PBD 2 C32 9 HVAC CDB Edits

ESKOM
INGULA PUMPED STORAGE SCHEME
HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

SPECIFICATION
LOT D, BOOK 2, PART C3.2, SECTION 9
TABLE OF CONTENTS
1 DESCRIPTION OF SYSTEM..........................................................4
1.1 Function.......................................................................................................4
1.2 Scope of System.........................................................................................4
1.3 Design work.................................................................................................6
1.4 Documentation............................................................................................7
2 DESIGN 8
2.1 Technical standards and regulations...........................................................8
2.2 HVAC plant and particular Requirements ...................................................8
2.2.1 Equipment..............................................................................................10
2.2.2 Water Analysis........................................................................................10
2.3 Functional Description...............................................................................10
2.4 Areas to be ventilated...............................................................................12
2.4.1 The Machine Hall Areas.........................................................................12
2.4.1.1 Operating Floor..............................................................12
2.4.1.2 Control Room Block.......................................................12
2.4.1.3 Clean Oil Handling Room...............................................13
2.4.2 The Generator Floors.............................................................................13
2.4.2.1 Western Generator Floor................................................13
2.4.2.2 Eastern Generator Floor.................................................13
2.4.3 Busbar Tunnels......................................................................................13
2.4.4 The Turbine Floors.................................................................................13
2.4.4.1 Western Turbine Floor....................................................13
2.4.4.2 Eastern Turbine Floor.....................................................14
2.4.5 The Drainage Gallery..............................................................................14
2.4.6 The Transformer Hall Areas....................................................................14
2.4.6.1 Cable Gallery.................................................................14
2.4.6.2 Transformer Hall Operating Floor...................................14
2.4.6.3 Transformer Hall Mezzanine Floor.................................14
2.4.6.4 Transformer Hall Battery Room Floor.............................15
2.5 Detail design requirements........................................................................15
2.5.1 General...................................................................................................15
2.5.2 Air handling for Air conditioning and ventilation......................................15
2.5.2.1 Fresh air system ............................................................15
2.5.2.2 Air conditioning systems.................................................16
2.5.2.3 Mechanical Ventilation systems.....................................16
2.5.2.4 Design conditions...........................................................16
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2.5.2.5 Air distribution................................................................16

2.5.2.6 Air filtration standards.....................................................16
2.5.2.7 Noise control..................................................................16
2.5.2.8 Main fresh air fans..........................................................17
2.5.2.9 Main fresh air filters........................................................17
2.5.2.10 Air handling units..........................................................17
2.5.2.11 Extract fans..................................................................18
2.5.2.12 All fans.........................................................................18
2.5.2.13 Fan redundancy requirements......................................19
2.5.2.14 Ducting and fittings.......................................................19
2.5.2.15 Dampers ......................................................................19
2.5.2.16 Thermal insulation........................................................19
2.5.3 Water Systems for Air conditioning and Ventilation ...............................20
2.5.3.1 Chilled water system......................................................20
2.5.3.2 Cooling water system.....................................................20
2.5.3.3 Design temperatures......................................................20
2.5.3.4 Chillers...........................................................................20
2.5.3.5 Filtration.........................................................................21
2.5.3.6 Chilled water pumps ......................................................21
2.5.3.7 Pipework........................................................................21
2.5.3.8 Chilled water buffer tank.................................................21
2.5.3.9 Valves............................................................................22
2.5.3.10 Pressure and flow indication.........................................22
2.5.3.11 Drains and vents..........................................................23
2.5.3.12 Expansion of pipework.................................................23
2.5.3.13 Materials to suit cooling water quality...........................23
2.5.3.14 Water treatment...........................................................23
2.5.3.15 Thermal insulation........................................................23
2.5.3.16 System fill and expansion.............................................23
2.5.4 Refrigerant systems................................................................................24
2.5.4.1 Refrigerant recovery.......................................................24
2.5.4.2 Refrigerant exhaust........................................................24
2.5.4.3 Safety in operation.........................................................24
2.5.5 Smoke ventilation systems ...................................................................24
2.5.5.1 System design airflows ..................................................24
2.5.5.2 Fans...............................................................................24
2.5.5.3 Ducting and fittings.........................................................25
2.5.5.4 Dampers .......................................................................25
2.5.6 Emergency ventilation............................................................................25
2.5.7 Automatic controls, system monitoring and management.......................25
2.5.8 General...................................................................................................26
2.5.8.1 Control Location Philosophy...........................................27
2.5.8.2 Maintenance Control......................................................28
2.5.8.3 Local HMI Control..........................................................28
2.5.8.4 Remote Control..............................................................29
2.5.8.5 Time synchronisation.....................................................29
2.5.9 LV Switchgear........................................................................................29
2.5.9.1 General..........................................................................29
2.5.9.2 Switchboard Panel Design.............................................30
2.5.10 Cables and cable accessories..............................................................30
2.5.11 Labelling...............................................................................................32
2.6 Calculation and drawings requirements ....................................................32
2.6.1 General...................................................................................................32
2.6.2 Air conditioning and ventilation ..............................................................33
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2.6.2.1 Air systems ....................................................................33

2.6.2.2 Water systems...............................................................33
2.6.2.3 Refrigerant system.........................................................34
2.6.3 Smoke ventilation systems ....................................................................34
2.6.4 Noise control ..........................................................................................34
2.7 Testing and Commissioning......................................................................35
2.7.1 General...................................................................................................35
2.7.2 Air conditioning and ventilation...............................................................36
2.7.3 Smoke ventilation systems.....................................................................36
2.7.4 Chilled water systems.............................................................................36
2.7.5 Cooling water systems............................................................................36
2.7.6 Refrigerant recovery system...................................................................37
2.7.7 Manufacturers test certificates................................................................37
2.7.8 Operating and Maintenance manuals.....................................................37
3 PRELIMINARY DESIGN INFORMATION.......................................38
3.1 Design Ambient Conditions.......................................................................38
3.2 Normal and smoke ventilation situation.....................................................38
3.3 Requirements for maximum air flow into cavern........................................38
3.4 Heat loads.................................................................................................38
3.5 Chilled water system..................................................................................42
3.6 Estimated cooling capacity, chilled water flow rate , supply air , fresh air for
air handling units..............................................................................43
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DESCRIPTION OF SYSTEM
1.1
FUNCTION
LOT D
The function of the Ventilation and Air Conditioning Systems in the Power house is to
Remove the heat generated within the underground areas and tunnels,
and maintain suitable environmental conditions for equipment and personnel.
Supply sufficient filtered fresh air for ventilation requirements

throughout the station
Remove any dangerous gases and oil vapours
Control and remove hot smoke gases generated by fire.
Provide fresh air replacement where necessary.
In principle, the rooms to operate at positive pressure under normal conditions and at
negative pressure under emergency operation.
In addition to these goals, the systems should be rugged yet simple in terms of the
design and equipment used, and should be easily maintainable.
System operation should be fully automated with the minimum of human interface.
1.2
SCOPE OF SYSTEM
The scope includes the detailed design, manufacture, supply, erection, testing,
commissioning and handover of the systems.
The systems shall comprise all necessary Plant, equipment, components, ancillaries,
distribution systems and automatic controls to fulfil the required functions.
The systems to be fully functioning include fail safe features where necessary and
meet the performance criteria described in the works information.
The systems shall be designed to maintain the integrity of fire compartments and fire
zones throughout the station.
The Plant and systems shall be designed for conditions existing in the station during
normal operation, emergency operation and when not in use.
The systems shall include but not be limited to:
Ventilation of all cavern areas.
Fresh air supply system.

The system to comprise a main fresh air inlet shaft, filters, fans, ducting,
dampers and final air distribution through the access tunnels to the Machine
Hall, Transformer Hall and ancillary areas.
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Cooled air/recirculated air systems.

The systems to comprise a central chiller Plant, air handling units strategically
located around the station and associated ventilating fans.
Main exhaust air systems.

The Main Access and Exploratory tunnels shall be used for exhausting used air
from the station. The balance of exhaust air shall be removed by the Smoke
extract system which will have a dual function of normal ventilation extract as
well as smoke removal in the event of a fire.
Battery room extract system.
Ancillary rooms and other areas requiring ventilation systems.
Smoke removal systems

Smoke removal systems to be use the same tunnels and exhaust air shaft as the
normal extract ventilation shown on the Tender outline drawings. The system
shall incorporate main extract fans, secondary fans and exhaust ducting for
rooms and areas remote from the tunnels.
Control and Instrumentation
All internal cabling within the HVAC system, control panel to dampers, sensors
etc
Control Cabling between switchgear and HVAC
400 V Switchgear, motor control units and feeder circuit for all the related HVAC
Plant.
Quality control and codification
Project Manager outline design information is included for reference by the

Contractor. The information includes drawings and other information included in the
Works Information.
The Contractor shall submit an outline description and schematics of the systems
together with main design criteria and the completed equipment schedules contained
within this specification.
If the Contractor proposes any changes to the Project Manager outline design and
other information, all the changes shall be clearly explained. Any changes shall not
prejudice the station operation or safety.
No changes will be allowed to the HVAC Plant and equipment redundancy i.e. the
number of duty and standby Plant and equipment items as shown in the Project
Manager outline design information.
The Project Manager is not bound to accept any changes.
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1.3
LOT D
DESIGN WORK
The Contractor to submit the following preliminary information to the Project Manager
for review:
Outline of Detailed Designs
Heat release data from the main Plant, equipment and cabling. This to be
obtained from Others as required.
Cooling and ventilation capacities
Chiller unit capacities
Air handling unit and fan capacities
Smoke fan and system capacities
Pump capacities
Noise levels from chillers, pumps and fans
Noise control proposals
Fire zoning
Control philosophies for all systems
Plant room space requirements
Electrical loads
Identify and provide remedial measures to remove dangerous gases and

vapours.
Identify heat and moisture loads.
Provide material selection and corrosion prevention measures.
Any special requirements
The design takes account of the heat release data for the station main plant, ancillary
mechanical and electrical plant, equipment and cabling. The heat release data to be
based on actual plant, equipment and cabling specifications approved by the Project
Manager for manufacture and installation.
The Project Manager outline design heat release data included in the Works
Information is a preliminary estimation and not to be used in the Contractors final
design. The Contractor shall collaborate with the Project Manager to obtain the actual
heat release for the Contractors final design
All preliminary information requested above shall be reviewed during the detailed
design stage. The information based on the final designs to be resubmitted for
Project Managers acceptance during the course of the detailed design process.
The requirements of the detailed designs are described below.
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1.4
LOT D
DOCUMENTATION
The technical documentation associated with the ventilation and air conditioning Plant
is split into four parts: Specification, Data Sheets, Schedules and Drawings.
1.
Works Information Technical Specification
This document, Section 9 in Lot D, Book 2, Part C3.2, is the Technical Specification
for the, ventilation and air conditioning system. It needs to be read in conjunction with
the Technical Data Sheets, because they contain the related numerical data, and the
General Technical Specification in Part C3.1
2.
Works Information Technical Data Sheets
The Data Sheets are associated with the whole Lot D contract rather than with
individual Sections. Two types of data are incorporated in the Data Sheets:
Scheme technical particulars such as station floor elevations and number of

pumps/units.
Nominal technical data consisting of data that may be affected by detailed

design from other related contracts, and which will be subject to confirmation
during project implementation. For example, the range of water pressure in the
station main waterways, heat release from the station main plant, ancillary
mechanical and electrical plant, equipment and cabling.
3.
Technical Schedules
There is one Technical Schedule associated with each Technical Specification. The
Technical Schedule contains the technical data and supporting submissions. The
Technical Schedule for the ventilation and air conditioning system is document D-1T22-9 in Lot D, Book 1, Part T2.2 Section 9. The Contractor is to furnish the details
required therein.
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DESIGN
2.1
TECHNICAL STANDARDS AND REGULATIONS
LOT D
The Plant shall comply with the latest revision of the following standards and any
other applicable standard.
GGS0462
Quality requirements for engineering and construction works
GGSS0456
Standard for Switchgear and associated plant for voltages

up to and including ac 1000 V and dc 1200 V
GGG0838
Battery rooms standard
(OHASA) 85 1995
Occupational Health and Safety Act
SANS 1200
SANS 10400
Standardized specification for civil engineering construction

The application of the National Building Regulations
SANS 60079 part 15
Electrical apparatus for explosive gas atmosphere
SANS 10108
The classification of hazardous locations and the selection of

apparatus for use in such locations
SANS 10173
Installation, testing and balancing of air-conditioning ducting
SANS 1238
Air conditioning ductwork
SANS1424
Filters used in air conditioning and general ventilation
SANS 193
ASHRAE G1
Fire dampers
British Standard: Code of practice for mechanical ventilation
and air conditioning in buildings
British Standard: Code of practice for sound insulation and
noise reduction in buildings
Charted Institution of Building Services Engineers Guide
Book
Guideline for commissioning air conditioning systems
ASHRAE 52/76
Standard test method of filters
ASHRAE 55
Thermal environmental condition for human occupancy
ASHRAE 62
American Society of Heating Refrigeration and Air

Conditioning
Engineers. Ventilation for acceptable indoor
air quality
ASHRAE 15
Safety Codes for mechanical refrigeration
BS 5720
BS 8233
CIBSE UK
2.2
HVAC PLANT AND PARTICULAR REQUIREMENTS

The installation shall be housed in respective Caverns as detailed in the drawings.
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Such an installation will be restricted due to the limited number of access routes to it
and the location and space available for HVAC & Fire Protection equipment is limited.
The Contractors designs shall take account of these restrictions.
The HVAC system shall consist of the following Plant located in the power house;
Fresh air Plants to be located at east end of machine hall.
The Air Handling Units to be located in the following areas:

o
Control Room Block AHU 1
Western Generator AHU 2
Western Turbine AHU 3
Machine Hall Operating Floor AHU 4
Transformer Hall Operating Floor AHU 5
Eastern Generator Floor AHU 6
Eastern Turbine Floor AHU 7
Smoke Extract / Normal Vent Plant to be located at west end of machine hall
Chiller Plant to be located at the east of the transformer hall.
For the design to conform to the minimum requirements, the following items are to be
addressed:
Provide fire/smoke venting to all fire risk areas
The HVAC systems need to maintain the Cavern at a positive pressure relative
to atmosphere in order to prevent dust and heat ingress from outdoors.
The Machine Hall, Transformer Hall, all tunnels, adits and shafts need to be
ventilated in normal and smoke extract mode.
Provide logical zoning and distribution of the ventilation and air conditioning
systems because of varying heat loads throughout the station which may change
significantly in a short period of time
Assess the risk of ingress of methane entering the Cavern from the surrounding
rock and provide adequate ventilation.
Assess the risk, if any, of oil vapour or mist collecting and forming an explosive
mixture and provide adequate ventilation.
Remove battery generated gases
The Main Access tunnel (MAT) and Exploratory/cable tunnels (ET) to be useable
as personnel escape routes in the event of a fire in the Cavern or a vehicle fire in
a tunnel.
The tunnels to be the entry points for the fire fighting team.
Provide adequate Plant and equipment redundancy to ensure any failure will not
prejudice the normal and safe operation of the ventilation, air conditioning and
smoke extract systems
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2.2.1
LOT D
Noise control of HVAC Plant to limit the noise in rooms and plant spaces to
specified levels
The Plant needs to be easily operable and maintainable.
Equipment
The equipment, where possible, shall be designed and manufactured in South Africa.
The Contractor or the sub-contractor, as the case may be, shall have a proven track
record in the field of manufacturing such equipment.
Where equipment is not available in South Africa then equipment shall be designed,
manufactured and supplied by well known international contractors.
These
contractors shall have an established presence in South Africa with backup service
and maintenance availability
The Contractor shall provide details of proposed South African and International
manufacturers for acceptance by the Project Manager.
2.2.2
Water Analysis
Analysis of the water in the stream beds that will make up the upper and lower
reservoirs indicates that the operating water will be corrosive to steel. The design of
the Plant shall take due account of the site environment to ensure long service life.
For further details on water analysis refer to Site Information, Book 4, Part C5, Water
Analysis Report.
Information on selection of materials and corrosion prevention / protection measures
to be provided by the tenderers
2.3
FUNCTIONAL DESCRIPTION
The Contractor designs the system to function as follows;
All fresh air required inside the Cavern to be brought in through a dedicated
fresh air shaft, located at the eastern end of the complex. The fresh air plant
rooms shall be as stated in the Schedules.
The fans shall facilitate bringing the air into the Cavern. The Fresh air plant
rooms shall be located in three (3) connecting tunnels to spiral tunnels at the
bottom of the fresh air shaft. The spiral tunnels are part of the construction
tunnelling system that is required to give access to the various areas. These are
basically extended sections of the exploratory tunnel which shall be used for
access during the construction of the main cavern, and which will serve as
permanent access links between the various levels within the Cavern once
operational.
Distribution of the air shall be accomplished by means of the aforementioned

construction tunnelling system. The air shall flow freely inside these sections
and distribution into specific areas will be facilitated by means of Air handling
Unit fans through which volume flow will be controlled. Some of the air shall be
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allowed to flow freely into specific areas. These include the link to bifurcation and
anchor galleries. The pressure from the main fresh air fans shall drive this
movement of air.
Air will be extracted via following routes: Firstly, Some air shall be allowed to
flow freely out of the complex via the Main Access Tunnel (MAT) and the
Exploratory Tunnel (ET). This outflow shall prevent fumes from vehicles
entering the complex. It will also assist in preventing dust ingress. Secondly, air
shall be extracted via two dedicated shafts at the western end of both the
Machine Hall and the Transformer Hall. Both of these shafts link up with smoke
extract tunnels and shaft.
Reverse air flow shall be prevented through the surge chamber access tunnel to
the natural ventilation / smoke extract ventilation shaft. Otherwise the operation
of the extraction system will be affected.
To facilitate extraction, both under normal and fire conditions, various extraction
fans shall be used. This is in line with the requirement to provide safety in the
event of a fire. The actual Cavern layout does not lend itself to the use of a
single extraction fan. To facilitate movement of air inside the two extraction
shafts a common extraction fan shall be installed in the smoke plenum. The
latter fan shall ensure that air is diverted to ambient and that short circuiting
cannot take place.
Due to the limited availability of space for the HVAC equipment, normal and
smoke extraction shall be combined as far as possible. In some areas air shall
be diverted to general areas before extraction is done, and in these instances
dampers, actuated from the fire control system shall be used to ensure routing of
smoke out of specific areas is possible.
Air Handling Units shall be provided as indicated in the Schedules.
Air-conditioning will be localised. This will be accomplished by means of a

central chilled water system, distributing chilled water to air handling units
located throughout the Cavern.
The nature of the anticipated heat load varies from area to area within the
complex. In addition to this, the load in a specific area may also vary
significantly within short periods of time. Therefore, the control of the airconditioning system aims to maintain internal environments by means of local
rather than global control.
The route for fresh air to reach the western areas requires that certain routes need to
be identified. Due to the cavern layout these two areas are of concern..
To bring air into the western generator floor area the following is recommended. The
required volume will need to enter the Cavern at high level in the machine hall
operating floor. From here it will be ducted across the length of the Cavern to an area
above the western workshop. From here a duct will need to run down and through
the floor of the operating area to supply air at high level inside the western generator
floor. The design and any deviation there from shall require the Project Managers
acceptance.
For air to reach the western turbine floor it must pass through the general drainage
gallery area and reach the turbine floor via a duct rising from below.
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This is preferred for two reasons: Firstly it allows a much bigger volume of air flowing
through the drainage gallery, which will aid in providing cooling on the said level
without the need for additional cooling. Secondly the larger volume flowing through
the area assists in meeting requirements under smoke extraction situations. Any
deviations from the design shall require the Project Managers acceptance.
2.4
AREAS TO BE VENTILATED
2.4.1
The Machine Hall Areas.
2.4.1.1
Operating Floor.
The operating floor area houses the excitation cubicles of the four generator units,
which protrude through the operating floor into the main Cavern / machine hall
area. Other than these the area houses an overhead crane system to be used
during installation and maintenance of the units and the main inlet valves (MIV).
Access to the MIV pits (on Turbine floor level) is via steel plates covering hatches
leading to lower levels.
On the western end of the operating floor is a workshop on low level, with a HVAC
plant room located above it. Similarly on the eastern end there is a workshop
area with a HVAC plant room above it.
The area links to the remainder of the Cavern complex via the main access tunnel
which leads to the transformer hall in the one direction and to bifurcation and
anchor galleries in the other, and via the exploratory tunnel spirals on the eastern
side of the Cavern which lead to the various levels of the machine hall. The
control room complex is housed above an extension of the main access tunnel
and has a clear view of the operating floor by means of a high level window
overlooking same.
The operating floor also links to the areas below it via the aforementioned hatches
located above the MIVs, and via four stairwells.
The roof of the operating floor is lined with a steel deck to prevent condensate
and trickle from the rock to reach critical equipment on the floor itself. This
volume will house ducting and a passage way for maintenance purposes.
2.4.1.2
Control Room Block

The control room block is located in an extension of the MAT to the one side of
the operating floor, away from the transformer hall.
It houses the control, communications and battery rooms. Part of the control
block also includes the sewage sump area, an office for the plant engineer,
ablution facilities (both male and female) and a short passage.
The control block links up with the remainder of the station via the MAT.
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2.4.1.3
LOT D
Clean Oil Handling Room

This is located off the operating floor, a small distance from the control block and
also directed away from the transformer hall. The area links up with the main
piping and drainage adit at the end furthest from the operating floor.
The only access to the clean oil handling room is via the operating floor and the
said adit.
2.4.2
2.4.2.1
The Generator Floors.

Western Generator Floor.
The generator floor is divided into two distinct non-interconnected areas. The
Western Generator Floor is that area in which the generators for units 3 and 4 are
housed.
The area comprises of a workshop and laboratory area, the actual generator
section and an area containing the 400V Services and Unit boards associated
with the Station and units 3 and 4.
Solid steel plates cover the access hatches (above the MIV pits) leading to the
turbine floor area below. Access to the area is only possible by means of either
the stairwells on the southern side of the general generator floor area, or via the
two busbar tunnels, connecting to the area at the southern side of the Cavern.
2.4.2.2
Eastern Generator Floor

The Eastern Generator Floor is that area in which the generators for units 1 and 2
are housed.
The area comprises of the actual generator section and a room containing the 3,3
kV switchboard equipment. The 400V Unit boards associated with units 1 and 2
are housed in the generator floor area.
Solid steel plates cover the access hatches (above the MIV pits) leading to the
turbine floor area below. Access to the area is only possible by means of either
the two stairwells on the southern side of the general generator floor area, or via
the two busbar tunnels, connecting to the area at the southern side of the Cavern.
2.4.3
Busbar Tunnels
There are four busbar tunnels, one each for linking up the generator with its
transformer via a busbar. The busbar tunnels are located between the machine hall
and the transformer hall.
2.4.4
2.4.4.1
The Turbine Floors

Western Turbine Floor
The turbine floor is divided into two distinct but interconnected areas. The
Western Turbine Floor is the area in which the turbines and MIVs for units 3 and 4
are housed and is located below the generator floor.
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The area comprises of a workshop area, the actual turbine section and a room
containing the blowdown air compressors for units 3 and 4. The area is open to
the two MIV pits for the specific units.
Access to the area is only possible by means of any of the stairwells on the
southern side of the general generator floor area and in the workshop, as well as
from the eastern turbine floor via the interconnecting passage.
2.4.4.2
Eastern Turbine Floor

The turbine floor is divided into two distinct but interconnected areas. The
Eastern Turbine Floor is that area in which the turbines and MIVs for units 1 and 2
are housed and is located below the generator floor.
The area comprises of the actual turbine section and a room containing the
blowdown air compressors for units 1 and 2. The area is open to the two MIV pits
for the specific units.
Access to the area is only possible by means of any of the stairwells on the
southern side of the general generator floor area and in the workshop, as well as
from the western turbine floor via the interconnecting passage, and via the
exploratory tunnel spiral.
2.4.5
The Drainage Gallery

The Drainage Gallery is housed in the lower part of the machine hall. It houses the
dirty oil handling room and the pump sump area. Access to the gallery is via
stairwells that connect to the turbine floor areas, and via the exploratory tunnel spiral.
2.4.6
2.4.6.1
The Transformer Hall Areas

Cable Gallery
The passageway on lowest level in the transformer hall houses the cable and pipe
gallery below the transformer level. It is connected to the transformer hall by
means of two stairwells. It also houses the oil and fire water containment tanks
for each of the four main transformers which are linked via a 300 mm diameter
overflow pipe.
2.4.6.2
Transformer Hall Operating Floor

The transformer floor houses the four main transformers, the station transformers,
the SFC input and output transformers and a passageway. The transformers are
all enclosed in block wall cubicles. At the eastern end of the Cavern the chilling
Plant for internal air-conditioning equipment will be housed. The area connects to
the passageway and mezzanine levels via two stairwells and connects to the
generator Cavern by means of the main access tunnel. Two tunnels connect to
the spirals / exploratory tunnel at the eastern end, one of these for cable runs, the
other for vehicle access. The enclosures to each of the main transformers also
open up to the busbar tunnels.
2.4.6.3
Transformer Hall Mezzanine Floor

The mezzanine floor area in the transformer hall Cavern houses the SFC
capacitor/filter complex. It is situated above the SFC switchgear and input/output
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transformer cubicles. Access is possible by means of the stairwell in between

transformer # 3 and the MAT. On the same level (at the eastern side), the
stations common services cooling water plant room is housed. Access is
possible by means of the stairwell east of transformer # 1s cubicle.
2.4.6.4
Transformer Hall Battery Room Floor

Above the Mezzanine floor area is located the battery floor area, in which the
batteries and DC charger rooms are housed.
Access is by means of the same stairwell that gives access to the mezzanine floor
level.
2.5
DETAIL DESIGN REQUIREMENTS
2.5.1
General
The air conditioning cooling and ventilation capacities are to be based upon:
Heat release from the station main plant, mechanical and electrical systems,
equipment, cabling, fresh air, other sundry sources and air conditioning systems.
The heat release data based on the approved plant and equipment shall be
supplied by the Project Manager to the Contractor.
Normal and smoke ventilation requirements shall be according to this

specification and related Codes and Standards.
Extract requirements for areas where explosive gases or vapours may be

present.
Airflow requirements in the high voltage cable tunnel (exploratory tunnel) to

ensure positive airflow to the outdoor air to remove heat.
Any cooling effect provided by the rock structure of the caverns shall not be taken
into account when deciding the cooling capacity of HVAC Plant.
In the event of a complete failure of all mechanical air conditioning and ventilation
systems, the design to provide ventilation by natural draught through the extract air
tunnels and main vertical shaft provided for normal mechanical extract ventilation and
smoke extract ventilation.
2.5.2
2.5.2.1
Air handling for Air conditioning and ventilation

Fresh air system
The requirements for fans and air distribution are outlined in Section 2.3
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2.5.2.2
LOT D
Air conditioning systems

The requirements for air handling units and ventilating fans are outlined in Section
2.3.
Multiple units and fans to provide zoned control of the varying heat loads throughout
the station.
2.5.2.3
Mechanical Ventilation systems

Ventilation shall be provided via tunnels, adits and equipment rooms, and in other
areas to ensure flow of fresh air and exhaust of used air through the station.
Exhausted air shall be collected by the main normal extract system for discharge to
atmosphere and also discharged via the Exploratory tunnel and the Main access
tunnel.
The Exploratory tunnel shall be investigated by the Contractor to see if roof mounted
jet fans to induce airflow from within the station to discharge through the tunnel
entrance portal shall be required.
Ventilation to be provided for areas where explosive gases will be generated i.e.
battery emitted hydrogen and where methane can collect in the station.
2.5.2.4
Design conditions
For outdoor ambient design Conditions refer to Book 4 Site information.
For design parameters regarding station cooling water temperature refer to the data
sheets and to the schedules for Internal Design Conditions
2.5.2.5
Air distribution
Fresh air supplied through the main access tunnels shall be regulated to ensure that
design airflow rates to the air handling units and other areas will be achieved.
The Contractor shall prepare a study for review by the Project Manager to
demonstrate how airflow balance will be achieved.
The air conditioning systems throughout the station shall be properly designed to
ensure that cooling air is distributed to the plant and equipment areas without
discomfort to operational and maintenance personnel.
Sizing of ductwork shall limit excessive pressure drop in long runs which would
otherwise cause difficulty in balancing of grilles and affect air distribution. To limit duct
pressure drops the static regain method of duct sizing shall be considered.
2.5.2.6
Air filtration standards

The filters shall comply with SANS 1424 and/or ASHRAE 52-76 standard.
The efficiency and performance of primary and secondary filters shall be as
recommended by the relevant Codes, Standards and guides.
2.5.2.7
Noise control
The noise from HVAC Plant shall be attenuated to ensure the design noise levels in
tunnels, plant areas and rooms do not exceed the values stated in the Schedules.
Balancing of regulating dampers at grilles shall not cause regenerative air noise
which exceeds the room design noise level.
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2.5.2.8
LOT D
Main fresh air fans

The fans to be high efficiency axial flow type with air straightening vanes and sound
attenuators on the inlets and outlets.
A bellmouth cone to be fitted to the inlet of each fan.
Fans to operate with a minimum design airflow variation from a clean filter condition
to a dirty filter condition as rated by the Contractor.
Each fan shall have a motorised damper for isolation when it is not in operation.
Reference airflow capacities are to be found on the drawings.
2.5.2.9
Main fresh air filters

All filters shall have a nominal overall face dimensions as stated in the Schedule, with
the maximum acceptable tolerance as per SABS 1424
The following efficiencies are required:
The primary and secondary air filters shall meet all the requirements stated in the
Schedules. A complete set of spare filters both primary and secondary shall be
supplied under the contract. The filters shall be of the disposable type and have
pressure drop indication. The filters shall be adequately supported in a steel frame
assembly.
Airflow blanking plates shall be provided around the contour of the tunnel section to
ensure air flows only through the filters.
The filter inlet chamber shall have high level steel platforms and ladders to access
filters inaccessible from ground level.
2.5.2.10
Air handling units

Each air handling unit shall comprise a fresh air/ recirculating air mixing box, primary
and secondary filters, cooling coils, and supply air fans. The units shall have an
automatic isolating/modulating damper and separate manual regulating damper on
the fresh air connection, and a modulating damper on the recirculating air connection.
Isolating motorised dampers shall be fitted on the discharge air connection.
Refer to section 2.5.7 for modulating of fresh air and recirculating dampers when
room overcooling may occur in winter with low room heat loads.
Each unit shall have a casing and components constructed from corrosion resistant
materials to ensure long life. The casing design shall have an acceptable acoustic
and thermal insulation performance.
Air filters shall be provided. The pre-filter and after-filter sets shall have pressure
drop indication. Air velocity through filters shall not exceed the values as stated in the
Schedules.
The face velocity across the cooling coils shall be as stated in the Schedules. The
coils fin spacing shall be adequate to ensure fins can be pressure cleaned. The coils
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shall have moisture eliminators where selection shows risk of moisture carryover.
Any condensate that may occur shall be piped to the nearest acceptable drain. Coil
tubes, fins and moisture eliminators shall be constructed from corrosion resistant
materials to ensure long life. Pipework connections to each coil shall allow easy
future removal of the coil.
All the fans shall be of the belt driven centrifugal type and constructed from corrosion
resistant materials to ensure a long life. The motors shall be suitable for a high
humidity environment. The air flow adjustment to the design value shall be achieved
by fan and motor pulley selection. Each fan shall have a motorised damper for
isolation when the fan is not in operation. Fan redundancy shall be considered as
referred below
Air handling units in the drainage gallery shall be protected from Turbine transient air
pressure surges which may have the potential to damage the air handling unit filters.
Details of the proposed protection method shall be submitted to the Project Manager
for acceptance
All the required reference airflow capacities are to be found on the drawings.
2.5.2.11
Extract fans
Extract air fans and any electrical installation within the battery room shall be of the
class 1 Division 2 type to SANS 10108
Fans shall be the axial flow type. Alternative type may be considered with reason
given for selecting the alternative, subject to the Project Managers acceptance.
Fans having a dual airflow function shall have suitable and approved method of
airflow control.
Fans operating in the presence of explosive gases i.e. battery emitted hydrogen and
methane in the station shall be of suitable materials and design.
All fans, except jet fans, if required, shall be equipped with a motorised damper for
isolation when not in operation.
The Contractor to provide a study with calculations of the proposed jet fan
arrangement in the Exploratory tunnel.
All airflow capacities are to be found on the drawings.
2.5.2.12
All fans
The fans shall be selected with a high total fan efficiency and low electrical power
rating. The fans shall be selected with the lowest operating speed wherever possible,
within the performance envelope and not at the extreme range of the envelope.
Fans shall have minimum airflow variation with filters in the Contractors rated clean
and dirty conditions.
Fan duties shall include a working margin appropriate to the system.
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2.5.2.13
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Fan redundancy requirements

The Fresh air fans in any two plant rooms shall be capable of providing the design
total fresh air requirements for the station. Each plant room shall be equipped with
the fan requirements as stated in the Schedules
Smoke extract/Normal ventilation fans shall be provided each capable the total
extract requirement as stated in the Schedules. These fans shall be of the non
flammable type
All air handling units shall be equipped with the fan requirements as stated in the
Schedules.
Special risk areas to have 100% duty and 100% standby fans. Non risk areas to
have one 100% duty fan only.
2.5.2.14
Ducting and fittings

Duct air velocities shall not exceed recommended values as specified in SMACNA
low velocity standard. The duct fittings shall be designed to minimize air pressure
drop. All duct bends shall have multi turning vanes.
Inspection/access hatches shall be fitted to the upstream and downstream of every
main regulating damper and fire damper, upstream and downstream of every duct
bend with turning vanes and at regular positions along the ducting
Ducts shall be positioned clear of walls to allow adequate access space for fitting of
thermal insulation and inspection. All ducts in fire walls and floors shall be fire rated.
Smoke handling ductwork shall be welded construction
2.5.2.15
Dampers
Regulating dampers shall be fitted at every grille and duct branch.
Fire dampers shall be fitted directly adjacent every fire wall. Dampers shall be of the
motor driven, opposed blade type. Motorised dampers shall be fitted at all air
handling units and fans
2.5.2.16
Thermal insulation
Low velocity ducting shall be internally insulated with sonic liner and externally
corrosion protected. High and medium velocity ducting shall be externally insulated
and vapour sealed.
Ventilation ducting shall not be insulated, but internally and externally corrosion
protected.
All air handling units shall have integral thermal and acoustic insulation.
Insulation shall be fitted to all supply air ductwork providing cooled air to the Machine
hall and transformer hall.
Insulation shall be fitted to the supply and return ducting serving the Control block.
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Insulation shall be fitted to fresh air ducting where condensation will occur on the
surface of the ducting.
Insulation shall be removable at access hatches and where any other access is
required to equipment and system components
2.5.3
2.5.3.1
Water Systems FOR AIR CONDITIONING AND VENTILATION

Chilled water system
Chilled water shall be supplied to air handling unit cooling coils by a controlled flow
system. The flow will result from the modulating action of the two way valves at each
air handling unit coils. The controlled water flow shall be managed by an advanced
control system.
The lowest water flow allowable in the system shall be limited by automatic controls,
which are managed by a centralised control system. The lowest flow will be
determined by the lowest flow allowable through a chiller or pump for practical
operation as advised by the chiller and pump Contractor.
Chilled water circulation shall be maintained continuously during normal system
operation and even when all air handling unit cooling coil control valves have been
closed due to no cooling demand required.
2.5.3.2
Cooling water system

Cooling water shall be directly supplied from the station cooling water system as
shown in the P&ID drawing 0.83/45 002.
The pipe materials and fittings are specified in Book 2, part C3.1 General technical
specification
Valves and other inline components and fittings of diameters up to and equal to
150 mm shall be stainless steel. Valves of diameters larger than 150 mm shall be
cast steel, painted as specified for the pipework, or better. Care shall be taken in
design and installation to prevent galvanic corrosion between different materials
2.5.3.3
Design temperatures
The chilled water flow temperature from the chillers shall be determined by the air
handling unit supply air temperature requirements of the cooling coils.
The systems main return water temperature shall be determined from selection of the
coils. If an alternative return temperature has been chosen by the Contractor, the
reason for the alternative value is to be justified.
The Contractor shall submit all proposals and calculations for review and acceptance
to the Project Manager, clearly documenting how the chilled water flow and return
temperatures were determined.
The station cooling water temperature is stated in the data sheets. The preliminary
cooling water flow and temperature difference have been stated in data sheets
2.5.3.4
Chillers
Chillers shall be of the hermetic centrifugal type design, complete with all ancillaries
and safety controls, capable of full modulation from 100% to 10% capacity. Chillers
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shall utilise refrigerant that has a low ozone depletion potential and complies with the
current requirements of the Montreal Protocol Agreement to which South Africa is a
signatory..
As there is international agreement to phase out CFC and HCFC refrigerant an
approved alternative is to be used.
The selected refrigerant to be utilised for the chiller Plant shall be readily available in
South Africa.
The chillers condenser water tubes to be stainless steel, taking into account both
pressure of the cooling water and the cooling water corrosivity.
The low cooling water temperature shall be taken into account as chillers operation
may be required when cooling water temperature is below required minimum for
chiller operation.
The Chiller microprocessor control systems shall interface with the overall HVAC PLC
system. For detailed requirements refer to Section 2.5.7
Marine boxes shall be equipped on each chillers condenser and evaporator shells.
Cathodic protection shall be provided for corrosion protection.
A refrigerant recovery vessel and all ancillary equipment shall be provided to the
specification and size recommended by the chiller Contractor. Spare refrigerant shall
be provided for storage on site for any future requirement. The amount of refrigerant
shall be advised by the Contractor.
2.5.3.5
Filtration
The degree of filtration shall be based on the equipment requirements, however shall
not exceed a diameter of 1.6 mm
Duplicate changeover filters shall be fitted in the chilled water and cooling water
systems, if the station strainers are not adequate, to protect Plant and equipment
from damage by foreign matter.
Automatic control valves, if required, shall be protected by filters.
2.5.3.6
Chilled water pumps

If required, centrifugal pumps shall be provided each with a capacity flow rate as
stated in the schedules. The pump duties shall have an added safety margin.
Pump maximum design flow rate shall be determined from the approved system load
with added margin, and the calculated flow and return temperatures referred to the
data sheets.
2.5.3.7
Pipework
Piping to be sized using a reasonable pressure drop rate.
Water velocity in any pipe not to exceed the amount stated in the schedules.
2.5.3.8
Chilled water buffer tank

A chilled water buffer tank shall be provided with a close loop chilled water system.
The Contractor shall determine the required water volume for the chilled water
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system, and ensure no short falls would result in oscillation of the chilled water supply
temperature. Reference shall be made to the specific plant design parameters in this
respect.
Any shortfall regarding the water volume shall be corrected in the selection of the
closed loop water tank design. The tank volume shall be calculated and submitted for
acceptance by the Project Manager
Valves
Manual isolating valves shall be fitted to:
2.5.3.9
the chilled water flow and return at each chiller,
the flow and return at each chilled water pump,
either side of the chilled water flow meter,
the main chilled water flow and return leaving the chiller plant room
each sub branch flow and return in the chilled water distribution system,
the flow and return of each air handling unit cooling coil,
the manual bypass at each cooling coil,
the station cooling water flow and return at each chiller,
and any other equipment that requires isolation for maintenance or replacement.
Flow regulating valves shall be fitted:
at each chiller,
on the return of each sub branch in the chilled water distribution system,
on the return of each air handling unit cooling coil,
on the bypass of each air handling unit cooling coil,
on the cooling water return at each chiller,
and any other equipment that requires isolation for maintenance or replacement.
Regulating valves shall have pressure tappings on the inlet and outlet to monitor and
set the flow rate (using portable instruments) at the commissioning stage. Non return
valves shall be fitted to the discharge side of each pump.
Pressure and flow indication
2.5.3.10
Indicating pressure gauges shall be fitted to:
the flow and return connections of each chiller, chilled water and station cooling
water circuits,
on either side of each chilled water pump,
on the inlet of the flow meter,
on either side of the chilled water and station cooling water plant room strainers,
on either side of the modulating control valves fitted at the end of each sub
branch chilled water mains. These valves shall control the pump water flow to a
minimum value for proper operation of the pump or chiller.
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Flow monitoring using pressure sensors shall be :
across the chiller, chilled water and station cooling water connections,
and across the modulating control valves at the ends of the chilled water mains.
All sensors and feedbacks and plant status shall interface to the HVAC central
controller.
2.5.3.11
Drains and vents

Drains shall be fitted on or adjacent to all Plant and equipment, also at all low points
of the system.
Drains shall discharge into a tundish and piping system. Tundishes shall be visible
and accessible.
Automatic air vents shall be fitted at all high points of a system. Vents shall discharge
into a tundish and piping system.
Permanent ladders shall be provided for easy access to high level vents and drains
on high level chilled water mains.
2.5.3.12
Expansion of pipework
The piping layout shall allow for expansion and contraction forces and ensure that all
piping stresses are within allowable limits.
Provision shall be made for the elimination of expansion and contraction forces where
piping is connected to chillers, pumps, air cooling coils and any other item of
equipment where these forces may overstrain or damage the Plant.
2.5.3.13
Materials to suit cooling water quality

All Plant, equipment and system components shall be suitable to resist the corrosive
effect of the incoming cooling water supplied by the station system.
Corrosion protection measures shall be implemented to minimise any risk to the
Plant. The pipe materials, corrosion protection and marking are specified in Book 2,
part C3.1 General technical specification.
2.5.3.14
Water treatment
A manual/automated chemical dosing system shall be fitted in the chilled water
system to protect pipework from electrolytic corrosion.
2.5.3.15
Thermal insulation
Insulation shall be fitted on all chilled water pipework, valves and wherever
condensation will occur on equipment or component surfaces. Insulation shall be
protected with vapour seal.
All valves shall have removable insulation jackets designed and provided by the
Contractor.
2.5.3.16
System fill and expansion

A quick fill pipe connection shall be fitted between the station water supply and the
chilled water system for a close loop system.
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A chilled water system feed and expansion tank shall be provided in an approved
location. The tank head shall be adequate to satisfy the Net Positive Suction Head
(NPSH) requirement of the chilled water pumps when working at maximum flow.
Should the NPSH not be satisfied then a mini pressure set shall be provided to
accommodate the required pressure head condition for the pumps.
2.5.4
Refrigerant systems
A single refrigerant shall be used. Mixtures of refrigerants shall not be permitted.
Refrigerant recovery
2.5.4.1
A refrigerant recovery vessel and equipment shall be provided in the chiller plant
room. Recovery will be required for refrigerant reuse or disposal.
Refrigerant exhaust
2.5.4.2
Refrigerant can exhaust from the chiller pressure relief valves and the purge vent
piping. Provision shall be made to contain such refrigerant and discharge it to a place
of safety. The Contractor shall liaise with the Project Manager as regards the point of
discharge of the refrigerant.
Safety in operation
2.5.4.3
Due to the possibility of refrigerant leaking into the chiller plant room, or any other
area where refrigerant may be stored, the following requirements shall be complied
with. These are additional to all other requirements as deemed necessary by the
Contractor.
2.5.5
Provide leak detection system and any portable instruments or apparatus. The
system shall continually monitor the area around the chillers and elsewhere in the
plant room where escape of refrigerant is a risk.
Provide breathing apparatus, protective goggles, gloves and clothing. These to

be located outside the chiller plant room in a secure marked housing.
Smoke ventilation systems

The requirements for fans and distribution are outlined in Section 2.3 and shown on
the drawings.
2.5.5.1
System design airflows

Fans shall be provided in the main smoke extract plant room as stated in the
Schedules.
The air shall be regulated through the station areas to ensure the design air balance
will be achieved in smoke operation mode and normal operation mode. The
Contractor shall provide a study with calculations ensuring that the air balance in the
smoke and normal ventilation mode will be achieved.
Reference airflow capacities are reflected on the drawings.
2.5.5.2
Fans
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Fans shall be of the high efficiency axial flow type with air straightening vanes and
sound attenuators fitted to the inlet and outlet.
Fans shall be suitable for the extract of hot smoke and gases. Airflow regulation shall
be provided to ensure the design flow rate capacity is achieved.
Each fan shall be fitted with a motorised damper for isolation when the fan is not in
operation.
The noise from fans shall be attenuated to ensure the design noise levels in tunnels,
equipment areas and the smoke fan plant room do not exceed the values stated in
Schedules.
Ducting and fittings
2.5.5.3
The duct air velocities shall not exceed the recommended values as specified in the
SMACNA low velocity standard.
In no instance shall the velocities selected for the extraction duct exceed 10m/s or a
pressure drop of 1Pa/m length of duct.
All the duct fittings shall be designed to minimize any air pressure drop. All duct
bends shall have multi turning vanes. The duct shall be fire rated for the application
installed.
Inspection/access hatches shall be fitted:
2.5.5.4
upstream and downstream of every main regulating damper and fire damper
upstream and downstream of every duct bend with turning vanes
at regular positions along the ducting

Dampers
All dampers shall be fire rated and electrically re-settable.

2.5.6
Emergency ventilation
All motorised dampers shall be remotely re-settable.
In the event of failure of all mechanical systems, ventilation by natural draught shall
be effected by exhausting hot air from the station into the main extract tunnels and up
the main vertical shaft to outdoors.
Replacement fresh air will be naturally induced into the Main access tunnel and
thence into the station areas.
Hot air will bypass the main extract fans and pass through large air dampers fitted at
high level above the fans. The dampers shall be normally kept closed but will be
manually opened in emergency. Position of the dampers shall be monitored by the
centralised HVAC PLC.
A steel platform and ladders shall be provided for access to the high level dampers.
2.5.7
Automatic controls, system monitoring and management
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2.5.8
LOT D
General
The requirements outlined for automatic
management are described in Section 2.3.
controls,
system
monitoring
and
The system to comprise of a centralised programmable logic controller (PLC), HMI

and an interface to the station control system network. All the plant status, events
and alarms shall be displayed on the station control desk HMI. The latest version of
the operating system software shall be installed fully developed and tested. All
software shall be written in one or more of the control languages of IEC 61131.
The system shall be capable of connecting to other I/O sub-systems, which may be
fieldbus (Profibus, ControlNet, DeviceNet, AS-I or Foundation Fieldbus). The system
shall also have the capability of supporting network configurations (Ethernet and
network protocols, Net Bios and TCP/IP), with NON proprietary gateways or custom
protocols enabling full connectivity to LANs, WANs, Internet, Intranet maintenance
management tools.
The control system shall interface with the Lot A contractors control network which
consists of network with Siemens S7 PLCs.
The system to have all necessary software to control, monitor and advise the
operator of normal and emergency operating conditions in all air and water systems.
A graphical flow diagram shall be shown on the control room SCADAs for each
system in normal operation and emergency operation. The Contractor shall
collaborate with the Project Manager to ensure that the interface and displays
representing the HVAC system on the station control system are satisfactory. The
diagrams shall show all operating airflow, temperature, humidity and pressure
conditions, also plant and equipment operating status.
Remote manual on/off control shall be provided for each Plant item on the localised
HVAC Plants. Manual override facility shall be provided locally at each Plant item. At
the localised HVAC PLC, a HMI shall be provided with a replica graphical flow
diagram and all Plant status as per the station SCADA, to operate and monitor the
Plant. Refer to the section 2.5.8.1 below for more detail regarding control.
Outstations shall be provided at each plant area to monitor the Chillers, air handling
units, ventilating Plant, ducting systems and any other position in the station where
needed. The data shall be transmitted to the central PLC.
The fire detection system shall interface with the HVAC central PLC, which will
regulate the supply air to the area affected in accordance with safe practice and
automatically close the motorised fire dampers in the event of a fire. The smoke
extract system shall operate automatically on signal from the HVAC PLC.
The HVAC central PLC shall advise the desired capacity, flow and pressure
conditions at the chillers, pumps and air handling units, fans, also in the air and water
systems under all normal and emergency operating conditions.
The HVAC PLC shall monitor each chiller status, chilled water and cooling water flow
and return temperatures, water flow rate through the chilled water and cooling water
flow rates and any general alarm condition that needs to be immediately reported to
the Control rooms. The alarms shall be graded as urgent or non urgent.
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An advanced control system shall be provided that will operate the chillers and
pumps in the most energy efficient way.
Each air handling unit cooling coil water flow shall be controlled by a two way
modulating valve. The valve shall be controlled by room averaging sensors in the
respective air conditioning zone.
Supply air temperature off a coil shall be prevented from falling below the design
temperature related to maximum cooling.
The fresh air temperature shall be monitored at the inlet to each air handling unit and
the temperature signal incorporated into the cooling coil valve control loop.
Each air handling unit shall maintain a constant fresh air flow rate by means of airflow
monitoring instrumentation and a modulating damper on the fresh air inlet connection.
Change of fresh air flow rate shall be controlled in the event of low room heat load
coinciding with low fresh air temperatures in winter, the room space may experience
uncontrolled overcooling. To counteract this the fresh air damper will need to
modulate to reduce the volume flow rate and the recirculating damper modulate to an
increasing open position to maintain a constant supply air flow rate from the air
handling unit.
The Control block air handling unit cooling coil and zoned duct heaters shall be
controlled by room temperature detectors. A stand alone independent air handling
unit from the station chiller Plant could be considered.
Chilled water circulation shall always be maintained to the end of the system during
normal system operation even when all AHUs cooling coil control valves have closed
due to no load demand.
Minimum flow shall be maintained at the chiller/pump Plant even when the system
flow demand falls below the minimum requirement of the chiller or pumps.
The chilled water flow meter shall monitor the system flow rate.
All doorways in tunnels carrying fresh air or exhaust air shall be monitored to confirm
their position i.e. open or closed. An alarm to be provided to advise if a door has
been left open thus interfering with proper operation of the ventilation system.
The Contractor shall submit for acceptance by the Project Manager detailed
proposals for the operation of all Plant, equipment and controls in normal, emergency
and smoke ventilation modes. The detailed proposals shall include all equipment,
calculations and standards utilised on the design.
Refer to E-2-C31 General Technical
instrumentation and supply requirements.
2.5.8.1
Specification
for
details
regarding
Control Location Philosophy

In general three operating modes shall be available and a key switch local to the
associated controller shall perform switching between these modes:
1.
Remote where control of the unit or auxiliary Plant item is from the duty
power station control room (i.e. the above ground or the below ground control
room whichever is currently the duty control location), via the power station
control network and the associated controller.
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2.
Local HMI where control of the unit or auxiliary plant item is from the
associated local HMI via the associated controller. The HMI may be directly
connected to the controller or may communicate with the controller via the
power station control network.
3.
Maintenance where control of the unit or auxiliary plant item is from the
vendor primary Plant, independent of the associated controller.
Control of any unit or Plant item shall only be possible from one location at a time.
2.5.8.2
Maintenance Control
Control panels local to individual items of Plant shall provide all necessary facilities
for the testing and manual local control of that Plant independently of the station
control system. This shall include independent indications of any measures
necessary for the safe operation of the Plant.
When in Maintenance mode two possible control locations are expected:
1.
2.
From the manual controls at the motor control centre or switchgear.

From the push button station adjacent to the actual Plant item being
controlled.
Both these control points shall only be functional when the Plant item is switched to
Maintenance. When switched to Remote or local HMI these controls shall be
disabled, with the exception of any Emergency Stop function at the push button
station, which shall always be functional.
While most interlocks will be implemented in the PLC logic and as such unavailable
when switched into Maintenance mode, safety related interlocks must always be in
service. The remaining interlocks, which would normally be performed by the
controller logic, shall be incorporated into the maintenance procedures if required.
2.5.8.3
Local HMI Control

When in Local HMI mode control of the unit or auxiliary Plant item shall only be
possible from the Local HMI, which will allow an operator to control the associated
facilities in a structure and methodology similar to, if not identical to, that provided for
control of the Plant from the power station control rooms.
A local Human Machine Interface (HMI) shall be provided for the associated auxiliary
Plant.
Operation of the facilities from the HMI shall be available to both order the operation
of individual components (e.g. open or close a valve) and to initiate automatic
sequences.
The control from the local HMI shall include all the functionality available from the
power station control rooms associated with the facility. Additional functionality may
also be available from the local HMI to facilitate the maintenance and commissioning
activities and for performance testing of the Plant, which will not be required to be
available from the power station control rooms.
Where displays on the local HMI cover the same plant areas as those on the remote
HMIs the displays shall be identical.
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2.5.8.4
LOT D
Remote Control
The remote control system shall be provided by the Lot A contractor. The Contractor
shall collaborate with the Project Manager to interface with the remote control system.
Two power station control rooms shall provide identical facilities for the centralised
monitoring and operator control of the power plant, one located in the underground
powerhouse and the other above ground in the Administration Building. When in
Remote mode, control of the unit or auxiliary Plant item shall only be possible from
one of the two power station control rooms.
Transfer of the duty control location from one control room to the other shall be
performed by software. Transfer of control between the two control rooms shall be
possible for the whole plant or on a unit basis.
The operation of the Plant from these control rooms shall be based on the use of
visual display units (VDUs), keyboards and other inputting devices and shall be
capable of providing control of individual items of Plant, of sequencing a functional
group of Plant to an optimised program of plant operation, and of sequencing
functional groups to provide full automatic plant operation, (e.g. one-command, with
the necessary confirmation, for start-up or mode change). A minimum of two
keystrokes, button clicks or actions shall be required to change any plant condition
(e.g. request and confirm type action).
The control system design shall be such that the safe monitoring and operation of the
entire power station is possible by a single operator. Facilities however shall be
provided in each control room for two operators to work together for training and
during commissioning of the Plant.
The control system configuration and associated real time data shall be resident in
the system database and shall reside in redundant central servers but accessible to
all controllers and operator devices.
2.5.8.5
Time synchronisation
A GPS system for time synchronisations shall be provided by Others. The GPS
system shall provide a time string to the communication bus to automatically
synchronise all devices with this master clock for the purposes of synchronising data
acquisition, data logging, alarm and trip events recording, etc. The time string signal
shall be propagated along the control bus. The HVAC control system shall obtain the
time string via the control network and ensure that all inputs are time stamped at the
source, and not at the processor.
2.5.9
2.5.9.1
LV Switchgear
General
The Contractor shall provide the complete fully functional 400V AC switchgear
(including protection) for all the HVAC Plant. The switchgear schedules and drawings
reflect the technical requirements for each switchboard.
All protection relays and protection schemes are supplied by the Contractor as per
this specification, Schedule A and GGSS0456. The Contractor performs the mounting
of protection equipment and performs the wiring of the protection and control circuits.
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LOT D
The Project Manager provides basic schematic drawings for different types of
protection and control circuits.
The Contractor is responsible for the switchgear as well as for marking the switchgear
room floor for the positioning of the cable entry holes. The room floor plan drawings
are provided as part of the Works Information.
The LV switchgear shall be of the metal-enclosed and controlgear assembly type with
withdrawable incomer and feeder circuit breakers, in accordance with GGSS0456,
IEC 60439 and IEC 60947. The equipment shall be altitude rated for use at an
elevation above sea level and in an ambient temperature specified in the schedules.
All motor controllers (where applicable) shall be of the fully withdrawable design.
Above this consideration shall be given to the weight of the device and towards fixed
installation.
The short circuit fault rating of all Plant given in the Schedules shall be for the
minimum duration stated in the Data Sheets.
2.5.9.2
Switchboard Panel Design

LV switchboards shall be of the free standing cubicle pattern suitable for 3-phase,
4-wire operation, solidly earthed.
The construction of the LV switchgear shall be such that the internal separation by
barriers complies with Form 4, Type 7 separation in accordance with the
requirements of IEC 60439-1.
All compartments shall be accessible from the front of the switchboard.
Each switchboard shall have space included to enable additional circuits to be added
at a later date. The space allowed shall be equivalent as specified in the schedules.
Allowance shall also be made to allow different rack sizes to be installed. All trip
devices shall be arranged for resetting from outside the cubicles.
All access doors shall be provided with facilities for locking in the closed position, and
for shutters in both the open and closed position.
The maximum overall height of switchboard panels supplied shall be no greater than
2.5 m. Operating devices, handles, etc shall be within the limits of 0.6 m and 1.8 m
above floor level.
The switchboard panel shall be made from suitable material of the nominal thickness
specified in the schedules.
The switchgear and control system life expectancy shall be a minimum as stated in
the schedules. This includes full service, spares and training support from the
Contractor during this period.
2.5.10 Cables and cable accessories

The cable design within the HVAC boundaries shall include all cables, cable
terminations, cable trays, cable ladder racks, junction boxes, glands, ferrules, lugs,
numbered ferrules, cable markers, clips and all fixings, fittings, brackets, cleats,
piping, conduits and accessories for all cables specified above. The Lot E contractor
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LOT D
will provide the station cable racking, which may be utilised to lay HVAC cabling on.
The Contractor shall collaborate with the Project Manager regarding the laying of
cables on these racks.
All cables shall be supplied with a flame retardant outer sheath. All cable sheaths
shall have low smoke and fume (LSF) characteristics and be anti-vermin
impregnated. Flame retardant outer sheaths shall be continuously marked with a red
stripe for ease of identification.
The conductor cross-section of each cable shall be adequate for carrying the
prospective fault current determined by the next relevant short circuit protection
device when operating under the specified load conditions, without deterioration of
the dielectric. Cable conductors shall be stranded high conductivity copper
AC and dc cables shall be sized to allow for a maximum of 15% voltage drop on
motor starting or for 3% running voltage drop whichever is greater.
Wherever cables pass through holes or slots in floors and walls or enter or leave
sleeve pipes in floors or walls, the openings will be sealed with a fireproof material
with a two hour fire rating. This material will be domed or slightly raised towards the
centre to prevent the accumulation of water or oil in the seal. The sealing material
will be water-resistant and provide a barrier for smoke or toxic fumes.
All cables shall be installed in accordance with the manufacturers and systems fault
requirements. Cables shall be selected in accordance with the application.
All ducts and covers shall be sealed after installation of cables. Where cables pass
through openings in walls for direct burial in ground, the outside of the seal shall be
made watertight by application of an accepted paint or sealing compound before the
cable trench is closed.
No intermediate joints will be allowed in any length of cable without approval of the
Project Manager in each case.
Single core cables shall be earthed at both ends unless specific requirements dictate
single point earthing.
Special cable types that may be required for thermocouple leads, high
temperature/high flexibility applications shall be covered by the system specification.
Cables shall be terminated at each end by an approved metal type mechanical
compression gland that is resistant to corrosion; the conductors shall be connected
by means of approved cable lugs. Glands shall be supplied complete with boot.
The insulation of each conductor shall be identified throughout its length either by
colour or embossed numbers.
Each cable shall be identified by means of indelibly marked identification labels
securely fixed adjacent to the cable gland at each end of the cable. The labels shall
be metal type, resistant to corrosion and mechanical damage. Cable labels shall be
fixed to cables as follows:
one label inside a floor mounted cubicle, switchboard, etc., visible through open
door and
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LOT D
one label below the cubicle, switchboard, etc., to permit identification of the cable
from below the fire barrier or other seal of the floor opening above which the
board is mounted and
one label at the cable entry into the field mounted equipment. For cubicles with
top or side entry or where a cable enters an enclosure from an open run only one
tag just below the cable gland is required.
Cable sheaths shall be embossed with metre marks, voltage rating, cross sectional
area and insulation type.
The drilling of gland plates, supply and fitting of compression glands and connecting
up of power cables shall be carried out under this contract.
All cables and cable accessories shall be provided with appropriate certification and
documents.
2.5.11 Labelling
All Plant shall be provided with a main label, the style of lettering shall be to the
acceptance of the Project Manager.
All compartments and components such as relays, fuses, switches, terminal and test
blocks and other devices shall have identifying labels relating to the schematic or
wiring diagram references.
Refer to E-2-C31 General Technical Specification for further details regarding labels.
2.6
CALCULATION AND DRAWINGS REQUIREMENTS
2.6.1
General
The Contractor shall submit a P&ID and Flow diagrams to show each air handling
unit, ventilation, smoke extract, cooling water and chilled water system.
The Contractor shall submit the computer simulated chilled water pipe work design,
especially, when the variable flow water system is offered. The simulation shall
include for hydraulic analysis from max. to minimum flow.
The Contractor shall submit detailed plans, elevations and sections to show all air
conditioning and ventilation systems clearly.
Plant areas shall be prepared to a larger scale than the system layouts.
The Contractor shall provide all information, operation and control philosophy,
calculations and system studies supported by plant layouts, ductwork layout
drawings, equipment drawings, cabling schedules and technical data sheets for
acceptance by the Project Manager.
The preparation of the detailed drawings and design shall only follow once the Project
Manager has accepted the preliminary design.
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2.6.2
LOT D
Air conditioning and ventilation

Air systems
2.6.2.1
The design and report shall include, but not be limited to all the parameters and
requirements described as follow;
Utilising the heat release values for the installed station equipment
Heat release values for all sundry heat loads, e.g. rock heat gain, lighting
gains and any other heat loads
Airflow and pressure calculations for selection of the fresh air fans
Airflow and pressure calculations for selection of all air handling units
Airflow and pressure calculations for selection of all extract fans throughout
the station
Airflow and pressure calculations for selection of the main smoke extract fans
Pressure loss calculations through tunnels and ducting systems with all
alternative modes of fresh air fan operation
Duct sizing calculations
Calculation of cooling coil design loads based on, the summer design
conditions with maximum heat release from station plant, equipment and all
other operating heat gains and a summer design conditions with the station plant
off. It shall include a winter design conditions with maximum heat release from
station plant, equipment and all other operating heat gains and a winter design
conditions with station plant off. Each coil load to be itemised into the elemental
loads that make up the total.
Air filter technical details
Fan selection and technical details
Cooling coil technical details
Air handling unit technical details
Performance details of all supply and return air grilles
Thermal insulation technical details
Study of Tunnel fresh air distribution system
Study of station air flow balance in normal ventilation mode
Study of airflow balance in natural ventilation mode
Study of jet fans in the Exploratory tunnel, if deemed necessary.
2.6.2.2
Study of materials and protective finishes provided for air handling Plant,
ancillary equipment and ductwork
Water systems
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Chiller selection and technical details
Pump selection and technical details including variable speed drive
Study for selection of chilled water design flow and return temperatures
Study for selection of cooling water design flow and return temperatures
LOT D
Chilled water and cooling water pipe sizing calculations (computerised design
for variable flow system)
Chilled water and cooling water pipe expansion calculations
Chilled water control valve selection and technical details
Buffer tank sizing calculations and technical details
Calculations for sizing of feed and expansion tank or alternative mini pressure
set
Thermal insulation technical details
Study of materials and protective finishes provided for Plant, equipment,

pipework and ancillary components
Refrigerant system
2.6.2.3
2.6.3
Calculations for sizing of refrigerant recovery tank
Technical details of refrigerant leak detection system

In addition to the calculations and equipment details required above, a Fire and
Smoke report shall be provided, identifying all types of fire risks and areas in the
station.
The report shall include the highest fire risk and required airflow on which the smoke
extract fans will be sized and the station smoke airflow balance for a fire condition.
The smoke extract calculations for all areas which have a fire risk, the formulae and
methodology on which the calculations have been based, and supporting drawings
detailing the risk areas shall be documented.
2.6.4
Noise control
The Contractors installation shall comply with the noise level detailed in the
Schedules.
A study shall be provided to determine the noise level in each of the following areas;
In a fresh air plant room with fans working but no sound attenuation
In a fresh air plant room with fans working and sound attenuation
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LOT D
In the tunnel area immediately adjacent to the plant room discharge grilles
In the smoke ventilation plant room with fans working but no sound
attenuation
In the smoke ventilation plant room with fans working but no sound
attenuation
In the smoke ventilation plant room with fans working and sound attenuation
In the Control block rooms with sound attenuation
In all other areas where fans will be operating with sound attenuation
At each air handling unit with sound attenuation
In the chiller plant room
In the Machine hall areas
In the Transformer hall
In the Exploratory tunnel in the vicinity of jet fans
The noise calculations for a fresh air plant room shall include the noise from fans
operating in the nearest adjacent fresh air plant room. The calculations for the
Machine hall, Transformer hall and all other areas shall be based on the station plant
not being in operation.
2.7
TESTING AND COMMISSIONING
2.7.1
General
Testing and commissioning shall be carried out in accordance with recognised
Codes, Standards and procedures.
Closed and open circuit shall be considered to control temperature and quality of
water.
All systems shall be tested and commissioned by competent personnel familiar with
all aspects of commissioning large HVAC plant and systems.
The details of such personnel and their experience shall be submitted to the Project
Manager for acceptance.
A Testing and Commissioning document, including a detail program shall be
submitted by the Contractor for acceptance by the Project Manager. All aspects of
testing and commissioning shall be discussed and agreed with the Project Manager
before the testing and commissioning commences. The Contractor shall declare any
special requirements to facilitate the work. The Contractor shall give adequate notice
of date and times when tests and commissioning will commence.
All the tests, commissioning and results obtained shall be witnessed by the
Supervisor. Copies of signed test certificates as indicated in the Schedules shall be
issued to the Project Manager.
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LOT D
Test and commissioning results shall be included in the Operating and Maintenance
manuals.
Water and electricity for testing and commissioning shall be provided by the
Employer, but the Contractor shall be responsible for all temporary water and
electricity connections needed during construction of the works.
The Contractor shall provide all scaffolding or other systems for access to high level
areas during testing and commissioning
The commissioning of the systems is likely to occur when there is a low heat load
within the Station and the outdoor air temperature is not at the summer design value.
Consequently the systems will not be operating at their design cooling capacity which
shall be verified at or near design load conditions.
To verify that the systems are operating at their design cooling capacity the
Contractor shall return to site at a later stage to measure and record the air
conditioning and ventilation system performance. The recorded results shall be
documented and reviewed with the Project Manager.
In the event that the cooling capacities of the systems are not being achieved the
Contractor shall advise what remedial measures will be taken. The Project Manager
shall direct when this shall be carried out.
The Contractor shall allow for the above mentioned work to be done without affecting
the Guarantee period at the Contractors cost. .
2.7.2
Air conditioning and ventilation

The final commissioning results shall be measured and recorded when all HVAC
systems and the fresh air fan systems are in operation.
The results to be provided with all combinations of any two fresh air plant rooms in
operation.
Commissioning of the Control block and Workshop air conditioning systems shall be
done with simulated design heat loads by means of electrical room heaters.
2.7.3

The final commissioning results shall be measured for every ventilation scenario
according to which fire zone is active.
2.7.4
Chilled water systems

The Chillers shall be commissioned by the Contractors engineer.
All the pipework systems shall be water pressure tested to 150% of the maximum
operating pressure.
Chillers, pumps and cooling coils shall be isolated by blank flanges during the water
pressure tests.
2.7.5
Cooling water systems

All the pipework systems shall be water pressure tested to 150% of the maximum
operating pressure.
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LOT D
The Chiller shall be isolated by blank flanges during the water pressure tests.
2.7.6
Refrigerant recovery system

The Contractor shall be advised by the chiller contractor on the requirements for site
testing of the pipework system.
2.7.7
Manufacturers test certificates

Factory test certificates shall be provided for all Plant and equipment
2.7.8
Operating and Maintenance manuals

The Contractor to hand over the numbers of copies stipulated in the Schedules on
completion of the contract.
All operation and maintenance documentations and drawings shall comply with the
requirements as indicated in the General technical specification and the Employers
documentation standards.
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PRELIMINARY DESIGN INFORMATION
3.1
DESIGN AMBIENT CONDITIONS
LOT D
The preliminary design executed by the Employer utilised an ambient state of 26.5
C (dry bulb) with a relative humidity of 53.25%.
3.2
NORMAL AND SMOKE VENTILATION SITUATION

For indicative details of air and smoke flow in different situations refer to drawing
0.83/25 043. The Contractor shall provide detailed documents of their design
philosophy for normal and smoke ventilation situations.
For indicative Airflow diagrams refer drawing nos. 0.83/25 042, 0.83/25 047 and
0.83/25 048 and layout drawings 0.83/60 001 to 0.83/60 008.
For Indicative Fresh Air Plant Rooms, Smoke Extract Plant Room, Chiller Plant Room
Layouts refer drawings 0.83/60 921, 0.83/60 922, 0.83/60 923 respectively.
3.3
REQUIREMENTS FOR MAXIMUM AIR FLOW INTO CAVERN

It is estimated that the 100m3/s fresh air quantity would be required. This quantity was
derived from 60m3/s normal vent exhaust which equals the smoke exhaust
requirement, 20 m3/s exhausts through ET for cooling of cables and 20 m 3/s exhaust
through MAT.
For details of air flow distribution through the cavern refer drawing 083/25 047. For
Details of air flow through various air handling Units refer drawing 0.83 /25 042.
3.4
HEAT LOADS
Table 3-1 Heat loads due to equipment and Lighting
Continuous Periodic Infrequent
Area
Load
Load
Load
(kW)
(kW)
(kW)
General Operating Floor Area
48.37
12.04
Western Workshop on Operating Floor
Western HVAC Plant Room on Op
Floor
Eastern Workshop on Operating Floor
Eastern HVAC Plant Room
Communications Room
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Lighting
Load (kW)
93.84
5.63
5.63
4.75
0.53
ESKOM
Continuous Periodic Infrequent

Load
Load
Load
(kW)
(kW)
(kW)
Area
Battery Room
Sewage Sump Area
Control Room
Office
Ablutions: Male
Ablutions: Female
Passage in Control block
Clean Oil Handling Area
General Western Generator Area
Western Generator Workshop and
Laboratory
Western Generator 380V House
Services Room
Busbar Tunnel # 3
Busbar Tunnel # 4
General Eastern Generator Area
Eastern 3,3 kV Switchgear Room
Busbar Tunnel # 1
Busbar Tunnel # 2
General Western Turbine Area
Western Turbine Workshop
Western Turbine Compressor Room
General Eastern Turbine Area
Eastern Turbine Compressor Room
General Drainage Gallery Area
Dirty Oil Handling Room
Pump Sump Area
Transformer hall cable gallery
Transformer No 1 Cubicle
SFC Input Transformer (Left) Cubicle
SFC Output Transformer (Right)
Cubicle
Station Transformer West Cubicle
Station Transformer East Cubicle
Transformer Hall Operating Floor Area
HVAC Chiller Plant Room
HVAC Switchgear Room
Mezzanine above Station Transformer
West
East
SFC Switchgear Room
Area to East on top of HVAC plant
Room
Transformer Hall Battery Floor and DC
Charger Room
Station Totals:
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LOT D
3.00
0.60
1.20
0.40
130.05
1.07
0.11
23.50
0.40
21.35
128.97
128.97
130.05
19.18
128.97
128.97
102.64
102.64
1.07
23.50
14.93
13.98
14.93
5.50
9.60
0.50
0.52
1.94
0.55
0.48
0.48
0.63
3.09
24.25
5.38
13.98
30.19
20.00
20.00
20.00
20.00
Lighting
Load (kW)
11.38
17.15
3.75
72.50
72.50
50.00
50.00
115.08
5.94
1.62
9.78
9.78
25.95
1.92
9.78
9.78
26.40
5.64
1.44
25.95
1.44
39.15
6.98
4.28
22.38
4.31
4.31
4.31
4.31
1.46
1.46
1.65
1.65
33.85
6.25
1.20
2.04
11.27
1.19
2.04
7.53
9.36
8.05
53.67
1474.68
12.68
82.83
17-Mar- 2009
236.43
447.57
ESKOM
LOT D
Due to the nature of work expected in the cavern the following information, as
presented by ASHRAE, was used to determine people heat loads.
Table 3-2 Heat loads as stipulated in ASHRAE documentation
Heat load contribution [W/person]
Type of work
Sensible
Latent
Seated at rest
67.4
35.2
Office Work
71.8
60.1
Sedentary Work
82.1
79.1
Medium Work
86.5
133.3
Hard Work
153.9
271.1
The following table shows people related heat loads for each area. Although the
number of people in a specific area is dynamic in nature the design needs to
incorporate the maximum allowance.
Table 3-3 Summary of people related heat loads
Area

Western HVAC Plant Room
Communications Room
Battery Room
Sewage Sump Area
Control Room
Office
Ablutions: Male
Ablutions: Female
Laboratory
Western Generator 380V House
Services Room
Busbar Tunnels
Pump Sump Area
Page 40 of 43
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Max No
of
people
ASHRAE
Work type
Latent
heat load
kW
kW
50
4
2
4
2
2
1
1
5
2
4
4
1
1
25
M
H
M
H
M
M
M
H
Office
Office
Office
Office
Office
M
50%M,50%H
6.665
1.084
0.267
1.084
0.267
0.267
0.133
0.271
0.300
0.120
0.240
0.240
0.060
0.133
5.055
4.325
0.616
0.173
0.616
0.173
0.173
0.087
0.154
0.360
0.144
0.288
0.288
0.072
0.087
3.006
1.084
0.616
0.267
0.173
25
2
5
25
3
2
25
2
1
1
1
1
50%M,50%H
M
M
50%M,50%H
H
M
50%M,50%H
M
M
M
M
M
5.055
0.267
0.667
5.055
0.813
0.267
5.055
0.267
0.133
0.133
0.133
0.133
3.006
0.173
0.433
3.006
0.462
0.173
3.006
0.173
0.087
0.087
0.087
0.087
17-Mar- 2009
Sensible
heat load
ESKOM
Area
SFC Output Transformer (Right)
Cubicle
West
East
SFC Switchgear Room
Room
Charger Room
LOT D
Max No
of
people
ASHRAE
Work type
Latent
heat load
kW
kW
10
10
10
10
5
M
M
M
M
M
1.333
1.333
1.333
1.333
0.667
0.865
0.865
0.865
0.865
0.433
0.667
0.433
5
5
5
2
1
M
M
M
M
M
0.667
0.667
0.667
0.267
0.133
0.433
0.433
0.433
0.173
0.087
0.267
0.173
0.267
0.173
0.667
0.433
0.400
0.260
0.400
0.260
Sensible
heat load
The following table summaries the anticipated heat loads in each area, incorporating
all the above calculated values
Table 3-4 Summary of Sensible and Latent heat loads in each area.
Area
Communications Room
Battery Room
Sewage Sump Area
Control Room
Office
Ablutions: Male
Ablutions: Female
Western HVAC Plant Room on Op Floor
Laboratory
Western Generator 380V House Services
Room
Busbar Tunnel # 3
Busbar Tunnel # 4
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0.27
0.13
0.27
0.30
0.12
0.24
0.24
0.06
1.08
0.27
5.06
0.70
0.59
0.67
6.50
1.69
0.77
0.77
0.70
6.25
5.80
181.87
Total
Area
heat load
kW
0.70
0.59
0.67
6.50
1.69
0.77
0.77
0.70
6.25
5.80
181.87
1.08
6.40
6.40
0.27
23.14
23.14
0.67
0.67
5.06
0.81
0.27
6.67
139.18
139.18
146.02
6.10
16.55
158.58
134.38
134.38
146.02
6.10
16.55
158.58
Latent heat
load
kW
Sensible
heat load
kW
17-Mar- 2009
AHU
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
3
3
3
4
ESKOM

Busbar Tunnel # 1
Busbar Tunnel # 2
Pump Sump Area
1.08
0.27
0.13
5.06
0.27
0.67
0.67
5.06
0.27
0.13
0.13
0.13
0.62
4.92
3.29
183.57
21.28
139.18
139.18
145.57
16.55
44.73
18.45
31.12
Total
Area
heat load
kW
0.62
4.92
3.29
183.57
21.28
134.38
134.38
145.57
16.55
44.73
18.45
31.12

SFC Output Transformer (Right) Cubicle
West
East
SFC Switchgear Room
Room
Charger Room
Station Totals:
0.13
1.33
1.33
1.33
1.33
0.67
0.67
0.67
0.67
0.67
0.27
0.13
56.41
25.18
25.18
25.18
25.18
74.39
74.39
52.08
52.08
34.28
121.50
7.23
56.54
26.51
26.51
26.51
26.51
75.06
75.06
52.75
52.75
34.95
121.77
7.36
0.27
2.21
2.48
0.27
13.48
13.75
0.67
9.16
9.82
0.40
17.67
18.07
0.40
66.61
67.01
48.58
2252.91
2301.49
Area
3.5
LOT D
Latent heat
load
kW
Sensible
heat load
kW
AHU
5
5
5
5
5
5
5
5
5
5
5
5
5
CHILLED WATER SYSTEM

For Indicative chilled water piping routes refer drawing 0.83/25 044 and for Chilled
Water Flow Diagram refer drawing 0.83/25 046.
The chilled water temperature supply to AHU used is 6C and for the return from AHU
is 12c. For the condenser cooling water temperature, refer to the site information
Book 4 for ambient conditions. The estimated maximum condenser cooling water
temperature used is 22 C. The estimated minimum condenser cooling water
temperature used is 10 C. For condenser water pressure refer to Book 4. For
Page 42 of 43
198763535.doc
17-Mar- 2009
4
4
4
6
6
6
6
7
7
7
7
7
5
5
5
5
ESKOM
LOT D
estimated Chillers capacity refer to section 3.6. The preferred refrigerant utilised for
the study is r134a
3.6
ESTIMATED COOLING CAPACITY, CHILLED WATER FLOW RATE ,

SUPPLY AIR , FRESH AIR FOR AIR HANDLING UNITS
AHU
Num
ber
Estimated
Cooling
Capacity
kW
1
2
3
4
5
6
7
Control Room Block AHU

Western Generator AHU
Western Turbine AHU
MH. Opp. Floor AHU
T/H. Opp. Floor AHU
Eastern Gen. Floor AHU
Eastern Turb. Floor AHU
Totals.
Page 43 of 43
198763535.doc
48
833
367
382
983
808
291
3712
Chilled
Water Flow
rate
kg/s at
increase
1.81
35.02
13.48
14.24
34.03
33.62
13.02
145.22
17-Mar- 2009
Supply
Air
Fresh
Air
m3/s
m3/s
1.6
31
12.4
12.8
39.18
30
10.8
1.6
11
12.4
6
33
11
6

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INGULA PUMPED STORAGE SCHEME

HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

INGULA PUMPED STORAGE SCHEME

2.5.2.5 Air distribution................................................................16

INGULA PUMPED STORAGE SCHEME

2.6.2.1 Air systems ....................................................................33

INGULA PUMPED STORAGE SCHEME

Supply sufficient filtered fresh air for ventilation requirements

Remove any dangerous gases and oil vapours

Control and remove hot smoke gases generated by fire.

Provide fresh air replacement where necessary.

Ventilation of all cavern areas.

Fresh air supply system.

INGULA PUMPED STORAGE SCHEME

Cooled air/recirculated air systems.

Main exhaust air systems.

Battery room extract system.

Ancillary rooms and other areas requiring ventilation systems.

Smoke removal systems

Control and Instrumentation

Control Cabling between switchgear and HVAC

Quality control and codification

Project Manager outline design information is included for reference by the

INGULA PUMPED STORAGE SCHEME

Outline of Detailed Designs

Cooling and ventilation capacities

Chiller unit capacities

Air handling unit and fan capacities

Smoke fan and system capacities

Noise levels from chillers, pumps and fans

Noise control proposals

Control philosophies for all systems

Plant room space requirements

Identify and provide remedial measures to remove dangerous gases and

Identify heat and moisture loads.

Provide material selection and corrosion prevention measures.

Any special requirements

INGULA PUMPED STORAGE SCHEME

Works Information Technical Specification

Works Information Technical Data Sheets

Scheme technical particulars such as station floor elevations and number of

Nominal technical data consisting of data that may be affected by detailed

INGULA PUMPED STORAGE SCHEME

TECHNICAL STANDARDS AND REGULATIONS

Quality requirements for engineering and construction works

Standard for Switchgear and associated plant for voltages

Battery rooms standard

Occupational Health and Safety Act

Standardized specification for civil engineering construction

SANS 60079 part 15

Electrical apparatus for explosive gas atmosphere

The classification of hazardous locations and the selection of

Installation, testing and balancing of air-conditioning ducting

Air conditioning ductwork

Filters used in air conditioning and general ventilation

Standard test method of filters

Thermal environmental condition for human occupancy

American Society of Heating Refrigeration and Air

Safety Codes for mechanical refrigeration

HVAC PLANT AND PARTICULAR REQUIREMENTS

INGULA PUMPED STORAGE SCHEME

Fresh air Plants to be located at east end of machine hall.