AFRICA EQUIPMENT & ENGINEERING, S.A.

BRIEF WORK DESCRIPTION

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 AFRICA EQUIPMENT & ENGINEERING, S.A.

WORK DESCRIPTION

1. - OVER HEAD TRANSMISSION LINE (DANI)

2. - WORK DESCRIPTION – KUTUS SUBSTATION

Substation description
The 132/33 kV substation will be located at Kutus. The new substation is being
constructed with the intention of reinforcing the Mt. Kenya North System.

Substation configuration:

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- Two 132 kV incoming bays.

- One single 132 kV bus section.
- Two 132/33 kV, 23 MVA Transformer bays.
- Single bus bar arrangement and bus section.(33kV)
- Six 33 KV outgoing feeders.
- Two 33 KV fused isolator feeder for auxiliary service supply

Auxiliary system
AC System
Auxiliary system will consist of TWO (2) 100 kVA 33/0.4KV station transformers
that supplies through an AC Distribution Board.

DC System
DC supplies shall be provides by a double 125 DC battery and charger with his
corresponding DC Distribution Panel. A double 48V DC and charger will be also
supplied.

Control and protection system

The integrated protection and control system (substation automation system
SAS) will be installed. Space provision will be taken into account for future bays.
For data processing and communication facility, new IEC61850 protocol shall be
used. Protections shall be latest on numerical technology.

Other Works
Access road, internal road, exterior, interior lighting as air conditioning is part of
substation design.
Special attention shall be given to environment.

PROJECT ORGANISATION
AEE project organisation will be as follows:

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In Spain (Madrid) a department for technical support will be created for, project
management, overseas purchasing, carrying out preliminary and final
engineering, preparing staff to be sent to job site etc.
This team will consist of a General Project Manager, Technical Manager,
Administrative Manager and an Engineering team.
The Engineering team will be responsible for definition and development of
project in terms of technical characteristics, safety, environmental requirements
etc. According to activities this teams will be organised and distributed in
electrical, electromechanical, civil, HSE (Health, Safety and Environment), etc.
All documents generated by engineering will be sent to client for approval. Once
the materials and the equipment have been approved by Client, purchasing of
equipment will take place.
The engineering team will be made up of people with appropriate educational
level and experience in similar projects in Africa.
In KENIA the project will be organised in the following way:
A general project office with the following structure will be installed, made up of
expatriate and local people.
- Local Manager
- Planning & Controller Manager
- Financial Responsible
- Engineering Responsible
- Warehouse Responsible
- Civil Works Supervisor
- Erection Supervisor
- Control & Protection Responsible
- Health & Safety & Environmental
- Quality Responsible
- Materials & Local Transport Responsible.

ORGANISATION – MATERIALS, EQUIPMENT AND SUPPLIES

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The proposed materials and equipment shall be analysed and sent for approval
to customer, with the specifications of each one and documentation of the
possible supplier.
Materials and equipment have to match on the whole with ones in the proposal.
If costumer is interested in new supplier or suppliers, the relevant
documentation will be presented in order to be approved.
Suppliers will participate in the transport of the materials from their country of
origin to the warehouse.
To carry out all transport steps, the project execution structure will consider one
logistic team, of which the larger part will be located in Spain and the rest in the
AEE´s offices at site.
After arrival of materials at warehouse, these will be classified and organised for
their correct distribution for substation or line work.

ORGANISATION OF ENGINEERING TEAM

As previously mentioned, preliminary and definitive engineering will be carried
out in Spain. Some engineering will be complemented by engineers located at
site. These personnel will be in charge of presenting all documents to client and
carrying out all of the small changes, transmitting them for execution and to the
central engineering department:
For greater agility in the execution of these tasks, all small engineering tasks
arriving from unforeseen situations at site will be carried out by local engineers
and supervised by the Client.

WORK ORGANISATION
The project execution organisation shall have two separated team
• Kutus Substation
• Transmission lines

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AEE QUALITY MANAGEMENT SYSTEM

The ISO standards are the leading European quality certifications that are
Awarded to organisations that rigorously adopt Quality Control and
Improvement processes that ensure optimum service and output quality is
Delivered to clients.

AEE´s Quality Policy constitutes a cornerstone of our Management Quality

System (QMS). Independent of projects, AEE’s programme ensures that
our processes are followed and best practices applied.
AEE has established a structure to document and implement
Methodologies so as to organize; control and direct resources to ensure
Effectiveness operation control of identified processes and continually improves
Its effectiveness. This ensures that products and services of the Company are
produced to define requirement and help to achieve organizational policy &
objectives.
The adoption of the QMS described in this manual is strategic to the interest
and emphasised that this manual is mandatory for all the employees of the Unit
towards commitment and adherence of applicable requirements.
WORK METHODOLOGY

GENERAL
Work method statements, procedures or work instructions, can assist relevant
people to consider how certain activities will be carried out safely and will be
issued once project starts.

A relevant person doing construction work needs to prepare a work method

statement for high-risk activities including, but not limited to:

• where a person is –
o to enter a trench more than 1.5 meters deep
o using explosives
o using a confined space
o using a hazardous substance
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• if a person could fall–

o at least 3 meters for housing construction work, or
o at least 2 meters for other construction work
• working on a roof with a pitch greater than 26°
• where the principal contractor concludes an activity could
result in death or bodily harm
• demolition work or asbestos removal work

A work method statement is also required for high-risk activities which include:

• tilt-up and precast construction work

• structural alterations that require temporary support to
prevent collapse
• moving powered mobile plant at the workplace
• working on a telecommunications tower
• working in, over or adjacent to water where there is a risk of
drowning
• working on, or adjacent to, a road or railway
• working on or near a pressurized gas distribution mains and
consumer piping
• working on or near a chemical, fuel or refrigerant line
• work near an exposed energized electrical installation
• work in an area that may have a contaminated or flammable
atmosphere
• Work in an area where there are artificial extremes of
temperature.

The work method statement must take into account the principal contractor’s
construction safety plan and also state:

• the high-risk construction activity

• the control measures to be used
• the way the activity will be performed
• how the control measures will be monitored and reviewed
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• Any relevant prescribed occupations.

For demolition work and asbestos removal work the work method statement
must also state:

• the relevant certificate number

• the arrangements for appropriate training and supervision

Work method statements must be easy to understand, signed and dated.

The work method statement must be amended if there is a change in the

activity and a copy must be given to the principal contractor. All people affected
by changes must be advised of amendments to the work method statement.

The work method statement must be readily available for inspection. It must
also be reviewed each year and amended if necessary.

PURPOSE.

The purpose of this document will be to summarize the Methodology of Work

that AEE will implement for the Project. It is intended as a guide.

To ensure continuing suitability and effectiveness, to meet quality system

requirement, this document may be modified from time to time.

Engineering development, procurement and construction will be based on

documents mentioned in point 3.0 References.

Using the Work Program as a guide, and following directions on documents in

reference, for each stage of project, will insure that same will be completed on
schedule, with due quality and on budget.

REFERENCES (TO BE PREPARED ONCE PROJECT STARTS)

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2.1 SITE MANAGEMENT PROCEDURES

2.2 WORK INSTRUCTIONS

2.3 QUALITY PLAN

2.4 QUALITY ASSURANCE PLAN

2.5 ENVIROLMENTAL MANAGEMENT PLAN

2.6 HSES MANAGEMENT PLAN

DOCUMENTATION MANAGEMENT SYSTEM

AEE, as contractor obligations with regards to preparation and submission of

drawings, calculations, samples, patterns etc shall be stated in Contract.

AEE shall prepare and submit to the Project manager for approval, dimensioned
general and detailed design drawings and other pertinent information of all
plant and equipment specified in BID document.
Approval of drawings shall not relieve AEE of his obligations to supply the plant
in accordance with specifications. AEE will be responsible of any error appear in
drawings and as soon as detected will deliver the correct documentation.
All documents shall be in English. Dimensions will be in millimetres.
The list of documents that shall be presented and be updated whenever
needed. The list of documentations shall include the date of original issue of
each document submitted as well as the dates of revision. The list of
documentation shall also include a time schedule for each submittal of
documentation.
Symbols used for electrical equipment shall be in accordance of IEC60617.The
coherent system for physical and functional reference shall be designed in
accordance with IEC61346.A similar systematic scheme shall be defined for
cable numeration.TheseSchemes shall be used throughout on the drawings and
documentations and designation shall be labelled on the components and
cables.
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The sizes of all documents and drawings shall conform to the ISO standard.
(A1,A2,A3,A4) The sizes larger than A1 shall be avoided.
The schematic diagrams and apparatus and cable list shall be of size A4 except
for the Original and possible transparency copies of schematic diagrams that
shall be inA3.Scales that shall be used in drawings shall be 1:10, 1:20, 1:40, 1:
50 and multiples of this series.
All drawings made special for this project including civil work, mechanical
drawings, layout drawings and circuit drawings shall be compiled on computer
aided design and as part of as built drawings shall be handed over on CD with
format readable in AUTOCAD version or in other format to be agreed upon in
addition to the paper copies.
The drawings shall show the dimensions, main working principles, internal
components and fixing methods to a detailed level allowing the employer to
evaluate the functionality and completeness of the plant and equipment.

Engineering Coordination
An Engineering Coordinator will be assigned to :
1. Checking survey result and documents prepared by engineering
department.
2. Verifying the supplier documents with respect to contract specifications.
3. Verifying the suitability of the equipment proposed in specifications.
4. Checking structure design calculation.
5. Verifying foundation designs for various equipment foundations.
6. Integrating control and protection features along with existing substation
system.
7. Checking electrical schematic drawings for control and protection panel,
Substation management system and 33kV switchgear panel.
Completing “As Built" Documentation on completion of commissioning work.

CIVIL WORKS
Before starting civil works in the new Substations, a detailed investigation of the
soil conditions will be carried out. The soil investigation will be carried out in
accordance with BS 5930, IEEE 80 or other approved standard.
These studies have will cover all parameters needed for appropriate design of
civil works (foundations, pits, buildings, drainage) as well as the earthing grid.
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For tendering purposes (quotation) it has been considered a normal ground (soil
resistance 1.5 – 2 kg/m2).
Likewise a ground resistivity of 30 Ohm-metre has been assumed.
Prior to excavation the topography team will mark the exact place for the
excavation. The excavation of the land will depend upon the data obtained from
the geotechnical studies and the depth necessary for excavation or filled; it
should be done in order to obtain land level which is required by previously
done studies.
The necessary team for the carrying out of the excavation work will be made up
of:
1 foreman
2 workers (excavator support)
1 operator (bulldozer)
Equipped with:
- Bulldozer
- Small tools (spades, picks, etc)
The next phase of the excavation will be the earthworks — the levelling of the
land and the redesign of the axes of the switchyard with the help of the
topography.

Earthing System
According to the data obtained for the soil conductivity and the later
calculations, the earth conductor will be buried. An approximate depth of 60 –
80 cm below the level of switchyard and an external distance of 1m from the
fence has been considered
The conductor will be laid together with the pile-driving of the rods for the
formation of the earthing mesh. Thermo welded joints will be used for the
buried grid. Connections between exposed earth conductors shall be made
using

Crimping terminals. Connections to the earth terminals shall be made using a

bolted connection.

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On completion of installation, the following tests shall be performed:

Earth resistance test, voltage gradient test, step voltage test and touch voltage
test.
The necessary team, for carrying out of the work is made up of:
1 foreman
2 specialist Technicians
2 unskilled workers
1 operator (Backhoe)
Equipped with:
- Backhoe
- Small tools (spades, picks, etc)

Drainage System
The drainage system of S/S shall be done according to approved design of
drainage. A drainage pipe will be placed for the sub-soil as well as storm
drainage for the switchyard.
After digging has been carried out the following step should be the filling of the
ditches with earth left over from the excavation and it compacting.
In order to prevent flow of water into the buildings, cable trenches shall be
sloped and drained away.
The necessary for carrying out of drainage works is made up of:
1 foreman
2 specialist technicians
3 unskilled workers
1 operator (backhoe)
Equipped with:
- Backhoe
- Small tools (spades, picks, etc)

Control Building

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In parallel to above mentioned jobs will start building of the control building
according to dimensions and characteristics of the technical drawings and
specifications issued by KPCL.
The Control Building will be divided into the following compartments:
- Battery Room
- Kitchen
- Store room
- Telecommunications Room
- Relay and Control room
- Four offices
- Rest room
Also a gate guard house should be constructed in the Substation according to
tender drawing.
A potable water supply to buildings including an overhead water tank shall be
installed. Also a Sewerage system to drain foul water shall be designed.

Foundations Phase 1
According to the engineering plans and with support of the topography, the
exact positioning for the excavation of the foundations will be carried out.
The excavation will be carried out according to the volumes calculated by the
engineers, for the efforts of each type of structure. Further the formwork tasks
will be carried out. Once this work is completed the placing of the templates for
the positioning of anchor bolts for the holding of the metallic structures will be
carried out. After fixing anchor bolts in the exact position the work will be
moved to the pouring and spreading of concrete for the formation of the
foundations.

Transformer foundations
The transformer foundations will be constructed in reinforced concrete.

Foundations Phase 2

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Once the metallic structure and the switchgear have been plumbed and
levelled, the following step is the filling of the concrete for the cementing of
phase 2.

Cable Trenches
At the same time to these jobs, the ditches for the building the channels for the
cable trenches in the switch yard will be dug.
The cable trenches will be of two types:
Primary Cable trench serving as the main cable collector to the control
building.
Secondary Cable trench normally feeding cables at right angles at the
primary trench.
Cable trenches will be of reinforced concrete, the trenches will be of different
size equal or less than 900 mm wide by 800 mm deep and 700 mm wide by 500
mm deep for primary and secondary trenches respectively.
All cable trenches will be provided with removable, suitably sized galvanized
steel chequered cover plates.
Pits and manholes in driveways shall he provided with heavy-duty cast iron
covers.
The type of cable trenches and dimensions shall be dimensioned on base of
quantity and their separation in particular trench.
The necessary team for the carrying out of the foundations cable trenches
works will be:
3 specialist technicians (form workers)
4 unskilled workers
1 operator (backhoe)
Equipped with:
- Backhoe
- Small tools (spades, picks, etc)

Fencing

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Around the outside of the switch yard of the new substation chain link fencing
will be built. AH framing and Bates consist of structural steel sections and the
wire for the fencing mesh will be plastic coated.
The earthing of fencing shall be studied as part of the earthing system.

Outdoor lighting
The lighting installation will be designed to achieve the specified levels of
illumination. The connection shall be as single phase, between phase and
neutral. All poles shall be connected to the main earth wire system by a
separate earth conductor.
Grave
Once the Switchyard works have been finished, a stone layer will be uniformly
spread over the finished surface of the platform, of a thickness around 100nun.
The stone will be hard and durable crushed rock with a maximum particle size
of 60.
The necessary team for the carrying out of the foundations, cable trenches and
gravel works will be made up of:
1 foreman
3 specialist technicians
3 assistants
Equipped with:
10 ton lorry crane
- Small tools

MOUNTING OF SUPPORT STRUCTURES

Depending upon the time taken by setting of foundation phase 1, the work will
proceed with raising, levelling and plumbing of the metallic structures and
gantries with their connections to the earthing system. Design and calculation
have to be approved previously the manufacturing.
For the raising of the structures we shall need one brigade made up of:
1 foreman
3 specialist technicians

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3 assistants
Equipped with:
10 Ton. Lorry crane
- Small tools

Electrical equipment erection

Outdoor-Once the metallic structures have been built; we shall progress to the
—plumbing of the electrical equipment open the structures.
The electrical equipment to be installed in the switchyard: circuit breakers,
disconnecting switches, voltage and current transformers, surge arresters etc.
Indoor- Erection of control, protection panels, telecommunication panels,
medium voltage cells, auxiliary service panels, lighting panels etc shall be done
fixing and levelling on the control building floor.

Cabling
Once the equipment is mounted in the switchyard and in the control building
(batteries, rectifier, auxiliary transformer, protection, control and
telecommunication equipment), the cabling and connecting will be carried out
with its corresponding labelling.
For the mounting of equipment and cabling we shall need one brigade for
substation made up of:
I foreman
4 specialist technicians
4 assistants
Equipped with:
10 ton lorry crane
- Small tools

Commissioning
Prior to taking over the Works or any section, the test on completion shall be
carrying out in presence of the Engineer.

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The tests will be done to all HV and LV equipment, with calculated set values for
protections, telecommunications and all other equipment that require set
parameter.
For commissioning we shall need:
1 Commissioning engineer
2 Assistants

Manuals for operation and maintenance:

AEE shall deliver manuals for operation and maintenance. These will contain,
but not limited to:
-Detailed description of all equipment. Individual components, relevant
clearances, tolerances, allowable temperature, settings etc.
-Detailed of main principles including flow diagrams, single line diagrams,
circuit diagrams, connection diagrams.
-Operation instructione.These shall illustrate operational sequences in a clear
and concise way.
-Test and adjustment procedures containing instruction for test and adjustment
of the equipment under operation, after inspection and maintenance

The documentation shall leave the operators and maintenance personnel in

position to operate the plant in safe and optimal way and to perform repairs
usual to be done by such personal. CLIENT has to approve the manuals before
final submission.

Management Commitment Statement

The organization is committed to provide all its services corresponding to the
customer’s requirement and all necessary measures to keep quality conformity
to international standard.

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