated short time withstand

kA (rms) 3s 25
current

Rated Peak Making Current Pk kA 63

Frequency Hz 50

Busbar Current Rating A 2000

Internal Arc Compliance kA 1s 25

Rated Short Circuit Breaking

kA 25
Current

Lightening Impulse withstand

kV(peak) 75
Voltage

Type of metal-enclosed
LSC2
switchgear

Class of Partitions PM

Protection -Gas Compartment IP56 or better

Protection - External IP4X or better

RH % 95

Maximum Ambient
°C 40
Temperature

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 Charging Motor V TBC

Panel Heaters V 230

Colour RAL

5.2.3 Installation and Safety

a) The switchgear should be suitable for side-by-side mounting on galvanised

steel channels or girders, pads, or similar, set into a reinforced concrete floor.
The necessary foundation and fixing equipment shall be supplied as part of this
contract and should be designed so that no damage or distortion will occur
under all conditions of operation including short circuits. Any civil works required
must be approved by the Customer and must not disrupt the operation of the
existing switchgear.
b) The switchgear should be suitable for installation in a building with a cable
basement.
c) All similar parts of the switchgear, including spares, should be interchangeable
without any modification.
d) The switchgear shall be designed for safety of personnel and limitation of
material damage in the event of internal fault. The switchgear should withstand
the effects of an arc at the full rated short-circuit current until the protective
devices have operated.
e) The switchgear should be suitably subdivided into individual gas-tight and arc-
proof compartments to limit the effects of an internal arc in any compartment.
f) Voltages induced in the compartments should not exceed safe limits in any
operational state. All compartments should be earthed, and all earthing
connections should remain operational if an arc occurs.
g) Gas compartments should have pressure relief devices to provide instant and
safe discharge of overpressure caused by an internal arc.
h) Pressure-relief discharges shall be directed away from the operator. The gas
discharge, if any, from the SF6 compartments shall be directed away from
normal operator positions. The Contractor is to provide design calculations if a

27 | P a g e
 pressure relief duct is not required to direct discharges outside the switchgear
room.
i) The HV panels are to be provided with an arc fault detection system. The output
from this system shall be integrated into the SCADA and alarm system. Arc
chutes shall be fitted to the top of the HV panels and designed/constructed to
remove all arc gases from the Substation. The Arc protection system shall not
be triggered when any of the substation doors are opened and/or with either
the circuit breaker panel doors open or closed.

5.2.4 Switchgear Features

5.2.4.1 General

a) The busbars are to be made of copper and all insulating materials should be
non-hygroscopic and incorporate fire-resisting properties.

b) The number of gas-tight compartments that needs to be degassed for

maintenance, repairs or extension should be minimised (Option 1).

c) The switchgear should be provided with adequate continuous copper earthing

bars running throughout the length of the switchboard and connected to the
substation earth and with facility for earthing and testing of individual items as
well as complete assemblies. Earthing of circuit breakers/switches shall be
through earthing switches integral to individual units or through interlocked
circuit breakers/switches. Loose attachments for circuit earthing are not
acceptable.

d) All main and operating parts of the switchgear should be suitably labelled. This
should include primary switches, auxiliary switches and gauges. Circuit
identifying labels should be fitted at the front, and in the cable basement of each
individual circuit assembly and on the local control cubicle. Such labels should
be fitted to non-removable parts of the enclosure. All labels should be secured
by screws or other approved fasteners. The name plate should be engraved
and any identifying name, type or serial number, together with details of loading
conditions under which the item of plant in question has been designed to
operate should be indicated.

28 | P a g e
 e) All circuit breakers, disconnectors, and earthing switches should have an
approved reliable mechanically operated position indicator to show whether the
main contacts of the device are open or closed. Where possible, inspection
windows capable of withstanding internal faults and external damage should be
installed for further visual checking of the contact positions of all three phases.

f) Power-operated mechanisms for disconnectors and earthing switches should

operate on 3 phases simultaneously and will be self-locking in both open and
closed position.

g) Facilities for primary current injection and low voltage checks should be
provided and should be insulated from earth and should incorporate a
disconnectable earth connection.

h) All equipment should be rodent and vermin proof and should have adequate
protection against contact and live parts as well as ingress of water.

i) All wiring used in the switchgear and control cubicles should be fire retardant.
Similarly, the terminal blocks and components used inside the switchgear and
control cubicles should be fire retardant.
j) Phase markings are required at the cable entry, busbar compartment, VTs, CTs
and on the withdrawable circuit breaker.

5.2.4.2 Control

a) Each panel shall be equipped with a bay controller installed on the front panel
of the LV compartment and which ideally should be placed at a height of
approximately 1.7m.

b) The bay controller should provide the necessary protections for the switchgear
(and circuit) and should also be the interface between the switchgear bay and
the SCADA for exchange of information regarding switchgear (circuit breakers,
disconnectors and earthing switches) status, parameters and commands.
There should be sufficient auxiliary contacts for monitoring and control by the
bay controller. All unused auxiliary contacts that could be reserved for future
use are to be wired to a terminal block in the control cubicle.

29 | P a g e
c) The bay controller shall interface with the existing ABB REF615 controllers
located at 4 sub-distribution centres on the Terminals. This complete
compatibility is required to implement protection discrimination (as the
substations could be on 1 network), better load shedding (switching off
faulty/overloaded networks without switching off critical loads) and one SCADA.

d) The bay controller shall be of the electronic type providing overcurrent and earth
fault protection, with the following minimum features:

 Phase overcurrent for each phase (selectable characteristics – define

time, standard inverse, very inverse, extremely inverse and
instantaneous).

 Sensitive earth fault (selectable as for phase current).

 Under-voltage alarm.

 Over-voltage alarm

 Arc Flash trip & alarm

e) Bay controller should have a graphical display and keypad for user friendly local
operation. All operation should be possible from it independently from the
SCADA.

f) All bay controllers should be networked as per IEC61850, configurable and their
data should be available from the keypad or from SCADA or from a laptop.

g) Bay controllers should retain their configuration during power loss and should
be powered by UPS.

h) Bay controller should have self-supervision facilities and raise an alarm if an

internal error is detected.

i) Bay controllers should comply with IEC60068, IEC60617 and IEC60255 or

equivalent.

j) A test block should be installed for ease of testing. The test blocks should have
terminals for both relay and wiring side connections which will accept both wires
and plug connections and be complete with lengths of flexible cable for
connection to a portable relay test set. The Contractor should supply two test
plugs to suit each different type of test blocks.

30 | P a g e
k) Each bay controller should be protected by an individual MCB and power supply
to it should not pass through this test block.

l) Local control of the switchgear should be through:

 the human machine interface (HMI) of the bay controller.

 electrically connected pushbuttons/switches
 mechanical means

The status of the circuit breaker, disconnectors and earthing switches should
be displayed on mimic diagrams on the HMI of the bay controllers. The display
will also show measured and calculated values such as but not limited to:

 The 3 phase (line) currents

 The 3 phase and line voltages

 Earth current and residual voltage

 Frequency and power factor

 Average and maximum values of currents determined over several

minutes

 Apparent, active and reactive powers

 Total switched currents

 Operating hours

 Active and reactive energy

m) Remote operation should be from the SCADA. Earthing switches should be

operated from the bay controller or manually.

n) Apart from electrical motorised operation, it should be possible to operate

disconnectors and earthing switches using manual means. Whenever the
crank is inserted in the drive mechanism it should be impossible to operate the
device electrically.

o) Each bay controller should be independent of each other (unless interlocked)

and its functions should not be affected by any fault occurring in the other bay
controllers of the DC.
p) Trip discrimination and interlocks shall be logically integrated with the current 4
Terminal Sub-Distribution Centres.

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5.2.4.3 Gas Insulation (Option 1)

i. A means for refilling SF6 should be provided unless the SF6 compartments are
hermetically welded and without any seals or gaskets. If the switchgear offered
has hermetically sealed compartments without means of refilling on site, then
the tenders should include proof that these compartments will remain gas tight
throughout the life of the switchgear. Furthermore, in such a case, the SF6
pressure or density should be transmitted to the outside through contact-less
measurement.

ii. If the design allows it, alumina or molecular sieve gas filters should be provided
for the absorption of the by-products of arcing. It should be possible to replace
such filters during maintenance.

iii. If necessary, gas handling shall be carried out by certified personnel. SF6 shall
be recovered and not allowed to escape into the atmosphere.

iv. After filling with SF6, the gas purity and dew point should be checked to confirm
that they are within acceptable limits.

5.2.4.4 Gas Density Monitors (Option 1)

i. All SF6 filled chambers should be fitted with a temperature compensated gas
monitor preferably colour-coded with under-pressure and over-pressure
sensing switches. Switches should be wired to the bay controller and should
be used to raise alarms about falling or rising pressures and for the provision
of facilities to trip and/or lock the switchgear.

ii. The Contractor together with Customer shall decide and agree on any
automatic action upon minimum SF6 pressure. It is proposed that the first stage
should operate an alarm to warn that the gas pressure is falling to a critical
level, and a second stage should either initiate automatic isolation of the gas
compartment concerned by tripping and/or locking associated circuit breakers
and busbar isolators as appropriate.

iii. If the design allows it, it should be possible to replace pressure monitors without
de-gassing the chamber.

32 | P a g e
5.2.4.5 Busbars

a) Busbars should be of high conductivity copper suitable for operating at the rated
current continuously. The busbars should be adequately supported against
short circuit forces with adequate clearances between busbars and between
busbar connections.

b) The busbars should be insulated with SF6 or through solid insulation only. The
busbar connections between adjacent panels may be SF6 insulated or through
solid insulation only. In the case of the latter, the solid insulation should be
screened and protected against touch and vermin. Air-insulated busbar
connections are not acceptable.

c) It shall be possible to earth each busbar section using either a dedicated

earthing switch or a combination of three-way disconnector and circuit breaker.

5.2.4.6 Disconnectors

a) The disconnectors shall be SF6 insulated (Option 1) or in air (Option 2).

b) Disconnectors should provide a means of isolation and earthing to permit safe

maintenance of any section of the equipment including circuit breakers, busbars
and parts of the main circuit when the remaining circuits are alive.
Disconnectors and related earthing switch should be mechanically interlocked
to each other.

c) Disconnectors should be designed for live operations and will not be required
to switch current other than the charging current of open connections and
busbars.

d) It shall be possible to earth the feeder using either a dedicated earthing switch
or a combination of a three-way disconnector and circuit breaker.

e) All disconnectors may be motor operated. Their mechanisms should operate

on 3 phases simultaneously and should be self-locking in both open and closed
position.

33 | P a g e
5.2.4.7 Circuit Breaker

a) Circuit breaker operating mechanisms should be of the motor-charged spring-

operated type. Provision is to be included for closing the circuit breaker by
manually. The charging springs shall be capable of being manually recharged
with the breaker in service.

b) All circuit breakers shall be provided with mechanical indication of the spring
charge condition.

c) Circuit breakers should have a proven rated rupturing capacity when tested in
accordance with IEC 62271-100

d) The circuit breakers should be of the vacuum or SF6 type. Construction for gas
tightness should be factory checked so that the enclosure need not be opened
during the life expectancy.

e) Circuit-breaker poles needing frequent maintenance, checking and gas refilling

will be rejected. The mechanical life of the interrupters should be of at least
10,000 openings. The Contractor should give the relationship of the number of
breaks versus the interrupted current.

f) Anti-pumping functions should be provided to prevent reclosing if the closing

coil remains energised and the circuit breaker fails to latch in the closed position
or is tripped during closing.

g) The trip coil should be equipped with a trip-circuit supervision circuit.

h) Power closing mechanisms should be recharged automatically for further

operations as soon as the circuit breaker has completed the closing operation.
Alarms should be raised if the mechanism fails to recharge.

i) If possible, means should be provided for a local manual ‘non-electrical’ tripping

of the circuit breaker even when in fully isolated position for test purposes.

j) For AIS (Option 2) the switchgear must be of the withdrawable type. The HV
devices shall be mounted on a withdrawable carriage with racking gear for
racking in or withdrawing and for positively fixing the unit into any one of the
following positions.

a. Connected

34 | P a g e
 b. Test / Isolated

c. Disconnected

d. Earthed

Auxiliary switch controls shall remain connected to the cubicle fixed wiring in
the Test/Isolated position.

Stored energy devices on the withdrawable carriage shall be automatically

discharged by any racking operation.

The Contractor shall supply and install automatic shutters, which can be
padlocked, to cover busbar and circuit connections.

An earthing contact, which will make before and break after, all other electrical
contacts on the carriage, shall be installed between the withdrawable carriage
and the switchgear earth busbar.

Two sets of racking handles shall be provided.

The switchgear shall have the facility to tag-out each circuit breaker in the open
position and earthing switch in both open and closed position.

A means of slow closing the circuit breaker for inspection and adjustment when
disconnected shall be provided.

The Contractor shall supply a set of tools personnel safety equipment

necessary for installation and testing servicing all HV equipment.

k) Each circuit breaker should be equipped with an operation counter to record

the number of operations.

l) Each circuit breaker should be equipped with led indicator lights. Lights shall
indicate ‘power available’, ‘closed’, ‘open’ and ‘earthed’ indicators for each HV
circuit breaker.

5.2.4.8 Instrument Transformers

a) All instrument transformers should be suitably rated for all rated and short-
circuit conditions.

35 | P a g e
b) Instrument transformers should have secondary terminals outside the high-
voltage enclosures, mounted in suitable, accessible and properly labelled
terminal boxes.

c) Secondary leads of all instrument transformers should be wired to terminals on

the terminal strip in the LV compartment or cubicle of each bay. Current
transformer secondary terminals should be of the shorting-type. The secondary
wiring of the current transformers should be terminated on the terminal blocks
and instrumentation by screwed terminals.

d) Voltage transformers should be of the metal-enclosed, (GIS– option 1),

inductive or RC-divider type. They should be mounted directly on the high-
voltage enclosure with plug-in contacts to allow easy removal. For Option 2,
they should be of the epoxy resin type, withdrawable and earthed via link for
testing. VTs should be capable of withstanding overcurrent conditions.

e) Means should be provided to isolate the voltage transformers on the HV side

when the respective circuit is de-energised without the need to de-gas
switchgear (option 1). The actual position of the voltage transformer link should
be indicated on the SCADA.

f) The primary windings shall be protected by HRC fuses

encapsulated/withdrawable housing in each phase of the VT. The secondary
wiring of the voltage transformers should be protected by MCBs. Tripping and
opening of the protection MCBs should be indicated on the SCADA.

g) The high voltage star point of voltage transformers should be segregated from
the low voltage star point for safety reasons in the terminal box.

h) VTs used for protection and general use should have an accuracy class of 0.5
or better respectively, with rated voltage factor of 1.5, 30s. VTs used for fiscal
metering should have an accuracy class of 0.2S. The low voltage side should
be protected by MCBs or HRC fuses.

i) CTs used for fiscal metering shall be separate from protection CTs to ensure
an accuracy class of 0.2S.

j) The rated short time current shall be not less than the short time current
equivalent to the prospective circuit fault level.

36 | P a g e
 k) The rated short time shall be not less than the maximum time setting of the
related circuit protective relay.

l) Protection current transformer characteristics shall provide the special current

transformers with characteristics as recommended by the protective relay
manufacturer. The current transformers shall be class P not less than 5P30.

m) The current transformers shall be mounted in switchgear enclosures so that

polarity markings and nameplate details may be readily viewed without removal
from the enclosure.

n) The Contractor shall supply, install and test current transformer shorting links
in accessible positions within metering panels. Each current transformer group
shall have a set of links comprising screw clamp slide links and an earth link.

o) Solder or lug type terminal blocks are not acceptable. Each terminal block shall
incorporate separate clamping assemblies for incoming and outgoing
conductors.

5.2.4.9 Metering Unit

Two Dry type metering units are to be provided each comprising of cast resin current
transformers, and 3 phase, 3 limb cast resin voltage transformer, all totally enclosed
in a weatherproof ventilated steel enclosure with cable boxes and pedestal to the
following specifications.

General
Rated Voltage 11kV, 3 phase
Type Dry, Cast
Short Time Current rating 18.4kA / 3s
Rated lightning Impulse
withstand 75kV peak
Rated 1min power freq.
withstand 28kV r.m.s
Frequency 50 Hz
Continuous Rating 1250A or more
Tap change Offload

37 | P a g e
 Class 0.2S
CT Standard IEC 60044-1
VT Standard IEC 61869-3
Ambient operating temp 0°C-42°C
Winding Cooper

Primary and secondary fuses are to be provided on the voltage transformers. All
secondary wiring is to be brought out onto terminal blocks in a control cable box. The
terminal blocks must have facilities for shorting out the current transformer
secondary’s. The metering terminal blocks must have a frontal transparent cover and
means for the application of anti-tampering security seals.

5.2.4.10 Low Voltage Compartment

i. The auxiliary supply switches and associated relays, MCBs, control switches,
indication and other ancillary equipment of the circuit breaker, disconnectors
and earthing switches should be accommodated in a sheet steel compartment.
This compartment should be mounted on the front of the switchgear and should
house the bay controller as applicable and associated test blocks, the control
wiring terminals from instrument transformers and the auxiliary contacts from
this panel and other panels required by the bay controller. Looping of supplies
shall not be permitted.

ii. These compartments should be of rigid construction and ventilated through

insect and vermin-proof louvres. The compartments should have a lamp inside
and should preferably be painted inside in glossy white. Provision is to be made
for locking.

iii. The compartment should be rated IP4X or better. The exterior finish and colour
of each cubicle should be the same as that of the switchgear.

iv. The LV compartment should be fitted with 230V, 50Hz anti-condensation

heaters with individually controlled and protected circuits.

v. Each bay controller unit should be individually protected by an MCB.

38 | P a g e
 vi. Critical auxiliary circuit MCBs and switches shall be equipped with suitable
auxiliary contacts wired to the bay controller unit or a remote terminal unit. It
shall be possible to transmit the position of such switches to the SCADA.

vii. Under no circumstance shall it be necessary to isolate the HV supply to either

individual circuit breakers or the HV panel to undertake fault analysis or repairs
or replacement of the Auxiliary circuits.

viii. All cables shall be terminated at each with pre-insulated crimp lugs and
identified as required by specification using an approved labelling system
solidly fixed to the cable.

ix. Any installed contactor must comply with the relevant IEC standard. The
contactors shall be of utilization category AC-3 or DC-3 as applicable, shall
have a rated operational current to suit the load controlled and rated duty to suit
the application.

x. Any ancillary circuit fuses must comply with the relevant IEC standards. The
fuse holder shall have fixed insulation, which shrouds live metal when the fuse
carrier is withdrawn. Fuse Links shall be enclosed, shall have high rupturing
capacity and be mounted in a fuse carrier. A ‘fuse blown’ indication, which is
visible with the link, shall be installed in its carrier.

5.2.4.11 Cable Connections

i. The switchgear should be provided with size 3 inner-cone or with outer-cone

plug-in type bushings to EN 50181, or equivalent, for the connection of cables
as shown in the specific technical requirements.

ii. Cable connections are to be designed and installed for cables approaching the
switchgear from the rear below. The two main feeders should also be suitable
for terminating single-core, XLPE insulated cables with stranded copper
conductors per phase, generally to IEC 60502 or equivalent. Provision should
be made to earth the body of each cable compartment directly to the secondary
earthing.

iii. Adequate clamping means should be provided as required to support each

single core cable or the 3 core SWA PILC or XLPE cables in order to avoid

39 | P a g e
 excessive pulling forces on the connection terminals and to have the cable
neatly stacked in the cable flat. Wherever possible, cleats/cable support should
be placed every 0.5m. Any instrument transformer installed in the cable
compartment should allow for removal of the termination.

iv. All cables should have a capacitive voltage detection and indication system to
IEC 61243, or equivalent, for verification of safe isolation from supply. This
should also have suitable sockets for phase comparison tests. The voltage
indicator should not operate on an auxiliary power supply and should indicate
adequately the presence of voltage on each phase of the cables. If access to
cable testing is from below the GIS, a voltage indicator should be installed close
to the test access.

v. The switchgear should have means for voltage testing of the power cable
connected to the switchgear without the necessity to unplug/disconnecting the
cables from the switchgear. The manufacturer should include necessary
precautions to ensure that a user will not insert MV prods on an energised
cable.

vi. Three MV prods or kits required for high voltage and medium voltage testing as
well as voltage and current injection test plugs should be included in the offer.
Supplied test prods are to be placed in clearly labelled wall mounted enclosure.

vii. The Customer reserves the right to employ Enemalta to supply new cables,
termination kits and to install the feeding cables between the Enemalta
Distribution Centre and MFT’s metering unit and main feeders.

5.2.4.12 Locks

i. Where a mechanism is required to be locked in a specific position, locking

provision should be made at that part of the mechanism where the operating
power is applied and not to remote or ancillary linkages. Each circuit breaker
shall be provided with a key interlocking system. The following locking facilities
should be provided if possible:

a. Circuit-breaker mechanisms in the open position

40 | P a g e
 b. Circuit-breaker mechanisms in the closed position if it is used to earth a
feeder

c. Isolating and earthing switches in both open and closed positions

d. Control position selector switches in all positions provided.

5.2.4.13 Interlocks

i. Isolating devices, earthing switches, circuit breakers etc should be provided

with an interlocking system which ensures safe equipment operation under all
service conditions.

ii. Mechanical interlocks, where employed, should be effective at the point where
hand power is applied so that stresses cannot be transferred to parts remote
from that point.

iii. Electrical interlocks should be supervised by the bay controller and should
function by interrupting the operating supply. Hardwired interlocks should also
be employed wherever necessary to ensure operational safety. In particular,
hardwired interlocks shall be applied for earthing switch operation.

iv. Failure of supply, or its restoration after an outage, to any electrical interlock,
should not produce or permit incorrect operation.

v. Interlocks should include, but not be limited to the following:

a. If possible, the cable testing facility should be available only after the circuit
has been earthed from the panel. Earthing switches should be interlocked
such that they cannot be operated unless the associated disconnector is
open.

b. Any section 11kV busbars may only be earthed when all the incoming,
outgoing feeders and bus-section busbar isolators connected to that
section of the busbar are opened.

c. 11kV bus-section, incoming and outgoing feeder busbar isolators in any

one section of the busbar may only be switched on if that section of the
busbar is not earthed.

41 | P a g e
 d. Where applicable, it should not be possible to earth a feeder if the far end
disconnector is closed. In case of a communication failure between the two
sites, a manual override should be possible.

e. The interlocks should prevent the following malfunctions: the release of

charged springs with the circuit breaker closed, the slow opening or slow
closing of the circuit breaker when in service and manual operation if the
charging springs fail.

f. A final list of interlocks and inter-trips shall be agreed upon by the Customer
and the Contractor after award. Before wiring of the switchgear
commences, drawings should be sent for the Customer’s approval.
g. It should be possible to disconnect the earthing switch with the cable
compartment open for cable testing purposes.

5.2.4.14 Battery Charger / UPS

A battery charging system or UPS for the requirements of the circuit breakers and
other HV switchgear as determined by the Contractor shall be designed supplied
secured and commissioned.

The battery system / UPS shall be provided with a comprehensive operating and
monitoring system. The battery system / UPS shall be integrated into the SCADA.

The battery system / UPS must have an autonomy of 2hours. A manual change over
system is to be provided in order to supply the battery system / UPS by means of a
generator.

Should the battery system / ups cannot be powered by the generator, the protection
system can be powered by the local supply directly.

5.2.4.15 SCADA

a) The SCADA should be designed for optimum performance, reliability and

availability. Preferably it should be integrated to the existing SCADA interfacing

42 | P a g e
 with the 4 Terminal Sub-Distribution Centres, the server at the Engineering
Office and a terminal/server installed at the distribution centre.

b) Must comply with IEC 61850. A fast and standard communication protocol such
as Ethernet TCP/IP must be used at station level. Connection to existing
SCADA can be done through the Customer’s F/Optic and Ethernet network. All
necessary hardware to be provided by the Contractor.

c) It should be designed around bay controllers and other data acquisition devices.

d) It should be flexible to receive data from any equipment installed in the future.

e) The Contractor should propose a 24-month assistance agreement during which

the Customer will be able to contact the manufacturer for online and, if
necessary, on-site assistance.

f) It should be programmed in a way to facilitate the programming of bay

controllers from pre-determined file downloads.

g) All equipment related and connected to the SCADA should be supplied from an
uninterruptible power source.

h) The fire alarm and CCTV are to be connected to the SCADA and
terminal/server respectively.

i) An Energy Management System shall also be included in the SCADA. SCADA

pages shall be identical to existing SCADA. Mainly but not limited to:

 The complete MFT Network Diagram

 Actual measured values; Current, Voltage, Frequency, Power,

Import/Export etc.,

 Events, Alarms, Trends, Faults (before, during and after)

 Switchgear status

 Fault oscillograms recorded by the bay controller

 Disturbance records

 Historical Trends with filtering and mathematical (e.g. average, maximum,

minimum) functions

 Control and monitoring of switchgear

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  Parameter downloads

 Predetermined automatic reports and able to export data to MS Excel.

 User authority levels

Additional screen layouts and pages to be discussed and agreed upon.

j) Load Shedding: The system shall be equipped with a load shedding process
designed to automatically switch off specified feeders of the existing
substations at the terminal if the load current of the feeders feeding the quay
cranes will be close to the trip current.

k) It should be possible to set, enable and disable the load shedding system from
the SCADA through a password.

l) Restoration of the tripped feeders can be either be performed manually or

automatically. To be discussed during the engineering phase of the project.

m) The two main feeders should be equipped with fiscal class energy meters.
These meters are to be connected to the SCADA. Should comply with
IEC62053 for 0.2S meters, preferably identical to the ones used by Enemalta.
Suitable for a 2-tier tariff system (day and night), import/export readings. The
Maximum Demand (both in W and VA) summation of both meters is to be
performed by the SCADA and calculated as per Enemalta’s tariff system.

5.2.4.16 Protection & Short Circuit Study

The tenderers are to confirm in writing the Enemalta fault levels at Malta Freeport
Terminals Limited “Point of Supply”.

The existing protection systems in the Malta Freeport 11 kV distribution networks is a

robust system based principally on CDG relays and fuses.

The protection system developed as part of this contract is to maintain the same level
of ‘robustness’, whilst at the same time providing the required level of equipment and
infrastructure protection.

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The electrical characteristics of the Freeport container terminal loads in particular the
quay cranes are very dynamic with rapid load demand changes on a short time base.
There is an energy (kWhr) flow of both consumption and regeneration.

With reference to Attachment 3; this is a simulated substation electrical demand (kW)

with seven (7) twin lift quay cranes and a base load of approx. 300 Refrigerated
Containers together with Office and Lighting loads.

The purpose of the attachment is to indicate only as to the rapid changes in demand
and regenerative loads from the quay cranes together with base loads.

As noted in b. iii (below) the contractor is required to undertake a series of electrical

tests to capture the characteristics of the energy flow and resultant demands to ensure
that the new protection system replicates the existing system.

a. It is required that a protection and earthing studies of both the existing and
upgraded protection system of the 11 kV/400V distribution network of the
complete terminal be undertaken as part of this contract.

The protection and earthing studies, the testing, commissioning and training of
Freeport engineering personnel shall be integrated with the contract for the
design, supply and commissioning of the new DC switchgear.

The training shall be completed prior to the delivery of the substations to the
terminal.

Onsite training shall be undertaken after during and after commissioning of the
substations at the terminal.

The protection study is to ensure integration/coordination of both the Enemalta

and Freeport existing protection devices together with the existing substations
at the Terminals.

The tenderers shall identify the protection and earthing study software
programs to be used by the contractor for the studies.

The contractor shall on contract award:

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 i. Provide all the data (protection devices and design input) and a status
report to Freeport to enable the contractor’s protection and earthing
studies to be reviewed and analyzed.

ii. Translay Relays (refer to Network Drawing Attachment 2 Appendix 2)

and their CTs must be relocated either in within the metering unit or
circuit breaker itself. The Contractor is to liaise with Enemalta regarding
the specifications of CTs and its interface with their switchgear. These
relays must also be interfaced with the SCADA for status and fault
reporting.

b. The protection study shall be undertaken as follows:

i. Survey network, measure electrical data, and document the electrical

protection details of all existing protection devices including the
integration/coordination with:

 Enemalta incoming circuit breakers.

 All Freeport’s distribution networks.

ii. Detailing Circuit Breakers supplying quay cranes, main transformers,

etc.

iii. Undertake a series of high speed electrical data (energy and power)
recordings of the existing network at various approved voltage levels and
distribution locations in the network during terminal operations at times
nominated by Freeport. This is to ensure that the electrical
characteristics of the loads on the distribution feeders and dedicated
equipment feeders, including quay cranes, transformers supplying
refrigerated containers, lighting etc., are captured electronically. The
data shall be applied to the design of the protection equipment and
network settings required for the commissioning of the equipment in the
new distribution centre.

c. Protection Study Reports

i. Produce detailed report on the existing (including the 4 sub distribution

centres) and proposed protection system installation, identifying any

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 protection coordination issues. The report is to include selectivity curves,
block diagrams and logic tables.

ii. The existing protection settings and logic for the 4 sub distribution
centres at the terminals are to be reviewed and adjusted as per new set
up.

iii. Produce an extract from the report specifically detailing the 11 kV

distribution network supplying all the Substations and Head Office
Building.

This report (extract) shall clearly demonstrate that the proposed

protection system shall satisfy the demands as captured by the
recordings clearly identifying the comparison with the existing protection
devices/systems.

d. Commissioning

i. Obtain all necessary approvals from Enemalta confirming coordination

with the Enemalta protection network.

ii. Install, commission and test the protection setting on substation

equipment at the contractors works prior to shipping to the Terminal. The
contractor shall supply Freeport with certificates confirming testing
results prior to delivery.

iii. Confirm by testing all the protection devices and settings after delivery
to Freeport as part of the commissioning of the substations.

iv. Provide protection setting commissioning certificates.

e. Maintenance

i. The contractor is required to provide a warranted engineer qualified and

proficient in the understanding, operation and adjusting of the protection
systems. The engineer shall be onsite at the terminal during weekday
daylight hours for duration of a minimum of 4 weeks after the acceptance
by Freeport of the switchgear. The engineer shall remain in Malta and in
phone contact with the terminal engineering staff at all times and be
available to provide technical advice in the event of technical issues with
the protection system.

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 At the sole discretion of the terminal engineering staff, the protection
engineer shall immediately return to the terminal.

ii. In the event of faults requiring the resetting or adjustments of protection

relays during the 4week period. The protection engineer is required to
remain at the terminal for a period of 2 weeks after the last protection
system fault or resetting.

5.2.4.17 Earthing System

The installation shall be properly and effectively earthed to provide a means of

protection against electric shock and fire caused by overload, earth leakage, short-
circuits currents, and transferred potentials.

The existing earthing system shall be checked to ensure correct operation of protective
devices and earth fault currents can be carried safely, having regard to thermal,
thermomechanical and electromechanical stresses.

The study, design and subsequent implementation of the earthing systems for the new
switchgear shall be undertaken by the Contractor, but not necessarily limited to the
following:

 The existing earthing system and any modifications to be implemented.

 Integration of the switchgear earthing with the incoming and outgoing HV

systems and services.

 The terminal’s earthing system consisting of earth pits, copper earth conductors
(flats and/or earthing cables), protective earthing conductors and equipotential
bonding conductors

The earthing systems shall be checked for and designed, but not limited, to ensure the
following:

 Effective operation of protection equipment under earth fault conditions.

 A system of equipotential bonding is provided to ensure protection of personnel

from hazardous voltages.

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  Step and touch potentials are kept to levels as determined by regulatory
standards.

 The transfer of voltages away from the site is controlled.

The new earthing system will be required to be installed, interconnected and

commissioned progressively during:

a. The installation of the new switchgear.

b. The integration with the existing 11 kV distribution network earthing system

during the transition from the existing HV distribution network to the new 11 kV
distribution network.

c. The earthing, bonding systems shall comply with the latest revisions of the
following standards (or approved IEC alternatives):

 ANSI/IEEE 80 Guide for Safety in AC Substation Grounding.

 ANSI/IEEE 81 Guide for Measuring Earth Resistively, Ground Impedance

and Earth Surface Potentials of a Ground System.

 ANSI/IEEE 142 Recommended Practices for Grounding of Industrial and

Commercial Power Systems

d. The design of earthing, bonding systems undertaken by the contractor awarded

the contract shall be based on following parameters, as a minimum:

i. Fault currents and their distribution as based on the protection and short
circuit study.

ii. Fault duration.

iii. Ground conditions (soil/ground fill resistivity, moisture content, seasonal

variations, geology, corrosive properties).

iv. Services and facilities nearby or further away that may be affected by earth
currents/voltage raises, or by induced voltages or currents due to fault
currents flowing in conductors.

v. Site testing requirements undertaken by the Substation contractor.

e. Any final earthing design/ recommended modification to the existing must take
into consideration the following

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 i. Copper Earth Grids and Stakes

Earthing connections between physically separate earth grids (or parts of

an earth grid) must comprise of at least two conductors connecting
between separate locations at each earth grid.

Each conductor must be rated for the maximum fault current that could
flow between the earth grids.

The conductor for the earth grid and equipment earth connections shall
be selected according to the electrical, environmental and mechanical
requirements of the operating environment in which it is installed. Copper
conductor must be used for buried conductors.

All conductors’ joints must be both mechanically and electrically sound

and suitable for their application. All exposed metal within the earth grid
area must be connected to the earth grid.

ii. Soil Resistivity

Soil resistivity test shall be carried out using either the Wenner method.

The raw data shall be evaluated to determine a likely soil resistivity model
of the ground under and around the power plant.

As soil resistivity may change with the presence or absence of moisture,

resistivity testing should be made when soil is at its driest. If this is not
practical, rainfall statistics shall be considered when interpreting raw
resistivity test data.

If required addition geotechnical surveys shall be undertaken by the

Contractor to determine soil types and location of soil layers and these
shall be considered when interpreting raw resistivity test data.

iii. Earth Conductor Size

The highest prospective fault current due to a fault in the distribution

network shall be used to determine the earth conductor size. In
establishing the earthing conductor size, the fault duration time shall be
the operating time for backup protection.

iv. Conductor Corrosion Prevention

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 Copper earthing conductors shall be tin plated when in contact with
galvanized steel structural members and at equipment earthing terminals.
Tin plating shall be carried out using a hot-dip or tin-flow process.

Soils with a pH value of less than 6 or greater than 10, or with an electrical
resistivity of less than 10ohm meters are hostile to copper and cause
corrosion. Under these circumstances, conductors shall be surrounded by
150mm of fine soil such as neutral clay, bentonite, or loams. High
resistivity gravel, sand and pumice shall be avoided around the
conductors.

v. Step and Touch Potentials

Maximum permissible step and touch potentials shall be determined in

accordance with the methodology detailed in IEEE Std 80 with the
following considerations,

 Both off-site and on-site faults affecting the distribution network shall
be assessed to determine the maximum earth grid return current. The
maximum grid return current shall be used in the evaluation of touch
and step voltages.

 For the evaluation of the maximum permissible step and touch

voltages, the fault duration time shall be the operating time for primary
protection.

 The calculated step and touch voltages are limited to prevent heart
fibrillation due to accidental contact by a person weighing 80 kg within
the substation site and 80 kg in public terminal areas.

 Touch potentials around gates and doors especially those that open
outwards are kept within safe limits.

 Crushed rock or asphalt may be used to increase tolerable touch and

step voltage limits.

A risk assessment shall be carried out to confirm that as far as practicable,

the design step, touch and transferred voltages are controlled to prevent
danger to personnel.

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 f. Protective Earthing and Equipotential Bonding

5.2.4.18 Works Requirements

The contractor shall perform the following as part of the Scope of Works.

a) Prepare foundations for the new switchgears opposite existing ones. Care is to
be taken not use any masonry equipment which causes excessive vibrations
and to create a dust proof environment for the existing (powered) switchgear.

b) Installation and testing of all the new switchgear. Only battery powered handling
equipment can be used inside the distribution centre. Any equipment used must
be approved by the Customer beforehand. All tests are to be documented and
upon successfully completing these tests a written confirmation by Contractor
is to be handed to the Customer.

c) The Contractor is to provide and prepare the necessary cables lengths to

terminate into one of the new main feeders (to be agreed with Customer) and
for jointing, via trifurcating kits, to the existing one (its’ old counterpart). The
Contractor is to liaise with Enemalta and the Customer for the switching off
Enemalta’s feeder. Once this is off the Customer would switch on the bus
section of the existing switchgear. The Contractor is to await confirmation from
the Customer prior to disconnect all cables from the existing feeder. These
cables will then be joined to the ones coming from the new feeder.

d) Contractor is to liaise with Enemalta what tests / test results they require so that
they will reenergise their feeder.

e) The new switchgear will be powered up and all necessary tests are to be carried
out on all components.

f) The Contractor is to provide and prepare all the necessary cables lengths to
terminate into each new feeder to join to the cables feeding the existing
switchgear. The contractor is to ensure that the cable lengths are planned in a
way to have the cable joints staggered along the cable pit. The Contractor is
also to provide all the necessary jointing and terminating kits.

g) The actual transfer of the exiting circuits to the new switchgear is to be planned
together with the Customer. The number of circuits that can be transferred in a

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 day or week will be determined by the Customer. Contractor is to consider more
than one crew to carry out this task and the possibility of working antisocial
hours / public holidays.

h) Decommissioning of the existing switchgear. The Contractor is to disassemble

the exiting switchgear.

5.2.4.19 Factory Testing

Malta Freeport Terminal shall have nominated representatives to inspect and witness
the testing of the equipment at the manufacturers test facility.

Tenderers are to nominate the time and location as to where the testing will take place.

A test procedure shall be submitted 4 weeks before the commencement of the tests
and shall detail the tests and the time frame.

i. High voltage dielectric tests

ii. Functional checks including:

 Testing interlocks

 Operating the switching devices from the bay controller and manually

 Confirming the positioning of devices with the mimic on the Bay Controller
/SCADA

 Random checks on some of the binary inputs

 Primary injection tests to check CTs, for ratio, polarity, phasing and
protection system wiring

 Secondary injection calibration checks of protection system

 SCADA testing

 Testing some protective functions

iii. Resistance checks on all bays, including copper bar used to earth the
switchgear.

iv. Withdrawable type switchgear shall be checked for interchangeability between

cubicles and circuit breaker carriages of the same ratings.

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 v. Operational checks on circuit and timing of operation of circuit breakers and
disconnectors.

vi. Other routine electrical and mechanical tests required by IEC 62271-200 and
recommended by the manufacturer, and other tests required by Customer to
ensure that the switchgear meets the specified requirements.

5.2.4.20 On-Site Testing & Commissioning

The contractor shall commission all equipment. The electrical equipment vendor shall
supply all the necessary equipment and labour for this commissioning. All test
equipment used shall be in good condition and be correctly calibrated before work
commences. Calibration certificates shall be available should the Engineer require to
view them.

The contractor must notify the Engineer prior to the commencement of commissioning
and on-site testing works so that the Engineer can witness testing.

The test form is to be filled out for each measurement instrument. The form is to include
equipment details, all calibration data and all commissioning settings and parameters
at the completion of commissioning.

Test forms shall be filled out for every field control device, motor, protective device and
relay. The completed forms shall be handed to the Engineer at completion of
commissioning.

All installation work shall be inspected to ensure that it has been carried out in
accordance with this specification and the manufacturer’s recommendations.

All test work shall be carried out by suitable, qualified personnel.

Commissioning check sheets, QA and test result forms are to be handed to the
engineer at the completion of works.

a) High voltage tests and other tests recommended in IEC 62271-200

b) Busbar resistance measurement

c) Check SF6 properties and density meter alarm thresholds (Option 1)

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 d) Functional checks including:

 Primary injection to test the wiring of the CTs and protection system wiring

 Secondary injection to test all protection functions on all panels

 Protection settings as per coordination charts

 Polarity test on CTs

 Check VT secondary wiring

 Ratio test on VTs

 Testing the interlocks

 Racking in and out; up and down (Option 2)

 Communication tests

 Secondary injection test to check the 2 fiscal meters

 Testing the binary inputs on all panels etc.

 Conductivity tests on all earth cables

 Test sheets for each panel should be provided for the SATs.

 Load Shedding

 Protection discrimination and logic with existing installations at the terminal

e) The Contractor shall submit all equipment type test certificates to the Engineer
for approval before delivery of the equipment to Malta Freeport terminals
Limited.

Earthing

Particular attention is to be paid to the inspection of earthing to ensure that all

equipment manufacturers’ requirements are met, and that safety earth and signal
ground wiring is correctly separated.

Uninterruptible Power Supplies

Where UPS equipment is installed, they shall be tested to confirm the manufacturer's
specification. They shall be tested to confirm that they function correctly on loss and
restoration of supply and tested for manual changeover without interruption to supply.

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UPS trigged automatic shutdown systems for IT or control equipment is to be tested
to ensure they work correctly.

Sequence Logic and indications

All sequence logic is to be tested to ensure correct operation and to ensure that a
malfunction at any time in the sequence will not leave the equipment or personnel
exposed to unsafe conditions.

All devices shall be tested to ensure that control room indications and alarms function
correctly.

5.2.4.21 Tools

The Contractor shall supply the following tools and equipment, and where applicable
all equipment supplied should be provided complete with instruction and service
manuals. The instruments can be used during commissioning.

a) Two sets of any special tools or gauges required for the installation and/or
normal maintenance of the plant including any fittings and accessories needed
for gas handling.

b) Two sets of any cranks or levers per switchboard used to operate the
switchgear.

c) Two sets of test plugs per relay and bay controller programming cables.

d) One set of three test devices (prods) for testing the 11kV cables connected to
the switchgear respectively and suitable for each type of cable termination
provided.

e) Programming / testing cables required to connect to all the installed relays.

f) If required, a mobile cross-over ladder (certified for safety) on wheels for use
by the Customer’s technicians to access and work on the low voltage cubicles
at various heights. The platform of this cross-over ladder should have an
approximate height of 1.5m and allow space for at least two technicians. The
platform should be able to carry a minimum weight of 200kg.

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5.2.4.22 Tender Documentation

a) Single-line diagram of proposed switchgear

b) Plan view of installation of the switchgear inside the designated rooms clearly
showing expected dimensions and layout.

c) Technical data and information about switchgear in conformity with the required
specifications.

d) Type tests of switchgear offered.

e) Reference list of past installations of the proposed equipment for the last five
years.

f) ISO 9001 and ISO 14001 certification

g) List of recommended strategic and programmed maintenance spares

h) Any other documentation regarding design, instrumentation and ancillary

equipment to enable proper evaluation of the offer

i) Training proposal for switchgear operation and for routine and first-line
maintenance.

5.2.4.23 Drawings, Manuals and Training

a) All drawings should be sent to the Company for evaluation and approval prior
to implementation. After contract award, hard copies of drawings and an
electronic version in ‘dwg’ format shall be provided.

b) The Contractor should supply assembly, operating and maintenance manuals

including drawings and material safety data sheets for the switchgear (including
any devices installed in the switchgear or at the DC) being supplied. The
information should also include technical information of equipment and the
names of suppliers. A version on CD should be included.

c) The operating instructions shall provide clear and simple descriptions of the
power system operation, and logical descriptions of both normal sequences in
time sequential order and of mains failure operating sequences. Descriptions
may refer to wiring/data flow diagrams but should not merely repeat what is on
those drawings.

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 d) All information in the manuals shall be specific to the project and shall contain
all information necessary for the operation of the system. The manuals shall
contain the full set of commissioning results, auditors report for all HV and
earthing installations, any calculations used in establishing protection settings
and all design and commissioning work and any calculation used to determine
earth loop impedance and protection operating times under fault conditions.
The final documentation provided shall fully describe the works, its
commissioning, on-going maintenance requirements and warranty documents.

e) The Contractor should provide on-site training for operations and maintenance.
The Contractor should make allowance for 1 sessions of 2 days of training for
4 persons each session including engineers and senior technicians. The
subjects should include:

 Explanation of the different components of the switchgear

 Control using bay controller and using mechanical means

 Mechanical and electrical interlocks

 Explanation of circuit diagrams and protective relays

 Fault finding, routine checks and regular maintenance

 Bay Controller Programming / Parameterisation.

 Basic SF6 handling (for Option1) & Procedures

5.3 Local Transformer

The existing local transformer will be replaced together with its’ feeding cable from the
switchgear. The new transformer shall satisfy the min requirements in the following
list:

General
Power rating 500kVA
Type Dry, Cast
Insulation class F
IP Rating (min) 20
No. of phases 3

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 Frequency 50 Hz
Tapings ±5%
Tap change Offload
Cooling N
Tap Change insulation Transparent cover
Ambient operating temp 0°C-42°C
Primary
Winding Cooper
Rated primary voltage 11kV
Rated primary insulation 17.5kV
B.I.L 1,2/50 µs 95kV
Secondary
Winding Cooper
Rated voltage at no load 433
Rate insulation level 1.1kV
Vector group Dyn11

The transformer shall be mounted on a rigid frame such that it can be removed from
the substation through the doors.

The transformer must comply with the following details:

 Any exposed busbars or connections shall be electrically insulated. No risk for

humans and the natural environment due to contamination. The transformer
shall be appropriately protected against human entry. This shall be by locked
cage / metal enclosure around it or by approved locked transformer housings
as per IEC 60529. This enclosure is to have a temperature controlled heating
element underneath the secondary winding.
 The transformers shall have two 2.5% full capacity taps above and below the
rated primary voltage. For a total of ±5%.
 Temperature gauge including over temperature protection with adjustable trip
setting shall be installed. A separate temperature sensor shall be wired up to
the MV breaker for over temperature trip protection.

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  MV and LV connections of the transformer shall be on opposite sides.
 Transformer is to conform and tested to the international standards, IEC 60076-
11, ANSI or IEEE. Insulation test rating shall be according to IEC60071 List 1
 Non-explosive and flame-retardant
 Compliant with EU directive 548/2014 for implementing the Ecodesign
guideline 2009/125/EG.
 Connection cable bolts shall be appropriately torqued and marked. Seller is to
handover all testing results and certificates
 Cable and terminating kits will be supplied by Customer. Contractor to install.

5.4 General Installation Requirements

This section details the minimum requirements for design, selection, manufacture,
installation and testing of electrical power and control equipment including high voltage
installations.

Supply of Equipment

All electrical and installation hardware shall be standard catalogue products from a
manufacturer who regularly sells and stocks the equipment in Malta.

Unless otherwise agreed in writing all electrical equipment and installation hardware
shall be new and previously unused.

All equipment for mounting outdoors shall be rated IP56 minimum.

All equipment shall be tested and commissioned in accordance with the requirements
of specification before being placed into service.

Operating devices

Switches shall be arranged as follows:

Clockwise: ON, CLOSE SWITCH. (White indication light)

Anticlockwise: OFF, OPEN SWITCH (Green, indication light)

Flashing: Requires action

Blue: Logical State e.g. Local/Remote, Auto/Manual

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Voltage Levels

The following voltage levels are in use throughout the Terminal

High Voltage: 11,000 Volt, 3 phase, 50 Hertz

Low voltage: 400 Volt, 3 phase, 50 Hertz

230 Volt, 1 phase, 50 Hertz

Indication Lights

Closed White indication light

Open Green indication light

Tripped Orange

Fault Levels

Determination of fault levels shall be made in consultation with the Engineer and
Enemalta fault levels.

Auditable work

The warranty engineers report shall be included in the handover documentation.

Cable Ladder

Cable ladder routes shall be planned to give the required segregation. Folded sheet
metal cable ladder, tray or duct is not permitted unless otherwise agreed or specified.

Cable ladder side rails must not be drilled, cut or otherwise modified to fit around
obstructions or to allow the passage of cables.

Bends, tees, elbows and risers shall be manufactured by the cable ladder supplier.

“Made on site” items are not acceptable unless otherwise agreed or specified

When run in a common cable ladder power and control cables shall be segregated by
a metal partition unless otherwise agreed or specified.

Cable ladders shall be aluminium 6061 alloy with T6 temper unless otherwise agreed.

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Cable ladder runs shall be made electrically continuous and bonded to earth. Where
cable ladder carries HV cables a dedicated earth conductor shall be used along the
entire length.

Cable ladder routes shall be planned to avoid running instrument signal cables and
cables to RF and EMI generating equipment, such as variable frequency drives, in the
same ladder.

Cable ladder routes must be approved by the Engineer prior to installation.

The Contractor shall fit peaked stainless steel cable ladder covers to all cable ladders.
Cable tray covers should not be fitted until commissioning is completed. They shall be
fixed with purpose designed fasteners.

Cables in cable ladder shall be run without crossovers, except where necessary for
drops onto or out of the cable ladder.

Cables shall be tied onto cable ladder at intervals of not more than three metres with
black nylon cable ties.

Minimum holding strength of cable ties for this duty shall be 50kg.

Holes in the side rails of cable ladder are not acceptable.

Cable Termination/Numbering

Metal glands shall be used where earthing of armouring or screen is required.

All cable entries shall be in the bottom of equipment using cable glands.

No more than one wire is to be terminated at each side of a terminal. Terminal bridges
or combs shall be used if required.

All cores of a multicore cable are to be terminated in adjoining terminals.

Power cable cores shall be terminated using crimp lugs. The lugs shall be crimped
with a correct sized die and tool specifically designed for the purpose.

Bi-metal lugs shall be used for all copper to aluminium connections. The lugs shall be
compound filled as recommended by the lug manufacturer.

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Heat shrink tubing in the appropriate phase colour shall be used to insulate lug barrels
and seal the lug barrel to the cable insulation.

The cables shall be positively identified by corrosion resistant tags with the cable’s
voltage and designated feeder number clearly shown by engraving or embossing. The
tags shall be securely attached to the relevant cable with a corrosion resistant securing
system.

The earth bar is to be labelled showing identification of every cable connected.

All earth bars shall have a minimum cross-sectional area of 150mmsq after taking into
account holes drilled for the securing of earth cables.

Openings through the Substation wall for the earth cables shall be undertaken by the
Contractor and after the installation of the cables sealed in an approved manner.

Each and every end of the cable shall be identified using an approved thread on ferrule
numbering system.

Labels are to be secured to the base plant by screws and are to be uniformly
positioned so as not to be obscured by cables.

The contractor is to allow for and provide the cable lugs, connections/busbar,
connection busbar tags etc., for the incoming mains cables and outgoing circuit cables
onto the respective circuit breakers.

Joints in cables shall be arranged and supported in the pit in a manner which will
provide easy access to all joints within the pit for future maintenance purposes.

Labels and Identification

All equipment shall be identified with labels.

Labels are to be secured on vertical surface of field equipment.

All circuit breakers and control devices are to be labelled by the Contractor using
engraved black on white UV stabilised "Twoplex".

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Label size and inscription and securing technique to be approved by Malta Freeport
Terminal.

Control devices shall be labelled showing duty, circuit numbers, item designation
number and loop number.

Securing and Fixing

Explosive power tool installed fixings shall not be used.

Girder or beam clamps or clips shall not be used unless otherwise specified or agreed.
This includes spring type conduit clips and all devices designed to be attached to
structural steel by means of clamping bolts or studs.

Holes tapped into steelwork shall not be used as a method of fixing.

All fasteners, fixing rivets or pins, nuts, bolts and screws shall be 316 stainless steel
unless otherwise specified or agreed.

Where required for extended life or due to environmental conditions, support channels
and all associated clips and screws shall be 316 stainless steel.

The approval of the Project Manager is required before any brackets or stanchions are
welded to structural steel, columns, etc.

Handrails or kick rails shall not be used for mounting of instruments, control devices,
cables or conduits.

Care should be taken to ensure that dissimilar metals, likely to form galvanic cells in
the presence of an electrolyte, are suitably insulated or protected. Special attention
should be given to conduit to conduit clip, conduit cable tray, conduit to structural steel
and cable ladder to support structure interfaces.

Stainless steel or similar strapping shall not be used as fasteners unless otherwise
specified or agreed.

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5.5 Optional Maintenance

The Contractor is to quote for the provision of a two (2) year maintenance contract.
This contact should include the maintenance the contractor is suggesting to perform
and an inspection schedule. The Contractor is to give the Malta Freeport Terminals
Limited at least five (5) working days prior notice of when each operational inspection
visit is due to be made. Report to the Malta Freeport Terminals Limited at the beginning
of each visit and provide a written report comprehensively detailing the inspection. The
inspection report should include any defects found in the equipment, also including
their protection devices, and the necessary recommendations to rectify such defects.
Before leaving the site, the report shall be signed by both the Supplier and the
Purchaser and a copy retained by each.

Only fully qualified tradesmen experienced in the plant shall be employed for the work,
and the Malta Freeport Terminals Limited retains the right to have removed from the
site any tradesman considered insufficiently competent.

The site shall be left clean and tidy and in proper working state after each visit.

Not less than fourteen (14) working days prior to the end of the Defects Liability Period,
the Supplier shall carry out a final inspection on the equipment. The Supplier shall give
not less than ten (10) working days’ notice of such inspection so that a Malta Freeport
Terminals Limited’s representative can arrange to be present.

During any work on the equipment, Contractor is not to interrupt the operation of the
plant unless the prior agreement of the Malta Freeport Terminal is obtained.

The Customer reserves the right not to renew this contract. However, if the Customer
decides to renew this maintenance agreement for a further three (3) years, the same
rate quoted in this tender should apply.

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 6. Conditions of Contract

6.1 General conditions

The following clauses are intended to give a clear idea of the terms and conditions
the Agreement with the awarded tenderer would be negotiated and concluded. The
list is not exhausted and both parties reserve the right to include other clause into
the negotiation.

As a general condition all clauses within the EPC contract apply, except for the
following clauses. The Clause numbers refer to the equivalent Clauses in Part 1:
General Conditions. These clauses in the general conditions are to be substituted by
the text as shown below, unless otherwise noted in the respective clause.

6.2 Definitions
For the purpose of this sub-clause, the respective address is:

The Company:

Mr. Alex Montebello – CEO

Malta Freeport Terminals Ltd.
Port of Marsaxlokk Kalafrana, Malta

6.3 Language
a) All written communications between the parties shall be drafted in the English
language.

6.4 Compliance with Laws and Regulations

b) The Law in force is the Laws of Malta

c) The Contractor shall comply with and fulfil all obligations imposed by the
Code of Police Laws and shall give all notices, obtain all permits, pay all fees
that may be lawfully demanded by Public Offices in respect of works and
comply with all the requirements of the law and lawful authority.

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6.5 Obligations of the Contractor

The Contractor shall perform the contract with due care and diligence, including,
where specified, the design, manufacture, delivery to site, erecting, testing, and
commissioning of the supplies and carrying out of any other work including the
remedying of any defects in the supplies. The Contractor who shall be awarded the
contract shall be considered and held responsible to provide all necessary
equipment, supervision, labor, and facilities required for the performance of the
contract, which is conformant to relevant EU standards.

All materials and methods of construction shall be in form and nature as specified
herein or indicated in the drawings and no variations whatsoever shall be permitted
unless it has been previously agreed to in writing with the Company.

Failure to adhere and complete its services in accordance to the required working
schedule due to an act of commission or omission by the Contractor. In the eventuality
that the Contractor repeatedly fails to assist and resolves complaints from the
Company with regards that the services are not being met as agreed, the Company
shall be entitled to cancellation of the Contract and recovery any applicable costs
directly incurred as a result of such delay.

The Contractor shall be solely responsible for all materials, spare parts and labour
necessary to carry out this service, such as insurance, fuel and maintenance of the
vehicles and personnel. No expenses or costs shall be borne by the Company. This
also includes any repairs carried out as a result of negligent driving which shall be
borne by the Contractor.

6.6 Safety

If and where applicable, the Contractor shall ensure and comply with all Health and
Safety Regulations are observed at all times and that all employees are provided with
the necessary equipment, clothing and safety material to work in a safe environment.
Contractor is solely responsible for safety of his workmen and the general public. All
costs related to this are to be borne by the Contractor. He shall also be responsible
for any damage caused to third party property that may be caused by him or his
employees.

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The Contractor shall be responsible for the safety of the works (including the
materials and plant) until they are taken possession by the Company and/or his
representative and shall stand the risk and be responsible for and must with all.

Contractor shall provide the following before works commence, if and where
applicable:

a) Health and Safety risk assessment covering the works to be carried out at
Malta Freeport Terminals Limited

b) Evidence that persons involved in the works have attended HSE Induction
training provided by the Terminal

c) Copies of training records if work involves working at height or in confined

spaces.

d) Copy of regulatory certificates of lifting device and/or lifting accessories to be

used in the works.

6.7 Quality Assurance

The Company shall have a quality assurance system in place to oversee all quality
control issues. Testing will be carried out on all items as indicated in the Technical
Specifications. Compliance with the quality assurance system shall not relieve the
Contractor of any of his duties, obligations, or responsibilities under the Contract.

The Contractor shall submit to the Company’s Engineer for his approval a quality
plan, prior to the commencement of works. The plan shall set out details of the
quality management system to be implemented by the Contractor to control all
design procurement and construction activities required by the Contract in such a
way as to ensure completion of the Works in accordance with the Contract.

Tests on any materials may be taken at any time during the course of the works and
the Contractor shall be bound to provide the Engineer with all such assistance,
instruments, machines, labour and materials as are normally required for
examining, measuring and testing any work, and the quality, weight or quantity of
any materials used and shall supply samples of materials before incorporation in

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the works, for testing as may be required by the Engineer.

6.8 Compliance with the Law and Regulation

The Contractor shall comply with and fulfil all obligations imposed by the Code of
Police Laws and shall give all notices, obtain all permits, pay all fees that may be
lawfully demanded by Public Offices in respect of works and comply with all the
requirements of the law and lawful authority.

6.9 Payment and Price Conditions

6.9.1 Variations
The right is reserved to increase or decrease the quantity of any work included in
the contract or to omit any such work as necessary up to a variance of 20%.

6.9.2 Increase or decrease of cost

The Contract Sum shall be a fixed amount and shall not be subject to adjustment in
the event of fluctuations in the cost of materials, labour, affecting the cost of
execution of the Contract.

6.9.3 Tendered rates

The tendered rates shall be inclusive of all works as specified, as well as any other
works, which are congruent, or of an indispensable nature of completing the work
in its entirety. The rates shall be inclusive of all materials necessary, profits, and
payments of Customs Duty and Landing Charges on all imported goods, all hire of
plant and machinery required, and also all transport of materials to the site of works
and so on and shall include any taxes / charges that may be or become payable on
any part of the works covered by this tender/contract.

6.9.4 Measurement of work

The work shall be measured as detailed in the Bill of Quantities and as specified by
the appropriate clause in the attached specifications.

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6.9.5 Payment to Contractor
An Interim Certificate of Payment may be issued at milestone intervals. Deposit
payments shall not exceed 20% of the total contract price. The interim payment shall
be divided into stages, including:

- Design approval
- Further milestones dependent on the approved program
- Completion of works / commissioning
- End of defects liability period (if and where applicable)

6.10 Insurance

The Contractor shall be required to have a Contractor’s All Risk Insurance Policy,
prior to the commencement of works. The Contractor shall provide the Company
with evidence that any required policy is in force and that the premiums have been
paid.

The Contractor shall provide insurance for Works and Equipment, including:

a) The Works, together with materials and plant for incorporation, to the
full replacement cost.

b) An additional sum to cover any additional costs of and incidental to the

rectification of loss or damage including professional fees and the cost
of demolishing and removing any part of the Works and of removing
debris of whatsoever nature.

c) Ensure the Contractor’s Equipment and other things brought onto the
Site by the Contractor, for a sum sufficient to provide for their
replacement at the Site.

d) Damage to the Company’s surrounding property arising out of the

contract works and business interruption as a result of such damage.

The Contractor shall also provide insurance against each Party’s liability for any
loss, damage, death, or bodily injury which may occur to any physical property
(except for things insured under Works and Equipment).

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6.11 Dispute Settlement and Arbitration

Should a dispute arise between the Company and the Contractor, either parties
shall issue and communicate to the other Party a notice of dispute outlining the
nature of the dispute in such detail as to allow a fair and equitable review of the
dispute matter. In the event the dispute is not amicably resolved, then resolution
shall be by arbitration in Malta according to the Arbitration Act (Chapter 387 of the
Laws of Malta) and the Arbitration Rules of the Malta Arbitration Centre.

6.12 Completion Period

The Contractor shall be required to submit a detailed program of works with the
tender documents and again immediately upon award of contract. This program
shall show how, week by week, it is proposed to proceed from the time of the award
of this contract up to completion date as herein described. The contractor shall
submit upon weekly bases, schedules of the main works, showing quantitative work
progress over the previous work and accumulative progress to date.

Before proceeding with the execution of work, the Contractor shall obtain the
Company’s and Projects Manager approval of the manner in which he proposes to
carry out each portion of the work and shall furnish such drawings, schedule of
works or information.

Thus, works shall be completed within the agreed Time-Frames. Tenderers may not
be considered if this clause is not accepted. In awarding the contract, the time factor
will be an important consideration. When a Contractor does not quote the period to
complete the works in its entirety, it is assumed that works will be completed within
the maximum time specified therein.

The Contractor shall take all risks of accident or damage to the works, from whatever
cause arising and shall be responsible for the sufficiency of all means used by him
for the fulfilment of the contract and shall not be relieved from such responsibilities
by any approval other than a written approval which may have been given by the
Company.

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6.13 Delay in Execution

If the Contractor fails to complete the works by the deadline specified in the contract,
the Company shall without prejudice to any other remedies under the contract, be
entitled to a penalty for mere delay for every day of delay or part thereof which
elapses between the agreed actual date of completion, at the rate and up to the
maximum amount specified in the Contract.

6.14 Execution of Works

6.14.1 Site Management

The Project Engineer shall be available on site of works during all working hours. Their
Representatives shall be empowered to receive and act on the instructions, directions,
or explanations as if given to the Contractor in person. The representatives must be
competent and acceptable to the Engineer in Charge.

It should be noted that the Company may have other contractors to install, join,
connect, test, and commission the outgoing HV cables from the DC immediately
following the installation and acceptance of the switchgear.

However, and preferably it is the Contractor (to this specification) that supplies and
installs the jointing kits etc., required and terminate/join these to the existing
cables/circuit breakers. This needs to be done in a specified time, preferably less than
8 hours, that is, more than 1 crew working at the same time to minimize down time.
The contractor must specify in what time all the necessary terminations/jointing works
can be achieved.

The number of joints, terminations and single core cables needed are to be specified
by the Contractor in the Bill of Quantity sheet. The contractor is to declare the brand
and type that will be used in the project for approval by the Customer.

The HV testing of the installation which shall be the responsibility of the substation
contractor shall be coordinated with the Company’s Project Manager.

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6.14.2 Materials and Workmanship
a) All materials required for the completion of the works specified shall be
provided by the Contractor unless stated otherwise on the Drawings and/or the
Contract Documents.
b) The work shall be carried out in the best customary practice and the Engineer
are to be satisfied that the quality of the materials conforms to that specified
herein.
c) The Contractor shall provide without extra charge all labour and equipment
required by the Engineer for testing, measuring or proving the efficiency of any
of the materials used or of any portion or portions of the completed works.

6.14.3 Possession of Site and Limit of Site of Work

Possession of the site shall be given to the Contractor only when given order to start
work. The work must be carried out with due diligence and expedition in order to
minimize disruption of operations and on-site time and the whole work must be
completed within the period mentioned in the contract.

The Contractor shall limit his work and storage of materials to the areas that will be
shown to him on the tender drawings, as required for the purpose. Under no
circumstances shall works being carried out by him or storage of materials be
allowed to interfere with other works being carried out in the vicinity.

The Contractor shall make good each trade and provision for such works shall be
made in respective rates. All rubbish shall be cleared and carted away as it is
accumulated from time during the progress of the works and on completion

6.14.4 Drawings and specifications

The work shall be carried out in accordance with the directions and to the
satisfaction of the Engineer and Projects Manager, in accordance with the drawings,
specifications and Schedule of Quantities and such further drawings and directions
as may from time to time be given by the Engineer. If the work shown on any such
direction be, in the opinion of the Contractor extra to that comprised in the
Specifications, he shall, before proceeding with such work, give notice to this effect

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to the Engineer; but if no notice is given to the Engineer before the execution of the
work, the Contractor shall have no claim to any extra payment in respect thereof.

The Contractor shall provide everything necessary for the proper execution of the
works according to the true intent and meaning of the drawings and specifications
taken together provided that the same be reasonably inferred here from, and if the
Contractor finds any discrepancy in the drawings, or between the drawings and the
specifications, he shall immediately refer the matter to the Engineer who shall
decide which shall be followed and the Contractor shall be held responsible for any
errors that may occur in the work through the neglect of precaution. Figured
dimensions are to be followed in the preference to scale dimensions, and all
dimensions, and particulars are to be taken from the actual work. It must be distinctly
understood that the whole specification is intended to be strictly enforced and that no
extra charge in respect of extra work will be allowed unless they are clearly outside
the spirit of specifications.

6.14.5 Working Hours

Subject to any provision to the contrary contained in the Contract, the Contractor
shall have the option to work continuously by day and night and on locally
recognized holidays or days of rest.

6.14.6 Access to works

The Engineer and the Engineer’s Representative or any persons authorized by
them shall have at all times access to the works. They shall also have access to
workshops or other places where work or material are being prepared.

6.14.7 Power of Engineer

The Engineer shall have the power, during the work, to order the Contractor to
remove from the site any materials which are considered to be of an inferior quality.
They shall also have the power to order the removal and proper re-execution of any
work executed with the rejected materials in a manner contrary to the spirit of the
Specifications. Such orders shall be carried out by the Contractor at his own
expense. In case of default on the part of the Contractor to carry out such orders,

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the Company shall have the power to employ and pay other persons to carry out
same at Contractor’s expense; such expenses shall be deducted from any monies
that may be due to the Contractor.

7. Attachments

Attachment 1 - Bill of Quantities

Attachment 2 - Photos and Drawings

a. Appendix 1 MFC DC Photographs and Drawings

b. Appendix 2 MFC MV Present Network Line Diagram
c. Appendix 3 MFC DC Current Setup Switchgear Details
d. Appendix 4 MFC MV New Network Configuration Line Diagram
e. Appendix 5 MFC DC New Setup Switchgear Details

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