Engineering, procurement and construction of the witbank depot fire system up...

REV DATE BY CHK DESCRIPTION HW FIRE As indicated BJ BJ - - A 2026-02-18 HS BJ ISSUED FOR ACCEPTANCE RESP. ENG TRANSNET PIPELINES WITBANK DRAWN REF. - -

• • Traced date proj. Manager hw fire cad file: design-drawn: date:

Ho1436-tpl_2024_09_0008 - checked approved - hs 2025-11-21 - _77334_rfp-fat-0001 hs - - client title:

SCALE - - GREYJONES (PTY) LTD. ROLE NAME SIGN DATE SECTION VIEWS ON PUMP HOUSE AND WATER PROJECT No: DRAWING No: REV: - - TPL DRAWING No. REV

• • Tanks 11364 11364-A1124 a    a1 drawing approval status - -

1 2 3 4 5 6 7 8 9 10 11 12

Drawing notes

1 all dimensions are shown in

Millimetres. 8285

A

870 860 804 326 556 860

B

4150

Pressure control valve

REV DATE BY CHK DESCRIPTION HW FIRE As indicated BJ BJ - - A 2026-02-18 HS BJ ISSUED FOR ACCEPTANCE RESP. ENG TRANSNET PIPELINES WITBANK DRAWN REF. - -

• • Traced date proj. Manager hw fire cad file: design-drawn: date:

Ho1436-tpl_2024_09_0008 - checked approved - hs 2025-11-21 - _77334_rfp-fat-0001 hs - - client title:

SCALE - - GREYJONES (PTY) LTD. ROLE NAME SIGN DATE SECTION VIEWS ON PUMP HOUSE AND WATER PROJECT No: DRAWING No: REV: - - TPL DRAWING No. REV

• • Tanks 11364 11364-A1124 a    a1 drawing approval status - -

1 2 3 4 5 6 7 8 9 10 11 12

Drawing notes

1 all dimensions are shown in

Millimetres. 8285

A

870 860 804 326 556 860

B

4150

Pressure control valve

{"briefingSession":"{"date":null,"time":null,"venue":"E PROJ. MANAGER HW FIRE CAD FILE: DESIGN-DRAWN: DATE","is_compulsory":false}"}

Rev date by chk description hw fire 1 : 200 ko bj - - a 09/10/25 bj ko issued for client review resp. Eng TRANSNET pipelines witbank drawn REF. - - b 22/10/25 bj ko updated as per site visit discussions

• • Traced date proj. Manager hw fire cad file: design-drawn: date:

Ho1436-tpl_2024_09_0008 - checked approved - ccad 2025-10-21 - _77334_rfp-fat-0001 ko - - client title:

SCALE - - GREYJONES (PTY) LTD. ROLE NAME SIGN DATE SITE LAYOUT - PART PLAN OF PUMP HOUSE PROJECT No: DRAWING No: REV: - - TPL DRAWING No. REV

• • And parking areas 11364 11364-A1046 b    n/a a1 drawing approval status - - n/a

1 2 3 4 5 6 7 8 9 10 11 12

220m2 AREA TO BE SHELTER

Cont hardened (g-block

(Demo) paving) for parking

D

New 6 bay covered parking gate

New v-drain to falls to shelter existing discharge at (demo) boundary wall.

D NEW DIESEL SHED 310m2

18258

20ftCONTAINER

7718

1.5m BUILDING LINE 3000

3m BUILDING LINE

{"name":null,"email":null,"phone":"000 1533000","department":null,"address":null}

REV DATE BY CHK DESCRIPTION HW FIRE As indicated KO BJ - - A 27/8/25 KO BJ FOR INFTERNAL REVIEW RESP. ENG TRANSNET PIPELINES WITBANK DRAWN REF. - - B 10/9/25 KO BJ FOR CLIENT REVIEW

• • C 11/11/25 ko bj pump house reduced and repositioned traced date proj. Manager hw fire cad file: design-drawn: date:

Ho1436-tpl_2024_09_0008 - checked approved - ccad 2025-04-18 - _77334_rfp-fat-0001 ko - - client title:

SCALE - - GREYJONES (PTY) LTD. ROLE NAME SIGN DATE PUMP HOUSE - FOUNDATION LAYOUT PROJECT No: DRAWING No: REV: - - TPL DRAWING No. REV

• 11364 11364-A1113 c    - a1 drawing approval status - -

1 2 3 4 5 6 7 8 9 10 11 12

Ffl toc 150 1532300 150 1532300

1532300G 400 250 250

1000 250 250 400

T1 - typical wall thickening detail t2 - typical edge thickening section vbb

Scale: 1 : 20 scale: 1 : 20 scale: 1 : 50

H

Designer project: scale checked: approved: references revisions project name

DWG NUMBER DESCRIPTION REV DATE BY CHK DESCRIPTION HW FIRE As indicated KO BJ - - A 8/08/25 KO BJ FOR INTERNAL REVIEW RESP. ENG TRANSNET PIPELINES WITBANK DRAWN REF. - - B 10/09/25 KO BJ FOR CLIENT REVIEW

• • C 23/01/26 ko bj for tender traced date proj. Manager hw fire cad file: design-drawn: date:

Ho1436-tpl_2024_09_0008 - checked approved - ko 2025-04-18 - _77334_rfp-fat-0001 ko - - client title:

SCALE - - GREYJONES (PTY) LTD. ROLE NAME SIGN DATE VALVE BANK TYPICAL DETAILS PROJECT No: DRAWING No: REV: - - TPL DRAWING No. REV

• 11364 11364-A1118 c    - a1 drawing approval status - -

1 2 3 4 5 6 7 8 9 10 11 12

A

Kliplok 700 aluminum sheeting

Osb

A1119 hdg diamond

Lightweight kliplok 700 aluminum sheeting

Scale: 1 : 50 scale: 1 : 50 scale: 1 : 50

H

Designer project: scale checked: approved: references revisions project name

Dwg number description rev date by chk description hw fire 1 : 50 ko bj - - a 29/08/25 ko bj for internal review resp. Eng TRANSNET pipelines witbank drawn REF. - - b 10/09/25 ko bj for client review

• • Traced date proj. Manager hw fire cad file: design-drawn: date:

Ho1436-tpl_2024_09_0008 - checked approved - ko 2025-04-18 - _77334_rfp-fat-0001 ko - - client title:

SCALE - - GREYJONES (PTY) LTD. ROLE NAME SIGN DATE DIESEL & OIL STORE SHED - TYPICAL DETAILS PROJECT No: DRAWING No: REV: - - TPL DRAWING No. REV

• 11364 11364-A1119 b    - a1 drawing approval status - -

1 2 3 4 5 6 7 8 9 10 11 12

A

100mm THICK MESH REINFORCED

Apron slab to min 1-100 falls

30.00°

C

Rc ring beam 2750 30.00° 10240 ø

3250 shell tank wta wta wta ø10240

A1121 a1121 a1121

Rc pile cap 2000

{"closingDate":"17 February 2026"}

5.5.3 AUTO / TEST Functionality ............................................................................................. 25

5.8 Quality Assurance .................................

5.8 Quality Assurance .................................................................................................................. 41

5.8.1 Quality Control Plan (QCP) ............................................................................................. 41

The fire control system is for the protection of a fuel storage depot with various fuel handling areas

which require fire protection.

This document defines the Works Information for the design, procurement, supply, manufacture, testing,

delivery to site, installation, commissioning and handover documentation of a control system,

instrumentation and associated equipment and materials such as cabling, trunking, instruments, and

local and remote-control panels required to control the fire protection system.

Key components of the control system are:

 Fire Control Panel (FCP)

o Controller

o Main operator interface

o Mimic display

 FCP battery backup power supply system

 First responder panel, located in the pump house

 Two repeater first responder panels, one in the operations control room and one in the security

office

 Control valves (supplied by others)

 Field mounted start stations (FMSS)

 Tank level sensors

 Externally mounted visual and audible alarms at the control room, the security office and the

pump house

 Interface to engine control panels (ECP’s) (supplied by others)

 Interface to jockey pump control panel (JPCP) (supplied by others)

 Interface to the site process control system (existing)

 Provision for interface to the NOC (National Operating Centre)

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2 acronyms

The following acronyms apply when reading this specification;

AC Alternating Current

AIA Approved Inspection Authority

API American Petroleum Institute

DB Distribution Board

DC Direct Current

ECM Engine Control Module

ECP Engine Control Panel

FAT Factory Acceptance Test

Fire Control Panel: Stand-alone unit used to control the overall fire system including

Fcp

the starting of the ECP’s

FIFO First in first out

FMSS Field mounted start station

IA Independent Authority

I/O Input Output

IP Ingress Protection

JPCP Jockey Pump Control Panel

LED Light emitting diode

NEC New Engineering Contract – Form of Contract applicable to this project

NFPA National Fire Protection Association

NOC TPL National Operating Centre

OEM Original Equipment Manufacturer

P&ID Process and Instrumentation Diagram

PLC Programmable Logic Controller

QCP Quality Control Plan

SANS South African National Standard

SABS South African Bureau of Standards

SLD Single Line Diagram

TPL Transnet Pipelines

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3 definitions

The following definitions shall apply when reading this specification;

Term Definition

Cold commissioning shall be witnessed by the Employer and shall include

Cold

functional tests to confirm the control logic. Cold commissioning is conducted

Commissioning

without product.

Command The transmission of a signal to initiate an action.

Contractor Contractor means the Contractor in terms of the NEC construction contract

Controller The master relay based logic controller housed within the Fire Control Panel.

Employer Employer means the Employer in terms of the Contractors NEC contract

Event The transmission of a signal indicating an action has taken place.

Engine Control Deep Sea Electronics (DSE) module or approved equivalent fitted within the

Module (ECM) ECP and used to control the diesel engine

Control panel for starting, control and operation of each engine driven fire

Engine Control pump, incorporating an operator interface, gauges and alarms and the engine

Panel (ECP) controller. Each pump-set will be fitted with a dedicated ECP interfaced to the

Fcp.

Field mounted These are push buttons located behind a break glass and are field mounted in

start stations locations where it is likely that there will be operators whenever a fire occurs in

(FMSS) these areas.

Fire Control Panel including the Controller, main operator interface and the indication mimic

Panel (FCP)

For this document, first responders will be considered the personnel on site

First responders

who are required to activate the protection system before evacuating.

First Responder First responder interface with the Controller for activation and deactivation of

Panel (FRP) scenarios with only one scenario permitted to be selected at a time.

Hot commissioning shall be witnessed by the Employer and shall include

Hot

operational tests to confirm system functionality and performance. Hot

Commissioning

commissioning is conducted with product.

Operator interface with the control system consisting of labelled buttons,

Main Operator

indicator lights and other indicators which allow the activation and deactivation

Interface

of individual protection systems with no limitations.

Jockey Pump Panel for the starting of the jockey pump. The JPCP is interfaced to the FCP.

Control Panel

(Jpcp)

Pre-commissioning shall be performed and signed off by the Contractor prior

Pre

to presentation of the system for cold commissioning. Pre-commissioning

Commissioning

includes installation verification and deenergized testing.

Repeater First A copy of the First Responder Panel, located in an alternate location to allow

Responder Panel multiple operator control locations.

A scenario is a specific fire event, e.g. tank bund fire, for which fire protection

Scenario (Fire)

system requirements can be predetermined.

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Control system for the process control of the fuel handling; tanks, pumping,

Site Process valves etc.

Control System

Separate to the fire control system.

Part of the fire protection, dedicated to the protection of one area of the site

System and supplied with water or premix through a single pressure regulating deluge

valve.

Note: words are capitalised when meeting these definitions

4 engineering standards

Although not bound in nor issued with this document, the following standardized specifications shall

form part of the contract document:

4.1 Applicable Standards

The installation, inspection and maintenance of equipment used in

SANS 10086-1 explosive atmospheres

Part 1: Installations including surface installations on mines

The petroleum industry - Part 1: Storage and distribution of petroleum

SANS 10089-1

products in above-ground bulk installations

The petroleum industry - Part 2: Electrical and other installations in the

SANS 10089-2

distribution and marketing sector

The classification of hazardous locations and the selection of equipment

SANS 10108

for use in such locations

Code of practice for design, installation, commissioning and maintenance

SANS 10139

of fire detection and alarm systems in non-domestic premises

The wiring of premises

SANS 10142-1

Part 1: Low-voltage installations

Fire detection and fire alarm systems - Part 3: Fire alarm devices -

SANS 50054-3

Sounders

SANS 50054-4 Fire detection and fire alarm systems - Part 4: Power supply equipment

SANS 50054-11 Fire detection and fire alarm systems - Part 11: Manual call points

Explosive atmospheres - Part 14: Electrical installations design, selection

SANS 60079-14

and erection

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4.2 Reference Standards

PL 100 Drawing Standards

PL 101 Plant & Equipment Tag Numbering Standards

PL 102 Equipment, Instrument & Electrical Symbology Standards

PL 103 General Drawing Standards

PL 631 Specification for Low Voltage Switchgear & Distribution Boards

PL 711 Specification for Equipment Cabinets to House Electronic Equipment

Specification for Cable, Racking, Trenching & Earthing Reticulation

Pl 727

Codes of Practice

PL 901 Fire Pump Specification

PL 908 Jockey Pump-set Specification

PL 916 ECP FCP control narrative

PL 917 Equipment Handover and Document Procedure (EHDP)

TPL-TECH-F-STD-001 Transnet Pipelines Technical Fire Protection Design Standard

TECH-DO-WI-001 Handover of As-built & other Docs

TECH-SOP-00x Shutdown Readiness

Hazardous area classification guidelines report for Transnet Pipelines

XPS/1015/13013

(TPL) infrastructure

5 control system and instrument specification

5.1 Fire Protection System Overview

The fire protection system includes a new pump house, water and diesel storage tanks outside the

pump house, foam concentrate storage, water and foam pumping and foam proportioning facilities

inside the pump house, and numerous Systems for the application of water or foam premix to fire zones.

There are two diesel engine pump sets (duty and standby), each with an ECP, diesel engine, water

pump and foam concentrate pump. Pressure will be maintained in the water system by a jockey pump

when not in use. The duty or standby diesel engine fire water pumps will be activated in the event of a

fire.

The water discharge from the supply system feeds water hydrants, water valve headers and foam

premix valve headers. There are take offs from the headers to the protection Systems; these have

solenoid actuated pressure regulating deluge valves which are controlled by the Controller.

There is an electrically actuated expanding plug valve on the foam concentrate feed line to the premix

system in the pump house.

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There are solenoid actuated pressure regulating deluge master valves in the tank top pourer headers.

Further detail is provided in the P&ID’s in the Works Information.

5.2 Control System Architecture

The principle of the fire protection system control is to have a centralised Controller managing all logic

and control functions.

The fire protection control system shall be based on hardwired relay logic only, the use of PLC’s will not

be accepted.

The Controller will receive command inputs from the main operator interface, the main and repeater

first responder panels and field mounted start stations (FMSS) if applicable and shall have provision to

receive command inputs from the NOC.

The Controller will receive event signals for indication, alarming and control from the ECPs, the jockey

pump control panel, the battery backup power supply system, the FMSS, the electrically actuated foam

concentrate valve and from the level sensors on the water and diesel storage tanks.

The Controller will provide command signals or outputs for activation and control of the various valves

within the system.

The Controller will provide command signals to start and stop the ECP’s as determined by the pump

start sequence logic described later in this document.

The Controller will provide event signals for indication of the system condition to the site’s process

control system and shall have provision for the future output of all event signals to the NOC.

The Controller will control the sirens and beacons.

The operator interface points are the main operator interface on the FCP, the three first responder

panels, the FMSS’s and the NOC. Operators can also override the individual engines from the

respective ECP’s.

The site-specific control system architecture is indicated on the EC&I Scope of Work Block Diagram

included in the Works Information.

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5.3 Battery Limits

The following items are included in the scope of works for this document:

 Fire control panel (FCP), including Controller, main operator interface and mimic display

 FCP Battery backup power supply system

 First responder panels

 Field mounted start stations (FMSS) (if applicable)

 Tank level sensors

 Externally mounted visual and audible alarms

 Interface to engine control panels (ECP’s)

 Interface to jockey pump control panel (JPCP)

 Interface to the site process control system

The following items are excluded from the scope of works for this document and will be provided for

elsewhere:

 Control valves

 Engine control panels (ECP’s)

 Jockey pump control panel (JPCP)

 Modification to, and terminations within, the site process control system

 Cable sleeves within the pump house

 Cable sleeves and draw boxes around the site

5.4 Control System Components

The fire control system shall comprise the following components:

1. FCP, including

 Controller

 Main operator interface

 Indicator mimic

2. Battery backup power supply (dual redundant).

3. First responder panel in the pump house

4. First responder repeater panels in operations control room and in the security office

5. FMSS (if applicable)

6. Fire alarm siren and beacons outside the pump house

7. Fire alarm sirens at valve banks

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8. Field equipment, including level switches for water and diesel tanks

9. Interface with site process operating system

10. Interface with NOC

Proposed layouts of the main panel and the first responder panels operator interfaces control system

architecture is indicated on the EC&I Scope of Work Block Diagram included in the Works Information.

The site-specific main operator interface, first responder operator interface and mimic panel layouts are

included in the Works Information.

The site-specific control system layout and proposed electrical and instrumentation cable routes are

included in the Works Information.

Each of the control system elements are described in detail below.

5.4.1 Controller

The Controller incorporates the relay and wiring arrangement which facilitates the logic operations of

the control system and processes the command inputs and outputs.

The Controller shall interface with the main operator panel, the first responder panels, the FMSS’s, the

ECP’s, jockey pump control panel, the NOC and the process control system, and shall facilitate all logic

operations including the activation and interlocking of multiple Systems in line with the cause-and-effect

matrix.

The Controller, the main operator interface and the indicator mimic from the FCP shall be located in the

pump house, along with a first responder panel which must be separate from the FCP.

5.4.1.1 NOC Interface

The Controller shall have provision for interfacing with the NOC system. This provision shall include:

 600mm x 400mm free space the full depth of the panel for the installation of the future signal

interface system

 Terminal connection points for input and output signals

 Sufficient trunking for wiring between the free space and the terminals.

NOC interfaces shall be via potential free contacts in the FCP. It shall be possible to activate and

deactivate all Scenarios from the NOC, overriding first responder panel activations but not main

operator panel activations.

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The Controller shall be provided with terminals for future connection to the NOC are as follows:

 Input from NOC for the starting of all Scenarios. These shall be interlocked so that only one

Scenario can be activated at a time.

 Input from NOC to reset all Scenario activations initiated from the first responder panels or the

NOC. This input shall also cause the top pourer master valve to close.

 Input from NOC for the control of the top pourer master valves

o Open

 Output to NOC to indicate all Scenario activations and system conditions.

o Which Scenarios are activated

o Status of foam valve

o Status of top pourer master valve

 Output to NOC to indicate which panel is the current system master:

o MAIN PANEL ACTIVE

o NOC ACTIVE

o FIRST RESPONDER PANEL # ACTIVE (a signal for each panel)

 Output to NOC to indicate all conditions reported on the main operator interface including:

o POWER SUPPLY FAULT

o CIRCUIT BREAKER FAULT

o WATER TANK 1 LOW

o WATER TANK 1 LOW LOW

o WATER TANK 2 LOW

o WATER TANK 2 LOW LOW

o DIESEL TANK 1 LOW

o DIESEL TANK 1 LOW LOW

o DIESEL TANK 2 LOW

o DIESEL TANK 2 LOW LOW

o JOCKEY PUMP RUNNING

o JOCKEY PUMP FAILURE

o JOCKEY PUMP ALARM

o FIRE PUMP 1 RUNNING

o FIRE PUMP 1 POWER FAILURE

o FIRE PUMP 1 FAIL

o FIRE PUMP 2 RUNNING

o FIRE PUMP 2 POWER FAILURE

o FIRE PUMP 2 FAIL

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5.4.1.2 Process Control System Interface

The Controller shall provide the following indications to the site process control system:

 Alarm signal:

o To be provided in all cases where a Scenario or System is activated or other fire alarm

signal is generated such as by direct starting of fire engine while FCP is in Auto mode.

o Activation of any one of the FMSS’s

 Water storage alarm:

o Activated whenever water level is below Low set point

 Diesel storage alarm:

o Activated whenever diesel level is below Low set point

 Fault condition: activated if any of the following faults occur:

o Engine 1 Fail

o Engine 1 Power Failure

o Engine 2 Fail

o Engine 2 Power Failure

o Jockey Pump Fail

o FCP Power Supply 1 Failure

o FCP Power Supply 2 Failure

5.4.2 Main Operator Interface

The main operator interface on the FCP is only for use by suitably trained, authorised site personnel.

The main operator interface allows activation and deactivation of each protection System, without any

interlocking, and thus full manipulation of the fire protection system.

The main operator interface also includes functions to facilitate maintenance of the fire protection

system.

The following control and indication devices will be included on the main operator panel:

 MAIN PANEL ACTIVE indication (GREEN)

 NOC ACTIVE indication (GREEN)

 FIRST RESPONDER PANEL # ACTIVE (GREEN) (one indicator for each panel) to indicate

which first responder panel initiated an activation.

 System OPEN illuminated push buttons (GREEN) to open the valves for the supply to each fire

protection System.

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 System CLOSE push buttons (RED) to close the valves for the supply to each fire protection

System. These CLOSE push buttons shall be located below the above-mentioned OPEN push

buttons.

 TOP POURER MASTER VALVE OPEN illuminated push button (GREEN), with transparent flip

cover, to open all top pourer master valves and to indicate when the valves are opened from

the main panel. One button for all top pourer master valves.

 TOP POURER MASTER VALVE CLOSE push button (RED) to close all top pourer master

valves. One button for all top pourer master valves.

 FMSS ACTIVATED indication (GREEN); one lamp per zone not per FMSS (if applicable).

 MASTER RESET push button to clear all selections, cease and reset the FCP starting

mechanism and close all valves; whether made from main operator panel or not. The engines

shall not be stopped by this button.

 Buzzer

 ALARM ACKNOWLEDGE push button to silence the panel buzzer as well as stop the

annunciation system but shall not override any activated Systems, Scenarios or plant.

 BUZZER ACKNOWLEDGE push button to silence the panel buzzer only.

 Voltmeter to indicate battery backup power supply output voltage.

 Ammeter to indicate battery backup power supply output current.

 POWER SUPPLY FAULT indication (RED)

 CIRCUIT BREAKER FAULT indication (RED)

 WATER TANK 1 LOW indication (AMBER)

 WATER TANK 1 LOW LOW indication (RED)

 WATER TANK 2 LOW indication (AMBER)

 WATER TANK 2 LOW LOW indication (RED)

 DIESEL TANK 1 LOW indication (AMBER)

 DIESEL TANK 1 LOW LOW indication (RED)

 DIESEL TANK 2 LOW indication (AMBER)

 DIESEL TANK 2 LOW LOW indication (RED)

 JOCKEY PUMP RUNNING indication (GREEN)

 JOCKEY PUMP FAILURE indication (RED)

 JOCKEY PUMP ALARM indication (AMBER)

 PUMP START push button.

 FIRE PUMP 1 RUNNING indication (GREEN)

 FIRE PUMP 1 POWER FAILURE indication (RED)

 FIRE PUMP 1 FAIL indication (RED)

 FIRE PUMP 2 RUNNING indication (GREEN)

 FIRE PUMP 2 POWER FAILURE indication (RED)

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 FIRE PUMP 2 FAIL indication (RED)

 AUTO / TEST key selector switch.

 AUTO mode active indication (GREEN)

 TEST mode active indication (RED)

 FOAM VALVE OPEN indication (GREEN)

 FOAM VALVE CLOSED indication (RED)

 TOP POURER MASTER VALVE OPEN indication (GREEN) to indicate when the valves are

opened from the main panel, the NOC or a first responder panel. One lamp for all top pourer

master valves.

 TOP POURER MASTER VALVE CLOSED indication (RED). One lamp for all top pourer master

valves.

 MIMIC LAMP TEST push button.

 LAMP TEST push button.

5.4.3 Indicator Mimic (On the FCP)

A mimic diagram of the site shall be located on the FCP to assist the operator in identifying protection

equipment which needs to be or is active during an event. The mimic shall consist of a stainless-steel

face with coloured, etched lines and labels to represent the layout of the site. LED indicator lamps shall

be placed on the layout and labelled to indicate the status of the control panels (main operator and first

responder) and fire protection Systems.

The indicator lamps on the mimic shall only illuminate once the final relay in sequence to operate the

control valve represented has operated, to indicate that barring failure of the wiring to the valve or the

valve itself, the System is in operation.

The mimic shall display the following:

 Which operator panel initiated the current state of activation (GREEN LED)

 Which fire protection Systems are active (RED LED)

 Location of hydrants on the site (Etched)

 Location of feed/ring main isolation valves on the site (Etched)

 Location of valve banks with indication of which zones are supplied from the valve bank.

(Etched)

 Location of the operator panels. (Etched, with indicator LED at location)

 Site roads (Etched)

 Bund areas (Etched)

 Buildings (Etched)

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5.4.4 Battery Back-up Power Supply

The FCP shall be provided with dual battery back-up power supply systems. Each battery backup power

supply system shall be sized to charge the batteries and provide sufficient power to maintain full

operability of the FCP, whilst meeting the requirements of the specification.

Each battery back-up power supply shall be sized to provide battery power for the operation of the FCP

for at least 15 minutes in the event of the essential power failing.

The battery back-up power supply systems shall be designed to maintain optimum battery voltage.

The battery back-up power supply systems shall be designed to provide continuous power to the FCP

even in the event of the batteries having been discharged.

The battery back power supply systems shall be linked to supply the FCP in such a manner that if either

is unavailable, the other will supply the full requirements of the FCP and that one system cannot

adversely affect the other through interference or drawing power.

The battery back-up power supply shall be a Blue Ginger or approved equivalent and shall have the

following provisions:

 Surge protection on the input to each power supply.

 Automatic bypass of the batteries in the event that a battery fails or is removed, with sufficient

power to operate the FCP.

 Meters on the supply side to each charger to indicate:

o AC Supply voltage

o AC Supply current

 Maters on each charger output to indicate:

o DC Charger voltage

o DC Charger current

Each battery system shall be housed in a single cabinet with charger, controls and batteries in the same

cabinet.

The cabinets and entire installation shall be IP66 rated and suitable for installation in a sprinkler-

protected room.

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5.4.5 First Responder Operator Panels

The first responder operator panels are for use by first responders. There will be first responder panels

in the pump house, the main control room and the main security office.

These panels have buttons for fire Scenarios rather than for specific Systems. Each Scenario will

automatically activate predefined Systems. The cause-and-effect matrix defines the Systems to be

activated for each Scenario considered. This allows effective firefighting while only requiring the first

responder to identify the location of the fire such that they do not need to make any detailed decisions

regarding how to address the fire.

These panels will have provision to activate the top pourer master valve related to an identified

Scenario. The Scenario will automatically activate the relevant control valve for the top pourer system,

but the pourer master valve will remain closed until specifically activated by the first responder. This is

to prevent incorrect tank top pourer discharge.

The following control and indication devices will be included in the first responder panels:

 MAIN PANEL ACTIVE indication (GREEN)

 NOC ACTIVE indication (GREEN)

 FIRST RESPONDER PANEL # ACTIVE (GREEN) (one indicator for each panel) to indicate

which first responder panel initiated an activation.

 Scenario selection illuminated push buttons (GREEN) to activate predefined Systems. Scenario

indication shall be indicated on all first responder panels, regardless of which panel activated

the Scenario.

 TOP POURER MASTER VALVE OPEN illuminated push button (GREEN), with transparent flip

cover, to open all top pourer master valves and to indicate when the valves are opened from

the main panel. One button for all top pourer master valves.

 SCENARIO RESET push button, which will de-activate the currently operating Scenario

selected on this operator panel and cause the top pourer master valve to close.

 FIRE PUMP 1 RUNNING indication (GREEN)

 FIRE PUMP 1 POWER FAILURE indication (RED)

 FIRE PUMP 1 FAIL indication (RED)

 FIRE PUMP 2 RUNNING indication (GREEN)

 FIRE PUMP 2 POWER FAILURE indication (RED)

 FIRE PUMP 2 FAIL indication (RED)

 Buzzer

 BUZZER ACKNOWLEDGE push button to silence the panel buzzer only.

 LAMP TEST push button.

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U n c o n t r o l l e d c o p y w h e n p r i n t e d

5.4.6 Field Mounted Start Station (FMSS)

Field mounted start stations (FMSS’s) are only required on sites where tanker loading facilities are

provided. The Contractor shall refer to the P&ID’s to determine if FMSS’s are required for this site.

FMSS’s will be provided at both ends of each tanker loading bay. These shall be connected such that

the switch is closed to activate.

The FMSS’s shall activate the corresponding System.

FMSS specification:

 Break-glass, latching switch

 Normally open contact such that failure of the switch or wiring will not cause activation.

 Locally resettable

 Red enclosure

 Explosion protection certification for use in Zone 1 hazardous area, supplied with an IA

5.5.6 Interlocking ...................................................................................................................... 28

5.5.7 Fault and Condition Monitoring ....................................................................................... 29

5.5.8 Local and Site Alarms ..................................................................................................... 32

5.6 System Technical Requirements ........................................................................................... 34

5.6.1 System Design ................................................................................................................ 34

5.6.2 Explosive Atmospheres ................................................................................................... 34

5.6.3 Battery Backup Power Supply ......................................................................................... 34

5.6.4 Panel Construction .......................................................................................................... 35

5.6.5 Cabling, Racking and Trenching ..................................................................................... 37

5.6.6 Component Specifications ............................................................................................... 37

5.6.7 Installation Specification .................................................................................................. 40

5.7 System Layout ....................................................................................................................... 41

5.8 Quality Assurance .................................................................................................................. 41

5.8.1 Quality Control Plan (QCP) ............................................................................................. 41

5.8.2 Design Review and Approval .......................................................................................... 41

5.8.3 Factory Acceptance Testing ............................................................................................ 43

5.8.4 Commissioning ................................................................................................................ 43

5.9 Training .................................................................................................................................. 44

5.10 Design deliverables ............................................................................................................... 45

5.11 Other Obligations of the Contractor ....................................................................................... 46

5.11.1 Erection Works ............................................................................................................ 46

5.11.2 Transport of Material on Site ....................................................................................... 46

5.11.3 Tools for Erection Works ............................................................................................. 46

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includes installation verification and deenergized testing.

The scope of works includes all aspects relating to the installation of the FMSSs, including the supply and installation of a mounting base and stand, cabling and cable racking. The FMSS’s shall be mounted in accordance with the standard drawing included in the Works Information. 5.4.7 Fire Alarms Beacons and Sirens On the activation of the protection system, an alarm siren will sound and be accompanied by a fire alarm beacon. A fire alarm siren, a red beacon and an orange beacon shall be installed outside the pump house. Fire alarm sirens shall be installed at all valve banks. The supply and installation of these visual and audible alarms is included in this scope of works. These sirens shall be adequately sized to provide an audible warning to the entire site as required by SANS 10089-1 and shall comply with SANS 50054-3. Each operator panel shall also have a buzzer which shall give local indication of fire alarms and condition alarms. PL 913 P a g e 20 | 46 Fire System Specification: Control System Rev 2 ©Transnet SOC Ltd U n c o n t r o l l e d c o p y w h e n p r i n t e d Sirens and beacons shall be suitable for extended exposure to the environment and a minimum service life of 15 years. 5.4.8 Valves The System control valves, the top pourer master valves and the premix feed deluge valve will be hydraulic pilot deluge valves with solenoid activation. The valves will be fail safe closed, energise to open. The foam concentrate isolation valve will be an electric motorised expanding plug valve with a quarter turn actuator. The actuator shall be supplied from the essential electrical supply. The actuator shall provide feedback to the FCP. This valve is actuated to open when a Scenario or foam System is activated in Auto mode. The valve open/close command shall be maintained until the valve position feedback indicates that the valve is open/closed. If the power is interrupted, the valve will continue to receive an open/close command which will resume operation once power is restored, unless the system has subsequently been reset. Manual operation of the valve will be possible and will not interfere with feedback functionality. 5.4.9 Level Switch The level switches for the water and diesel storage tanks form part of this scope of works. The switches shall provide signals to indicate low and low-low levels. The Contractor shall procure, supply, delivery, install, connect, set and commission the level switches. The Contractor shall consider the tank design and shall interface with the tank manufacturers to ensure that the switches can be suitably mounted. 5.4.10 Engine Control Panels There will be two fire pump sets, one assigned as duty, and one assigned as standby. The supply and installation of the ECP’s will be by others as part of the pump set supply scope. Each pump set will comprise of a diesel engine, a water pump, a foam pump and an ECP. There shall be interconnection between the ECP’s and the FCP in order to allow the pumps to be started from the FCP as well as for the reporting of the pump status from the ECP’s to the FCP. PL 913 P a g e 21 | 46 Fire System Specification: Control System Rev 2 ©Transnet SOC Ltd U n c o n t r o l l e d c o p y w h e n p r i n t e d 5.4.11 Jockey Pump Control Panel The supply and installation of the jockey pump control panel will be by others as part of the jockey pump-set supply scope. The jockey pump will have a dedicated control panel. There shall be interconnection between the jockey pump control panel and the FCP for the reporting of the pump status. 5.5 Control System Operation The Contractor shall develop cause and effect matrices based on the control system operation described in this section. Preliminary cause and effect matrices are included in the Works Information. 5.5.1 Main Operator Panel 5.5.1.1 System Open Activation of any System Open button on the main operator interface shall cause the selected System control valve to open. This shall also initiate the start of the main fire pumps, if they are not already running, and the manipulation of the supply system valves as required for the selected System. The fire pump start control sequence must be started only if one of the pumps is not already running or if an ‘Engine Failure’ event does not already exist for both pumps. The foam concentrate isolation valve is only opened if the FCP is in Auto mode. 5.5.1.2 System Close Activation of any System Close button on the main operator interface shall only cause the selected System control valve to be closed. 5.5.1.3 Top Pourer Master Valve Open Activation of the Top Pourer Master Valve Open button on the main operator interface shall cause all top pourer master valves to be opened. 5.5.1.4 Top Pourer Master Valve Close Activation of the Top Pourer Master Valve Close button on the main operator interface shall cause all top pourer master valves to be closed. PL 913 P a g e 22 | 46 Fire System Specification: Control System Rev 2 ©Transnet SOC Ltd U n c o n t r o l l e d c o p y w h e n p r i n t e d 5.5.1.5 Master Reset Activation of the Master Reset button shall cause all valves to return to their normal state; the foam concentrate isolation valve, the premix system deluge valve, all top pourer master valves and any open system valves must be closed. This shall also return the Controller to a state where any panel can cause the next activation. This shall reset the engine start sequence in the FCP such that in a healthy system, the next start attempt would be made on the duty ECP. Activation of both the Alarm Acknowledge and the Master Reset shall be required to switch off the exterior fire alarm beacon. 5.5.1.6 Alarm Acknowledge Activation of the Alarm Acknowledge button shall cause the local buzzer alarms at all panels and all external sirens to be switched off. In addition, activation of this button shall cause all condition alarms to be reset; this button should therefore be used after maintenance or repair to clear the condition alarms. The alarm shall only be cleared if the source of the alarm is no longer present; it may be momentarily removed while the button is pressed, but it shall be reinstated if the alarm signal is still present. Activation of both the Alarm Reset and the Master Reset shall be required to switch off the exterior fire alarm beacon. 5.5.1.7 Buzzer Acknowledge Activation of the Buzzer Acknowledge button shall cause all buzzer alarms on the main operator panel and first responder panels to be silenced. 5.5.1.8 Auto / Test Switch This is a key switch to change the FCP between Auto and Test modes. 5.5.1.9 Lamp Test and Mimic Lamp Test Activation of the Lamp Test button shall cause power to be provided to all indicator lamps on the main operator interface; whether incorporated into a pushbutton or separate lamps. This is to check the condition of the lamps to ensure that if they receive a signal they will illuminate. PL 913 P a g e 23 | 46 Fire System Specification: Control System Rev 2 ©Transnet SOC Ltd U n c o n t r o l l e d c o p y w h e n p r i n t e d Activation of the Mimic Lamp Test button shall cause power to be provided to all indicator lamps on the mimic. This is to check the condition of the lamps to ensure that if they receive a signal they will illuminate. 5.5.1.10 Pump Start Activation of the pump start button shall initiate the FCP controlled pump start sequence of the duty and standby pumps. 5.5.2 First Responder Panel Scenarios may only be activated if they have not been locked out by the Controller. This means that either the system has not been activated, or the system was activated from that first responder panel and the system has not been overridden from the NOC or the main operator interface. 5.5.2.1 Scenario Activation Button Activation of any Scenario button on any operational first responder panel or the NOC shall cause the Controller to open the appropriate System control valves to address that Scenario as defined in the cause and effect matrices. This activation shall also initiate the start of the fire pumps, if they are not already running, and the actuation of the premix supply deluge and concentrate isolation valves as required for the selected Scenario. The fire pump start control sequence must be started only if one of the pumps is not already running or if an ‘Engine Failure’ event does not already exist for both pumps. The foam concentrate isolation valve is only opened if the FCP is in Auto mode. 5.5.2.2 Top Pourer Master Valve Open Activation of the Top Pourer Master Valve Open button on any operational first responder panel or the NOC shall cause all top pourer master valves to be opened. 5.5.2.3 Scenario Reset Activation of the Scenario Reset button on any operational first responder panel or the NOC shall cause all System valves and all supply system valves, including the top pourer master valves to be closed. This shall also return the Controller to a state where any panel can cause the next activation. PL 913 P a g e 24 | 46 Fire System Specification: Control System Rev 2 ©Transnet SOC Ltd U n c o n t r o l l e d c o p y w h e n p r i n t e d 5.5.2.4 Buzzer Acknowledge Activation of the Buzzer Acknowledge button on any first responder panel, or the NOC shall only cause the local buzzer alarm to be silenced. 5.5.2.5 Lamp Test Activation of the Lamp Test button shall cause power to be provided to all indicator lamps on the local first responder panel; whether incorporated into a pushbutton or separate lamps. This is to check the condition of the lamps to ensure that if they receive a signal they will illuminate. 5.5.3 AUTO / TEST Functionality AUTO or TEST modes are activated through the AUTO/TEST selector key switch located on the main operator interface. The operating mode, AUTO or TEST, shall be indicated on the main operator interface by a LED indicator lamp and on the NOC system, and transmitted to the ECPs. The AUTO mode shall be the standard mode which the Controller shall remain in unless otherwise required. This mode allows full functionality of all panels, all interlocking, operation of all valves and thus the protection of the site as designed. The TEST function is provided for maintenance and testing activities. This function inhibits the opening of the foam concentrate isolation valve so that no matter what activations are made; the valve remains closed. This allows for the foam premix System to be tested without the introduction of foam into the system. In TEST mode, the ECP’s shall be switched to a safe operating mode in which the ECP’s will monitor the engine operating conditions and safely shut down the engine in the event of the operating conditions posing a risk to the pump or engine. In AUTO mode, the ECP’s shall inhibit engine protection functions such that the engines will “run to destruction”. In TEST mode, the Controller shall prevent the transmission of a fire alarm signal to the site process control system 5.5.4 Pump Operation The Controller shall incorporate pump start control logic to control the starting sequence of the fire pumps in the event of an activation from the main operator interface, the NOC or one of the first responder panels. PL 913 P a g e 25 | 46 Fire System Specification: Control System Rev 2 ©Transnet SOC Ltd U n c o n t r o l l e d c o p y w h e n p r i n t e d The pump start control logic shall also be relay based and may employ timers and counters as required, however, a PLC may not be used. The signals between the FCP and ECP shall be in the form of potential free contacts in the originating panel. The pump starting sequence shall be designed and constructed as per the requirements defined in the ECP and FCP Control Narrative, document PL 916. The Controller will provide the following event signals to each ECP:  AUTO / TEST command signal. o A signal shall be provided by the controller to enable the ECP to switch between Auto and Test modes. This shall be configured by the ECP to disable protections in the engine control module (ECM) when the FCP is in Auto. The Auto signal shall cause the ECP/ECM to run without engine monitoring protection such that the engine will ‘run to destruction’. o The command signal shall be configured such that if it is lost, the ECP will revert to operate with protection.  START command signal o A signal shall be provided to initiate the start of the engine through the ECM. This signal shall be maintained for sufficient time to ensure that the signal is received and processed. o The start signal may only be provided if one of the pumps is not already running, and if both pumps have not reported failure to the FCP o The start signal shall be given multiple times and shall alternate between the duty and standby pump until a pump starts, or other parameters are met. o The ECM shall latch and continue to attempt to start the engine even after the start command signal generated by the controller is withdrawn so that there is no need to provide a continuous signal to the ECP. A stop signal shall be provided by the controller to terminate the start attempt when necessary.  STOP command signal o The controller shall provide a stop signal to the ECP’s to terminate the start sequence attempt when required.  FAIL TO START signal o The controller will generate a ‘Fail to Start’ command and transmit the command to the respective ECP/ECM if the sixth count is reached by the controller counting mechanism. PL 913 P a g e 26 | 46 Fire System Specification: Control System Rev 2 ©Transnet SOC Ltd U n c o n t r o l l e d c o p y w h e n p r i n t e d The controller shall receive the following event signals from each ECP:  Run  Engine Failure  Power Supply Fault (Engine # Power Fail)  Normal Termination If the FCP starting sequence has been initiated, has not been reset and has not been stopped by the mechanisms described in the ECP and FCP Control Narrative, and all Systems have been deactivated but the Master Reset button has not been activated, the FCP starting sequence shall resume and ensure that at least one engine is running. In addition to the FCP starting sequence reset mechanisms described in the ECP and FCP Control Narrative, the FCP starting sequence can only be reset at the FCP by the Master Reset activation on the main operator interface. Resetting of the starting sequence will mean that the next start command will be provided to the duty pump set. There shall be no provision to stop the operation of the fire pumps from the main operator interface, or any other operator interface except the respective ECP’s. 5.5.5 System Condition Indication The system shall be fully integrated such that all operator panels will indicate the state of the fire system at any stage. To facilitate this the following is required:  If a Scenario is activated on any of the first responder panels or NOC, all first responder panels, the NOC and the main operator interface shall indicate the Scenario / Systems activated.  If Systems are activated from the main operator panel or the Systems activated by a first responder panel activation are manipulated from the main operator panel, all first responder panels and the NOC shall indicate MAIN PANEL ACTIVE and Scenario activation indication shall not be indicated. Scenarios shall only be indicated to be operational on the first responder panels or NOC if the full Scenario is active.  If a Scenario is activated from any of the first responder panels, all first responder panels, the main panel and NOC shall indicate FIRST RESPONDER PANEL # ACTIVE, to indicate which first responder panel was used to activate the Scenario.  If a Scenario is activated from the NOC, all first responder panels, the main panel and NOC shall indicate NOC ACTIVE, to indicate that the NOC is the current system master. PL 913 P a g e 27 | 46 Fire System Specification: Control System Rev 2 ©Transnet SOC Ltd U n c o n t r o l l e d c o p y w h e n p r i n t e d 5.5.6 Interlocking 5.5.6.1 Main Operator Panel  There shall be nothing to limit the activation of multiple fire protection Systems from the main operator interface.  Simultaneous start-up and running of both duty and standby pumps shall not be permitted.  If a Scenario is activated from a first responder panel or the NOC: o It shall be possible for additional Systems to be selected on the main operator interface without limitation. This will result in the MAIN PANEL ACTIVE indication on all first responder panels and the NOC, and block all further inputs from the first responder panels and the NOC. o It shall be possible for Systems, selected through a first responder panel or NOC input, to be deactivated from the main operator panel without resetting the whole Scenario. For example, if Zone 1 Bund Fire is activated on a first responder panel, the bund pourers for Zone 1 along with the top pourer for Zone 1 will show as activated on the main operator panel. It shall then be possible for the bund pourers or top pourer to be deactivated without affecting the other operating System(s). This will result in the MAIN PANEL ACTIVE indication on all first responder panels and the NOC, and block all further inputs from the first responder panels and the NOC. 5.5.6.2 First Responder Panels  Only one Scenario may be activated at any time; all other Scenarios shall be inhibited.  If a Scenario is activated on any of the panels no further input shall be processed from any of the other first responder panels.  Consequently, only one Scenario may be selected from any of the first responder panels at any time.  The SCENARIO RESET input shall only be effective if received from the first responder panel which generated the initial selection. This is so that one operator cannot remotely override another operator with the same authority. A SCENARIO RESET shall clear the FIRST RESPONDER PANEL # ACTIVE and the Scenario selection lamps. PL 913 P a g e 28 | 46 Fire System Specification: Control System Rev 2 ©Transnet SOC Ltd U n c o n t r o l l e d c o p y w h e n p r i n t e d 5.5.6.3 NOC  Only one Scenario may be activated at any time.  Inputs from the NOC shall override any selections from the first responder panels.  Inputs from the NOC shall not override any selections from the main operator panel.  Further inputs from the first responder panels shall not override activations from the NOC 5.5.7 Fault and Condition Monitoring The Controller shall monitor various inputs and generate condition outputs based either on rules in the Controller or directly based on input signals. 5.5.7.1 Water Tank Levels  Each water tank shall have a level switch with two switching points.  The first switching point shall be a Low-level alarm to indicate the level is below the level required for 60 minutes firefighting (90% tank level).  The second switching point shall be a Low-Low level alarm to indicate the level is below the level required for 20 minutes firefighting (30% tank level).  Low and Low-Low level alarms shall be reported by the Controller. o There are Low and Low-Low indicator lamps for each water tank on the main operator interface. o There shall be provision to transmit these conditions to the NOC. o These conditions shall cause a general condition alarm signal to be transmitted to the site process control system. o The main panel buzzer shall be activated. PL 913 P a g e 29 | 46 Fire System Specification: Control System Rev 2 ©Transnet SOC Ltd U n c o n t r o l l e d c o p y w h e n p r i n t e d 5.5.7.2 Diesel Tank Levels  Each diesel tank shall have a level switch with two switching points.  The first switching point shall be a Low level alarm to indicate the level is below the level required for 66 minutes firefighting (44% tank level).  The second switching point shall be a Low-Low level alarm to indicate the level is below the level required for 20 minutes firefighting (13% tank level).  Low and Low-Low level alarms shall be reported by the Controller. o There are Low and Low-Low indicator lamps for each diesel tank on the main operator interface. o There shall be provision to transmit these conditions to the NOC. o These conditions shall cause a general condition alarm signal to be transmitted to the site process control system. o The main panel buzzer shall be activated. 5.5.7.3 Fire Control System Power Supply Condition  Each battery backup power supply for the FCP shall have a mechanism to report any fault to the FCP as a power supply fault signal. o There shall be a Power Supply Fault indicator lamp for the FCP power supply, on the main operator interface, activated by the power supply fault signal. o There shall be provision to transmit this signal to the NOC. o This signal shall cause a general condition alarm signal to be transmitted to the site process control system. o The main panel buzzer shall be activated  All circuit breakers and fuses in the FCP shall be monitored and a fault with any of them shall generate a fault signal. o There shall be a Circuit Breaker Fault indicator lamp on the main operator interface, activated by this signal. PL 913 P a g e 30 | 46 Fire System Specification: Control System Rev 2 ©Transnet SOC Ltd U n c o n t r o l l e d c o p y w h e n p r i n t e d

elsewhere:

 Control valves

 Engine control panels (ECP’s)

 Jockey pump control panel (JPCP)

 Modification to, and terminations within, the site process control system

 Cable sleeves within the pump house

 Cable sleeves and draw boxes around the site

5.4 Control System Components

 Run

 Engine Failure

 Power Supply Fault (Engine # Power Fail)

 Normal Termination

Rev date by chk description hw fire 1 : 365 bj bj - - a 2026-02-11 hs bj issued for acceptance resp. Eng TRANSNET pipelines witbank drawn REF. - -

• • Traced date proj. Manager hw fire cad file: design-drawn: date:

Ho1436-tpl_2024_09_0008 - checked approved - np 2025-11-21 - _77334_rfp-fat-0001 np - - client title:

SCALE - - GREYJONES (PTY) LTD. ROLE NAME SIGN DATE GENERAL ARRANGEMENT LOCATION PLAN PROJECT No: DRAWING No: REV: - - TPL DRAWING No. REV

• 11364 11364-A1201 a    - a1 drawing approval status - -

1 2 3 4 5 6 7 8 9 10 11 12

New draw box

Rev date by chk description hw fire 1 : 365 bj bj - - a 2026-02-11 hs bj issued for acceptance resp. Eng TRANSNET pipelines witbank drawn REF. - -

• • Traced date proj. Manager hw fire cad file: design-drawn: date:

Ho1436-tpl_2024_09_0008 - checked approved - np 2025-11-21 - _77334_rfp-fat-0001 np - - client title:

SCALE - - GREYJONES (PTY) LTD. ROLE NAME SIGN DATE GENERAL ARRANGEMENT LOCATION PLAN PROJECT No: DRAWING No: REV: - - TPL DRAWING No. REV

• 11364 11364-A1201 a    - a1 drawing approval status - -

1 2 3 4 5 6 7 8 9 10 11 12

New draw box

Construction of the Witbank Depot Fire System Upgrade

Contents

Number Heading

The Tender

Part T1: Tendering Procedures

T1.1 Tender Notice and Invitation to Tender

T1.2 Tender Data

{"briefingSession":"{"date":null,"time":null,"venue":"ion will not be repeated for the benefit of","is_compulsory":true}"}

{"name":null,"email":"[email protected]","phone":"+27 31 816 9770","department":null,"address":"OCEDURE ENQUIRIES AND TECHNICAL ENQUIRIES MAY BE DIRECTED TO"}

Construction of the Witbank Depot Fire System Upgrade

Contents

Number Heading

The Tender

Part T1: Tendering Procedures

T1.1 Tender Notice and Invitation to Tender

T1.2 Tender Data

Bid Bond: Form of Guarantee

Part C2: Pricing Data

C2.1 Pricing Instructions

C2.2 Activity Schedule

Part C3: Scope of Work

C3.1 Works Information

Part C4: Site Information

C4.1 Site Information

Tender Data CPM 2023 Rev 11 of 11 Part T1: Tendering Procedures

Transnet Pipelines

Tender Number: TPL/2026/07/0460/85

No specific requirements found

B-BBEE Minimum Level: 3

Points Allocation: 60 points

B-BBEE Details: RS WILL BE ACCEPTED

C.2.16 The tender offer validity period is 12 weeks after the closing date. Tenderers are to note

that they may be requested to extend the validity period of their tender, on the same terms

and conditions, if Transnet’s internal evaluation and governance approval processes has

not been finalised within the validity period.

C.2.23 The Tenderer is required to submit with his tender:

1. A valid Tax Clearance Certificate issued by the South African Revenue Services.

Tenderers also to provide Transnet with a TCS PIN to verify Tenderers

compliance status.

2. A valid B-BBEE Certificate from a Verification Agency accredited by the South

African Accreditation System [SANAS], or a sworn affidavit confirming annual turnover

and level of black ownership, in line with the code of good practice, together with the

tender;

3. A valid CIDB certificate in the correct designated grading;(Mandatory)
4. Proof of registration on the Central Supplier Database;
5. Letter of Good Standing with the Workmen’s compensation fund by the tendering

entity or separate Letters of Good Standing from all members of a newly constituted

Jv.

Note: Refer to Section T2.1 for List of Returnable Documents.

Returnable Documents means all the documents, Sections and Annexures, as listed in T2.1 for List of

Returnable Documents. There are three types of returnable documents as indicated below and Respondents

are urged to ensure that these documents are returned with their bids based on the consequences of non-

submission as indicated below:

Mandatory FailuretoprovidealltheseMandatoryReturnableDocumentsatthe

Returnable Closing Date and time of this RFP will result in a Respondent’s

Documents disqualification.

Returnable Documents Used FailuretoprovideallRet

{"name":null,"email":"[email protected]","phone":null,"department":null,"address":null}

SUPPLY No: PANEL RESPONDER OPERATOR BACK-UP 11364-A1072 GM DESIGN-DRAWN: PUMP PUMP ELECTRICAL NORMAL ELECTRICAL NORMAL HOUSE HOUSE MCC POWER DB POWER DATE:

Bj approved:

Rev:b 2025-09-11

(031) noc (future

816 use) 6

9386

And greyjones 3-PHASE pump maintenance

A3 hw 1 fire TRANSNET project: fire title: bund shell top pourers cooling pourers first panel

Tank west tank1 1 green active responder control pipelines & &

2 close open close open 2& close open buzzer red manifold red 3 red &3 red close open tank1 main

& Green monitors green &4 green 4 green panel acknowledgement 2 panel green active

• DRAWING GM CHECKED: BUND SHELL 5 11364-A1026 No: RM CLOSE OPEN TANK7

Red design-drawn: pourers cooling green witbank

Main date: fire

Close open tank8 panel bj red green approved:a rev: 2025-09-04

Close open tank9

Valve premix valve water valve water valve premix 3

F11364 cad scale 4

x NTS FH PROJECT FILE:

No: VALVE

1Bank 4 _77334_rfp-fat-0001 ho1436-tpl_2024_09_0008 bund top

FH POURER POURER SHELL x FMSS ZONE FMSS PETROL TANK5 COOLING 5 RM ZONESPILL ZONETANKER F

11 12 - basin loading bundc drawing

FMSS 11364-A1028 No: RM GM CHECKED: BUND SHELL 5 BUND FMSS RING NOZZLES DESIGN-DRAWN: WATER BUND BUND TANK MAIN POURER

Ring bund pourer isolation date: 6 pourer separator pourer shell ring foam zone main f diesel tank9

Top top main isolationb rev: 2025-09-11 shell shell valve water bund zone transformers d valve 6 pourer pourer 10 manifold bund first f e isolation foam cooling cooling slop tank4 zone4 slop tank3 zone3 4

x VALVE PREMIX BUILDING PANEL OFFICES FH TANK RESPONDER DIESEL BUND 8 TOP

Slop tank2 zone2 slop tank1 zone1 top pourer shell pourer top shell shell

(031) POURER POURER BUND COOLING COOLING TOWER MAST EAST MONITOR COOLING ZONE8816 [email protected] GREYJONES

F storeoil port car 4 bund

x POURER F9386 FH 2 7

x ROOMS CHANGE (PTY) CONTROL ZONE TANK BUND 7 PETROL 7 TOP MANIFOLD WORKSHOP TANK WATER POURER LTD. PUMP VALVES EAST POURER SHELL VALVENEW MONITOR www.greyjones.co.za 2BANK HOUSE MAIN PANEL FIRST PORT CAR OFFICES COOLING B A REV TANK WATER FIRE HOUSE GUARD SUBSTATION F PANEL

4 RESPONDER x 8 PANEL FIRST MAIN FH DATE REVISIONS

Gate ring water ring foam ring water ring foam 2026-01-28 2025-09-11 responder main main main main premix premix

{"name":null,"email":null,"phone":"065 1534750","department":null,"address":null}

TRANSNET pipelines a 22/10/25 ko bj for client review hw fire

Cad file: design-drawn: date: drawn REF.

Traced dateh hw fire ho1436-tpl_2024_09_0008_77334_rfp-fat-0001 ko - ccad 2025-09-09 greyjones (pty) ltd. Checked approved

TITLE:  SCALE PROJECT No: DRAWING No: REV:

TYPICAL DETAILS - PIPING DEMOLITION TPL DRAWING No. REV

11364 11364-A1047 a  a3 capping details

1 2 3 4 5 6 7 8 9 10 11 12

D MIN IN-SITU SOIL LEVELLED AND 150 COMPACTED, WITH ALL LARGE STONES AND BOULDERS REMOVED E BEDDING PADDING, PLASTER 300 SAND / WASHED RIVER SAND / LEACHED MINE SAND AS PER PL 150 IN-SITU SOIL LEVELLED AND COMPACTED, WITH ALL LARGE F STONES AND BOULDERS REMOVED TYPICAL PIPE TRENCH BEDDING DESIGNERRESP. ENG SCALE: 1 : 10 PROJ. MANAGER CLIENTG ROLE NAME SIGN DATE DRAWING APPROVAL STATUS PROJECT: SCALE CHECKED: APPROVED: REVISIONS PROJECT NAME 1 : 10 KO BJ REV DATE BY CHK DESCRIPTION TRANSNET PIPELINES A 15/08/25 KO BJ FOR INTERNAL REVIEW HW FIRE CAD FILE: DESIGN-DRAWN: DATE: B 10/09/25 KO BJ FOR CLIENT REVIEW DRAWN REF. C 30/09/25 KO BJ CHANGED TO A3 FORMAT TRACED DATEH HW FIRE HO1436-TPL_2024_09_0008_77334_RFP-FAT-0001 KO - CCAD 2025-09-09 GREYJONES (PTY) LTD. CHECKED APPROVED TITLE:  SCALE PROJECT No: DRAWING No: REV: TYPICAL DETAILS - TRENCH BEDDING TPL DRAWING No. REV 11364-A1106 C  A3 11364 1 2 3 4 5 6 7 8 9 10 11 12 NOTE: THE TYPICAL DETAILS AND A 12 DIMENSIONS PROVIDED IN THIS DRAWING PROVIDE THE MINIMUM REQUIREMENTS ACCEPTABLE. THE GUNNED INTO PLACE CONTRACTOR IS TO PRODUCE DURACOL GHM THE FINAL DESIGN AND TO DURACORD ⌀15 TAKE OWNERSHIP OF THE POLYSUPHIDE JOINT BACKER ROD DETAIL DRAWINGS FOR SEALANT (OEA) CONSTRUCTION AND SIGN NEW CONC. EXIST. CONC. OFF AS PER THE PROJECT B SCOPE OF WORKS AND SPECIFICATION DOCUMENTS 12mm FLEXCELL (OR SIMILAR) C 'IJ' ISOLATION JOINT NEW EXTENDED BUND SCALE: 1 : 2 WALL DRILL AND DOWEL Y10 REINFORCING BARS MIN 120mm INTO EXSITNG CONCRETE AT 250mmc/c AND SECURE GUNNED INTO PLACE D IN PLACE WITH HILTI HIT-HY 200 DURACOL GHM REQUIRED CHEMICAL ADHESIVE POLYSUPHIDE JOINT 8 DURACORD ⌀15 SEALANT (OEA) BACKER ROD AS SCABBLE EXISTING RC WALL TO EXPOSE CLEAN AGGREGATES TO PROVIDE A NEAT KEY FOR NEW RC WALL & APPLY WET TO DRY EPOXY 25 TO EXISTING SURFACE PRIOR TO 45 APPLICABLE TO CASES OF EXISTING CASTING OF NEW CONCRETE BUND FLOORE 20 10x10 SQUARE VOID TO BE FILLED WITH DURAKOL G HM SEALANT OR SIMILAR. MIN. 3 TYPICAL INSIDE AND 120 OUTSIDE FACE EXISTING BUND WALL F 'SCJ' SAW CUT JOINT SCALE: 1 : 2 BUND WALL EXTENSION DESIGNER RESP. ENG SCALE: 1 : 5 PROJ. MANAGER CLIENTG ROLE NAME SIGN DATE DRAWING APPROVAL STATUS PROJECT: SCALE CHECKED: APPROVED: REVISIONS PROJECT NAME As indicated KO BJ REV DATE BY CHK DESCRIPTION TRANSNET PIPELINES A 15/08/25 KO BJ FOR INTERNAL REVIEW HW FIRE CAD FILE: DESIGN-DRAWN: DATE: B 10/09/25 KO BJ FOR CLIENT REVIEW DRAWN REF. C 30/09/25 KO BJ CHANGED TO A3 FORMAT TRACED DATEH HW FIRE HO1436-TPL_2024_09_0008_77334_RFP-FAT-0001 KO - CCAD 2025-09-09 GREYJONES (PTY) LTD. CHECKED APPROVED TITLE:  SCALE PROJECT No: DRAWING No: REV: TYPICAL DETAILS - JOINTS & SEALANT TPL DRAWING No. REV 11364-A1107 C  A3 11364 1 2 3 4 5 6 7 8 9 10 11 12 NOTE: THE TYPICAL DETAILS AND DIMENSIONS PROVIDED INA HOT DIPPED GALV. MENTIS RS40-40x3.0 MENTIS RS40-40x3.0 50x50x6 L SEAT RECTAGRID COVER OR RECTAGRID COVER OR THIS DRAWING PROVIDE THE 7 GAP SIMILAR APPROVED SIMILAR APPROVED 7 GAP MINIMUM REQUIREMENTS ACCEPTABLE. THE M16 HILTI HSA CONTRACTOR IS TO PRODUCE ANCHORS AT 250 THE FINAL DESIGN AND TO CENTERS TAKE OWNERSHIP OF THE DETAIL DRAWINGS FOR CONSTRUCTION AND SIGN OFF AS PER THE PROJECT B SCOPE OF WORKS AND SPECIFICATION DOCUMENTS HOT DIPPED GALV. 150 LONG FISHTAIL LUGS 80x60x8 L SEAT AT 300 CENTERS 4CFW TO 50x50x6 L SEAT C CAST IN ANGLE DETAIL A CAST IN ANGLE DETAIL B SCALE: 1 : 5 SCALE: 1 : 5 40x40x10 THK SPACER LUGS D WELDED TO CORNERS OF ALL PANELS AS SHOWN PANEL TO BE A60x80x5.5 BANDED ALL 5 GAP 10 SIDES HD GALV AFTER FABRICATION E 40 110° 150 F 30x5x240 LONG FISHTAIL LUGS AT 250 CENTERS 90° DESIGNER RESP. ENG CAST IN ANGLE DETAIL C PROJ.CLIENTMANAGERG SCALE: 1 : 5 ROLE NAME SIGN DATE DRAWING APPROVAL STATUS PROJECT: SCALE CHECKED: APPROVED: REVISIONS PROJECT NAME 1 : 5 KO BJ REV DATE BY CHK DESCRIPTION TRANSNET PIPELINES A 15/08/25 KO BJ FOR INTERNAL REVIEW HW FIRE CAD FILE: DESIGN-DRAWN: DATE: B 10/09/25 KO BJ FOR CLIENT REVIEW DRAWN REF. C 30/09/25 KO BJ CHANGED TO A3 FORMAT TRACED DATEH HW FIRE HO1436-TPL_2024_09_0008_77334_RFP-FAT-0001 KO - CCAD 2025-09-09 GREYJONES (PTY) LTD. CHECKED APPROVED TITLE:  SCALE PROJECT No: DRAWING No: REV: TYPICAL DETAILS - CAST IN FRAMES TPL DRAWING No. REV 11364-A1108 C  A3 11364 1 2 3 4 5 6 7 8 9 10 11 12 150 AS PER PLAN REQUIREMENT 150 NOTE: THE TYPICAL DETAILS AND A DIMENSIONS PROVIDED IN THIS DRAWING PROVIDE THE 150 MINIMUMACCEPTABLE.REQUIREMENTSTHE CONTRACTOR IS TO PRODUCE THE FINAL DESIGN AND TO 300 TAKE OWNERSHIP OF THE DETAIL DRAWINGS FOR CONSTRUCTION AND SIGN 150 OFF AS PER THE PROJECT B SCOPE OF WORKS AND SPECIFICATION DOCUMENTS MENTIS RS40 40x4.5 HDG RECTAGRID GRATING (FULLY BANDED) (OR SIMILARLY APPROVED) C STORMWATER CUT-OFF DRAIN PLAN SCALE: 1 : 20 D 150 300 150 50x50x5L HDG CAST-IN FRAME 150 LONG FISHTAIL LUGS AT 300 CENTERS 4CFW VARIES E TO 50x50x5 L SEAT CONCRETE BENCHING 150 GRADE 20/13 F STORMWATER CUT-OFF DRAIN SECTION DESIGNERRESP. ENG SCALE: 1 : 20 PROJ. MANAGER CLIENTG ROLE NAME SIGN DATE DRAWING APPROVAL STATUS PROJECT: SCALE CHECKED: APPROVED: REVISIONS PROJECT NAME 1 : 20 KO BJ REV DATE BY CHK DESCRIPTION TRANSNET PIPELINES A 15/08/25 KO BJ FOR INTERNAL REVIEW HW FIRE CAD FILE: DESIGN-DRAWN: DATE: B 10/09/25 KO BJ FOR CLIENT REVIEW DRAWN REF. C 30/09/25 KO BJ CHANGED TO A3 FORMAT TRACED DATEH HW FIRE HO1436-TPL_2024_09_0008_77334_RFP-FAT-0001 KO - CCAD 2025-09-09 GREYJONES (PTY) LTD. CHECKED APPROVED TITLE:  SCALE PROJECT No: DRAWING No: REV: TYPICAL DETAILS - STORM WATER CUT OFF TPL DRAWING No. REV 11364 11364-A1109 C  A3 DRAIN 1 2 3 4 5 6 7 8 9 10 11 12 HD CAST IRON ST GOBAIN HD CAST IRON ST GOBAIN NOTE: 230 1030 230 BESAANS DUPLESIS 2230 (OR 230 1030 230 BESAANS DUPLESIS 2230 (OR THE TYPICAL DETAILS AND DIMENSIONS PROVIDED INA EQUALLY APPROVED) IN HIGH EQUALLY APPROVED) IN TRAFFICKED AREAS. HIGH TRAFFICKED AREAS. THIS DRAWING PROVIDE THE LAYERWORKS & LAYERWORKS & MINIMUM REQUIREMENTS MD COVER IN LOW MD COVER IN LOW SURFACE AS PER SITE SURFACE AS PER SITE ACCEPTABLE. THE TRAFFICKED AREAS TRAFFICKED AREAS CONTRACTOR IS TO PRODUCE REQUIREMENTS REQUIREMENTS THE FINAL DESIGN AND TO 150 150 TAKE OWNERSHIP OF THE DETAIL DRAWINGS FOR CONSTRUCTION AND SIGN OFF AS PER THE PROJECT B SCOPE OF WORKS AND SPECIFICATION DOCUMENTS STEP IRONS AT 300mm STAGGER STEP IRONS AT 300mm STAGGER VARIES VARIES PIPE OUTLET BENCHING VARIES AS PER INLET OF (MIN) INLET & OUTLET LEVELS.C MIN 1-200 SLOPE DIA INLET OUTLET 150 150 MESH REF 395 CENTRALLY PLACED MESH REF 395 CENTRALLY PLACED D SECTION MHA - OWS FIRE TRAP SECTION MHB - OWS EFFLUENT SCALE: 1 : 25 SCALE: 1 : 25 230 1030 230 E EACH MANHOLE MUST BE CLEARLY NUMBERED 230 WITH ROAD MARKING PAINT, INCLUDING DIRECTIONAL FLOW ARROWS, IN LINE WITH THE EMPLOYER'S REQUIREMENTS. A1110 MHA 1030 A1110MHBF DESIGNER 230 RESP. ENG PROJ. MANAGER CLIENTG TYPICAL MANHOLE ROLE NAME SIGN DATE SCALE: 1 : 25 DRAWING APPROVAL STATUS PROJECT: SCALE CHECKED: APPROVED: REVISIONS PROJECT NAME 1 : 25 Checker Approver REV DATE BY CHK DESCRIPTION TRANSNET PIPELINES A 15/08/25 KO BJ FOR INTERNAL REVIEW HW FIRE CAD FILE: DESIGN-DRAWN: DATE: B 10/09/25 KO BJ FOR CLIENT REVIEW DRAWN REF. C 30/09/25 KO BJ CHANGED TO A3 FORMAT TRACED DATEH HW FIRE HO1436-TPL_2024_09_0008_77334_RFP-FAT-0001 Designer- Author 2025-09-09 GREYJONES (PTY) LTD. CHECKED APPROVED TITLE:  SCALE PROJECT No: DRAWING No: REV: TYPICAL DETAILS - OWS TPL DRAWING No. REV 11364-A1110 C  A3 11364 1 2 3 4 5 6 7 8 9 10 11 12 NOTE: 25x25x3L FULLY WELDED THE TYPICAL DETAILS AND A DIMENSIONS PROVIDED IN THIS DRAWING PROVIDE THE 70 35 MINIMUM REQUIREMENTS 1335 ACCEPTABLE. THE EACH CABLE DRAW BOX MUST BE CLEARLY CONTRACTOR IS TO PRODUCE NUMBERED WITH ROAD MARKING PAINT, 60 60 THETAKEFINALOWNERSHIPDESIGN OFANDTHETO INCLUDING DIRECTIONAL ARROWS, IN LINE 200 DETAIL DRAWINGS FOR WITH THE EMPLOYER'S REQUIREMENTS. CONSTRUCTION AND SIGN OFF AS PER THE PROJECT B 60 SCOPE OF WORKS AND SPECIFICATION DOCUMENTS 12mm ROUND BAR LIFTING 935 HANDLES 1335 6CFW TO PLATE LIDS TO BE STRAPPED AND SEALED C 200 VASTRAP COVER SCALE: 1 : 25 VASTRAP PLATE COVER COMPLETE WITH LIFTING LUGS D 230 855 230 STRAPS AND TO BE SEALED 250SQUARE LAYERWORKS & OPENING IN EXTERNAL BRICKWORK ABOVE SURFACE AS PER SITE BASE FOR GROUND TO MATCH EXISTING REQUIREMENTS WATER 230 BUILDINGS SOAK AWAY E MHC MHC A1111 855 A1111 1500 NF BRICK WALLS WITH BRICKFORCE EVERY 4TH CABLE SLEEVES AS PER ELECTRICAL ENG. COURSE DRAWINGS AND REQUIRMENTS 230 15mm INTERNAL PLASTER F 300x300x300 SUMP FILLED WITH 19mm STONE DESIGNER MESH REF 395 CENTRALLY PLACED 230 855 230 RESP. ENG PROJ. MANAGER CLIENTG ROLE NAME SIGN DATE TYPICAL MANHOLE CABLE SLEEVES TYPICAL SECTION - MHC SCALE: 1 : 25 SCALE: 1 : 25 DRAWING APPROVAL STATUS PROJECT: SCALE CHECKED: APPROVED: REVISIONS PROJECT NAME 1 : 25 KO BJ REV DATE BY CHK DESCRIPTION TRANSNET PIPELINES A 15/08/25 KO BJ FOR INTERNAL REVIEW HW FIRE CAD FILE: DESIGN-DRAWN: DATE: B 10/09/25 KO BJ FOR CLIENT REVIEW DRAWN REF. C 30/09/25 KO BJ CHANGED TO A3 FORMAT TRACED DATEH HW FIRE HO1436-TPL_2024_09_0008_77334_RFP-FAT-0001 KO - CCAD 2025-09-09 GREYJONES (PTY) LTD. CHECKED APPROVED TITLE:  SCALE PROJECT No: DRAWING No: REV: TYPICAL DETAILS - CABLE DRAW BOX TPL DRAWING No. REV 11364-A1111 C  A3 11364 1 2 3 4 5 6 7 8 9 10 11 12 SPLICE CONNECTIONS FOR NOTE: CONSTRUCTABILITY TO BE THE TYPICAL DETAILS AND A 1 2 DETARMINED MAX 1/ 1416 DIMENSIONSTHIS DRAWINGPROVIDEDPROVIDEINTHE 1300 MAX 20m SPAN FROM SUPPORT MINIMUM REQUIREMENTS 1300 ACCEPTABLE. THE 1000 1000 1000 CONTRACTOR IS TO PRODUCE THE FINAL DESIGN AND TO 60x60x5L TYP. PC100x50 TAKE OWNERSHIP OF THE DETAIL DRAWINGS FOR CONSTRUCTION AND SIGN OFF AS PER THE PROJECT B SCOPE OF WORKS AND 1506 1392 SPECIFICATION DOCUMENTS 60x60x5L PC100x50 PC100x50 70x70x6L TYPICAL BRACING 70x70x6L PC100x50 PC100x50 SPAN TO BE PRE-CAMBERED 70x70x6L FOR CALCULATED DEFLECTION C 5000 100x100x8L 100x100x8L MIN 356x171x45UB TYPICAL CROSS SECTION SCALE: 1 : 50 D 0.000 TYPICAL SECTION SCALE: 1 : 100 E 1 2 4 1300 22200 80x80x6L 1300F 70x70x6L PC100x50 70x70x6L D 80x80x6L 60x60x5L TYPICAL CROSS BRACE PLAN LAYOUT DESIGNER SCALE: 1 : 100 RESP. ENG PROJ. MANAGER CLIENTG ROLE NAME SIGN DATE DRAWING APPROVAL STATUS PROJECT: SCALE CHECKED: APPROVED: REVISIONS PROJECT NAME As indicated KO BJ REV DATE BY CHK DESCRIPTION TRANSNET PIPELINES A 15/08/25 KO BJ FOR INTERNAL REVIEW HW FIRE CAD FILE: DESIGN-DRAWN: DATE: B 22/10/25 KO BJ FOR CLIENT REVIEW DRAWN REF. TRACED DATEH HW FIRE HO1436-TPL_2024_09_0008_77334_RFP-FAT-0001 KO - CCAD 2025-09-09 GREYJONES (PTY) LTD. CHECKED APPROVED TITLE:  SCALE PROJECT No: DRAWING No: REV: TYPICAL DETAILS - BRIDGE DETAILS TPL DRAWING No. REV 11364-A1112 B  A3 11364

Role name sign date 'PS-T1' pipe support 'PS-T2' pipe support 'pst7' pipe support

Scale: 1 : 10 scale: 1 : 10 scale: 1 : 10 drawing approval status

Project: scale checked: approved: revisions project name

1 : 10 ko bj rev date by chk description TRANSNET pipelines a 15/08/25 ko bj for internal review hw fire

Cad file: design-drawn: date: b 10/09/25 ko bj for client review drawn REF.

C 30/09/25 ko bj changed to a3 format traced dateh hw fire ho1436-tpl_2024_09_0008_77334_rfp-fat-0001 ko - ccad 2025-09-09 greyjones (pty) ltd. Checked approved

TITLE:  SCALE PROJECT No: DRAWING No: REV:

TYPICAL DETAILS - T POSTS SHEET 1 TPL DRAWING No. REV

11364-A1091 c  a3 11364

1 2 3 4 5 6 7 8 9 10 11 12

Note:

Project: scale checked: approved: revisions project name

1 : 10 ko bj rev date by chk description TRANSNET pipelines a 15/08/25 ko bj for internal review hw fire

Cad file: design-drawn: date: b 10/09/25 ko bj for client review drawn REF.

C 30/09/25 ko bj changed to a3 format traced dateh hw fire ho1436-tpl_2024_09_0008_77334_rfp-fat-0001 ko - ccad 2025-09-09 greyjones (pty) ltd. Checked approved

TITLE:  SCALE PROJECT No: DRAWING No: REV:

TYPICAL DETAILS - T POSTS SHEET 2 TPL DRAWING No. REV

11364-A1092 c  a3 11364

1 2 3 4 5 6 7 8 9 10 11 12

TOS NOTE: 6mm PTFE TEFLON PAD

11364 11364-A1094 c  a3 supports - sheet 1

1 2 3 4 5 6 7 8 9 10 11 12

Note:

11364 11364-A1095 c  a3 supports - sheet 2

1 2 3 4 5 6 7 8 9 10 11 12

Note:

180x70PC STRINGER, 6CFW TO 10 THICK BASE 180PFC/100PFC COLUMN, 6CFW TO 16 THE TYPICAL DETAILS AND

DIMENSIONS PROVIDED INA PLATE WITH 2 x 18mm DIA HOLES FOR 2 x M16 THICK BASE PLATE WITH 4 x 22mm DIA

HILTI HIT-HY CHEMICAL ANCHORS (OEA) HOLES FOR 4 x M20 GR 4.8 GALVANIZED THIS DRAWING PROVIDE THE MINIMUM REQUIREMENTS HD BOLTS. ACCEPTABLE. THE

11364-A1101 c  a3 11364

1 2 3 4 5 6 7 8 9 10 11 12

Note:

M16 gr4.8 Hd bolt m20 gr4.8 Hd bolt the typical details and

Dimensions provided ina gr4 nut m24 gr4.8 Hd bolt

Gr4 nut gr4 nut this drawing provide the

Washer minimum requirements 150 washer 150 20 washer 150 washer acceptable.CONTRACTORTHEIS To produce washer washer top of plinth the final design and to 50 gr4 nut top of plinth top of plinth take ownership of the 50 gr4 nut gr4 nut

Specification documents 150 pocket 150 pocket pocket deep 200 deep

Deep

330 75 wide pocket

• Round washer to be used

• Bolt shanks to be

70 x 70 x 12 ANCHOR PLATE 600 DEGREASED BEFORE 2010 EMBEDDING IN CONCRETE

6Cfw both sides of

• All bolts, nuts & washers

D 763.

12 70 x 70 x 12 ANCHOR PLATE

• All washers to be heavy

6Cfw both sides of m16 hd bolt 18 plate u.O.S.

Scale: 1 : 5

M16/M20 gr4.8 Thread bar m20 hd bolt / hilti hit-z-r rode

Scale: 1 : 5

Gr4 nut

12 85 x 85 x 12 ANCHOR PLATE WASHER

110 plate washer 18 6cfw both sides of top of concrete nsg gr4 nut plate u.O.S.

F m24 hd bolt

180 hole to be drilled into existing scale: 1 : 5

150mm LAYER OF OFF AS PER THE PROJECTB SCOPE OF WORKS AND

Imported g5 compacted specification documents

To 98% mod aashto

150mm LAYER OF

Imported g7 compacted

To 95% mod aashto

USB green polyethylene (provisional)

C SHEETING (TAPED) 150mm SUB-GRADE RIPPED

And re-compacted to 93% soil poisoned ripped & mod aashto recompacted insitu material

Compacted to 95% mod aashto. Paving layerworks

Scale: 1 : 10

Sheeting (taped) paving joint medium

E bedding padding, plaster 300 sand / washed river sand /

DIMENSIONS PROVIDED INA HOT DIPPED GALV. MENTIS RS40-40x3.0 MENTIS RS40-40x3.0

50x50x6 L SEAT RECTAGRID COVER OR RECTAGRID COVER OR THIS DRAWING PROVIDE THE

7 gap similar approved similar approved 7 gap minimum requirements acceptable. The

M16 hilti hsa contractor is to produce

Anchors at 250 the final design and to

HOT DIPPED GALV. 150 LONG FISHTAIL LUGS 80x60x8 L SEAT AT 300 CENTERS 4CFW

TO 50x50x6 L SEAT

{"closingDate":"03 September 2025","briefingSession":"{"date":null,"time":null,"venue":"tend and participate in all project meetings,","is_compulsory":false}"}

{"name":null,"email":null,"phone":null,"department":null,"address":"safety risk"}

situation safe. A DSTI is based on a simple checklist/evaluation tool that is completed prior

SHEQ Safety Health Environment and Quality

Upgrade project

Health and Safety Specifications

Document Number: HO1436-SP-0001

Project

Applicants must be authorized (in writing) to receive (or accept) Permits to Work and must

be competent to do so by virtue of their training, experience and knowledge of the area or

plant in which the work is to be performed.

Authorized Person (Permit to Work)

A person (typically an employee of the client) who has been authorized (in writing) to issue

(a) has in respect of the work or task to be performed the required knowledge,

training and experience and, where applicable, qualifications specific to that

work or task,

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

(b) is familiar with the OHS Act and with the applicable Regulations made under the Act.

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

• Documentation and Document Control project-specific documentation required for the

effective management of health and safety on the project must be developed and

maintained, and processes must be in place for the control of these documents,

• Processes and procedures for maintaining Operational Control, including rules and

requirements (typically contained in Safe Work Procedures) for effectively managing

health and safety risks, particularly critical risks associated with working at heights,

confined spaces, mobile equipment and light vehicles, lifting operations, hazardous

chemical agents, etc.,

• Emergency Preparedness and Response procedures,
• Management of Change a process must be in place to ensure that health and safety

risks are considered before changes are implemented,

• For a principal contractor a process must be in place for the assessment of their

contractors and service providers regarding health and safety requirements and

performance (before any contract or purchase order is awarded),

• Measuring and Monitoring plans, including a plan for the measuring and monitoring of

employee exposure to hazardous substances or agents (e.g. Noise, dust, etc.) to

determine the effectiveness of control measures,

• Incident Reporting and Investigation procedures describing the protocols to be

followed regarding incident reporting, recording, investigation and analysis,

• Non-conformance and Action Management procedures concerning the management of

corrective actions,

• Performance Assessment and Auditing procedures concerning health and safety

performance reporting, monthly internal audits to assess compliance with the project

health and safety requirements, and daily site health and safety inspections, and

• Details concerning the Management Review process followed to assess the

effectiveness of health and safety management efforts.

incidents, injuries, and illnesses, and ensuring legal compliance must be the primary

considerations for setting objectives. When setting objectives, consideration must be given to

the following:

• Leading indicators such as inspection findings, audit findings, hazard reporting, and

observations,

• Lagging indicators (i.e. Incidents including Near Misses),

• Leading practices and lessons learnt, and

• Injury frequency rates with due understanding that the goal is "zero harm".

• Acting consistently and strictly against any contractor employee who transgresses a

health and safety rule or requirement,

• Ensuring that an effective management of change process is in place,
• Implementing, testing, and maintaining an effective Emergency Response Plan for

contractors’ activities, and ensuring that the plan is adequately resourced,

• Ensuring that workplace exposure of contractors’ employees to hazardous substances

or agents is measured and monitored to determine the effectiveness of controls and

compliance with legal (and project) requirements,

• Ensuring that all incidents are reported without delay and are investigated thoroughly,
• Participating in investigations into significant incidents,
• Ensuring that accurate health and safety statistics are maintained, and that health and

safety performance reports are compiled as required,

• Providing the necessary resources for regular health and safety audits and inspections

to be conducted and supporting the auditing process,

• Participating in health and safety audits and carrying out workplace inspections,
• Ensuring that corrective actions (arising from incident investigations, audits,

inspections, etc.) are implemented, and that adequate resources are provided for this

purpose,

• Participating in an annual review of the contractors Health and Safety Management

• Carrying out Planned Task Observations on an ad hoc basis,

• Assisting with the implementation, testing and maintenance of an effective Emergency

Response Plan for the contractor’s activities,

• Responding to workplace incidents (as appropriate),
• Participating in incident investigations,
• Maintaining accurate health and safety statistics for the contractor and compiling

health and safety performance reports as required,

• Monthly auditing of the Health and Safety Management System and workplace

activities by the contractor, to assess compliance with the project health and safety

requirements,

• Tracking and reporting on the implementation of corrective actions (arising from

incident investigations, audits, inspections, etc.).

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

The Contractor’s Health and Safety Officer shall possess qualifications and have acquired

the necessary experience as follows:

• Minimum of 5 years’ experience in assisting with development, implementation and

maintenance of Health and Safety Management Systems in civil or mechanical

construction.

• Minimum Certificate in Safety Management (NQF Level 5) or Environmental Health or

appointment letter) must be

B-BBEE Minimum Level: 5

Document Number: HO1436-SP-0001

Project Name: Witbank Depot Fire Protection System Upgrade

Project No.: HO1436

Author: Thulani Manana

Owner: Transnet Pipelines

Client: Transnet Pipelines

Project Sponsor: Russel Bradbrooke

Senior Project Manager: Sechaba Kunene

Revision No.: Revision 0

Approved by: Sechaba Kunene

Release Date: 03 September 2025

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

1. Purpose. 5
2. Project Scope. 5-6
3. Scope. 6
4. Definitions. 6-13
5. Abbreviations. 13-15
6. Health and Safety Management Plan. 15-16
7. Health and Safety Policy. 17
8. Hazard Identification and Risk Assessments. 17-22
9. Legal and Other Requirements. 23
10. Health and Safety Objectives. 23
11. Resources, Accountabilities and Responsibilities. 23-36
12. Competencies, Training and Awareness. 37-39
13. Communication, Participation and Consultation. 39-43
14. Documentation and Document Control. 43-44
15. Contractor Health and Safety File Requirements. 44-45
16. Construction Work Permit and Notification of Construction Work. 45
17. General Rules of Conduct. 46
18. Site Establishment. 47
19. Access Control. 47-48
20. Visitors. 48
21. Alcohol, Drugs and Other Intoxicating Substances. 48-49
22. Light Vehicle. 49-50
23. Mobile Equipment. 50-53
24. Traffic Management Plan. 53-54
25. Loading and Offloading of Containers and Material. 54
26. Signs and Notices. 54-55
27. Machinery. 55-56
28. Barricading. 56-58
29. Excavation. 58-62
30. Cranes and Lifting Equipment. 63-72
31. Fall Protection. 72-79
32. Scaffolding. 79-86
33. Ladders. 87-88
34. Permit to Work. 88-94
35. Electrical Safety. 94-102
36. Confined Spaces. 102-104
37. Hot Work. 104-110
38. Tools and Equipment. 110-116
39. Manual Handling and Vibration. 116-118
40. Personal Protective Equipment. 118-127
41. Fuel/Flammable Liquid Storage and Refueling. 127-129
42. Fire Protection and Prevention. 129-132

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

43. Housekeeping. 132-133
44. Waste Management. 133
45. Stacking and Storage. 133-134
46. Facilities. 134
47. Occupational Hygiene. 134-135

48 Hazardous Chemical Agents. 136-138

49. Fitness for Work. 138-142
50. Measuring and Monitoring. 142-143
51. Temporary Works. 143-144
52. Structures. 144
53. Emergency Preparedness and Response. 144-146
54. Incident Reporting and Investigation. 146-149
55. Performance Assessment and Auditing. 149-151
56. Management Review. 152
57. Management of Change. 152-153
58. Non-Conformance and Action Management. 153

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

adequate provision has been made to ensure compliance. This Health and Safety

which requirements are applicable. The contractor shall conduct a health and safety risk

assessment specific to the project and specific to the contractor's scope of work. All

applicable requirements must be addressed in the Contractor's Health and Safety

shall be submitted to project management prior to commencement of work for approval. The

contractor shall adhere to the approved Construction Methodology.

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

construction site including where the construction activities interact with the existing

operations. The requirements specified in this document are applicable to principal

contractors as well as any contractor, EPCM, consultants, visitors and service providers. It is

the principal contractor's responsibility to ensure that all their contractors comply fully with

all legal requirements as well as the requirements of this Health and Safety Specification.

legal requirements and the Health and Safety Policy adopted for the project.

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

ALARP (As Low As Reasonably Practicable)

necessary to avoid the risk. With respect to health and safety, it is assumed that the

measures should be implemented unless it can be shown that the sacrifice is grossly

disproportionate to the benefit.

Applicant (Permit to Work)

inadvertently coming into contact with an identified hazard.

any person at work under his or her control to prepare a design, including an employee of

that person where he or she is the employer or an architect or engineer contributing to, or

having overall responsibility for a design.

Discipline Lock (many locks with a restricted number of identical keys)

(e.g. Low voltage electricity).

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

Equipment Lock (many locks with one unique key)

eliminate, or minimize exposure to workplace health and safety hazards:

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

• Elimination – Completely removing a hazard or risk scenario from the workplace,
• Substitution – Replacing an activity, process, or substance with a less hazardous

alternative,

• Engineering Controls – Isolating a hazard from persons through the provision of

mechanical aids, barriers, machine guarding, interlocks, extraction, ventilation, or

insulation,

• Administrative Controls – Establishing appropriate policies, procedures, and work

practices to reduce the exposure of persons to a hazard. This may include the

provision of specific training and supervision, and

• Personal Protective Equipment – Providing suitable and properly maintained PPE to

cover and protect persons from a hazard (i.e. Prevent contact with the hazard).

Lost Time Injury (LTI)

A lost time injury (LTI) occurs when a person is injured in the execution of his/her duties and

as a result of this injury is unable to perform his/her regular duties for one full shift or more

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

on the day following day which the injury was incurred. Note: Regular duties are those

duties associated with the job description of the injured.

Lost Time Injury Frequency Rate (LTIFR)

Number of LTI's multiplied by 200,000 and divided by manhours worked.

normal first aid including initial treatment given for more serious injuries.

The procedure is to be of an invasive nature (e.g. Stitches, removal of foreign body). The

following procedures are generally considered medical treatment:

• Application of sutures (stitches),
• Cutting away dead skin (surgical debridement),
• Loss of consciousness due to an injury or exposure in the work environment.
• Positive X-Ray diagnosis (fractures, broken bones etc.)
• Removal of foreign bodies embedded in the eye,
• Removal of foreign bodies from the wound by a physician due to the depth of

embedment, size or shape of object or the location wound,

• Reaction to a preventative shot administered because of an occupational injury,
• Sprains and strains series (more than one) of hot and cold soaks, use of whirlpools,

diathermy treatment or other professional treatment,

• Treatment of infection,
• Use of prescription medications (except a single dose administered on first visit for

minor injury or discomfort), and

• Treatment for second- or third-degree burns.

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

In the context of this guideline, Regulation(s) refers to the latest version of the Construction

Regulations, as required by Section 43 of the Occupational Health and Safety Act .

hazards, analyzing, and evaluating the associated risks, determining whether the risks are

acceptable, and controlling and monitoring the risks on an ongoing basis.

any building, steel or reinforced concrete structure (not being a building), railway line or

siding, bridge, waterworks, reservoir, pipe or pipeline, cable, sewer, sewage works, fixed

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

vessels, road, drainage works, earthworks, dam, wall, mast, tower, tower crane, bulk mixing

plant, pylon, surface and underground tanks, earth retaining structure or any structure

designed to preserve or alter any natural feature, and any other similar structure.

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

Nebosh National Examination Board in Occupational Safety and Health (UK)

OHSA Occupational Health and Safety Act () as amended

SOC’S Safety Observations and Conversations

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

minimum, include the following:

• A copy of the contractor's Health and Safety Policy in terms of the OHS Act Section 7,
• Procedures concerning Hazard Identification and Risk Assessment including both

measures to ensure that this information is accessible to relevant personnel,

• Details concerning Health and Safety Objectives, a process must be in place for

setting objectives (and developing associated action plans) to drive continual

improvement,

• Details concerning Resources, Accountabilities and Responsibilities this includes the

assignment of specific health and safety responsibilities to individuals in accordance

with legal or project requirements, including the appointment of a Construction

• Details concerning Competence, Training and Awareness a system must be in place to

ensure that each employee is suitably trained and competent, and procedures must

be in place for identifying training needs and providing the necessary training,

• Communication, Participation and Consultation arrangements concerning health and

safety, including Safety Observations and Coaching, Toolbox Talks, Daily Safe Task

designated personnel for review and if found to be adequate, will be accepted (typically

"with comments"). Work may not commence until the Health and Safety Management Plan,

and other health and safety file documents have been accepted/approved. There are two

types of approval, PROVISIONAL meaning site establishment and FULL meaning the

contractor can commence with executing work.

The contractor shall take action and resolve any issues within 14 days from commencement

of work if PROVISIONALLY approved. If the issues requiring corrective action are not

resolved within this 14-day period, the contractor will be required to stop any work related to

the outstanding actions until they have been resolved. Any proposed amendments or

revisions to the contractor's Health and Safety Management Plan and other health and safety

file documents must be submitted to the PrCHSA or designated personnel for acceptance.

has omitted the activity and associated control measures from the Health and Safety

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

clearly states the contractor's values and objectives for the effective management of health

and safety in terms of the OHSA Section 7. These values and objectives must be endorsed

by the contractor's management representatives and must be consistent with those adopted

for the project. The policy must be signed, dated and reviewed annually. The Health and

• Compliance with all applicable legal and other requirements,
• The effective management of health and safety risks,
• The establishment of measurable objectives for improving performance, and the

provision of the necessary resources to meet these objectives,

• The prevention of incidents, and
• Achieving continual improvement regarding health and safety performance.

be performed as well as for all associated equipment and facilities as required by the

Construction Regulations 9. TPL as the client will provide a Baseline Risk Assessment

informing the contractor on inherent hazards and risks within the project site. Contractor

must ensure that effective procedures and risk assessment systems are in place to control

hazards and to mitigate risks to levels that are as low as is reasonably practicable. The risk

assessment processes must be applied to:

• The full life cycle of the project,
• Routine and non-routine activities,
• Planned or unplanned changes,
• All employees, contractors, service providers, and visitors, and
• All infrastructure, equipment, and materials.

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

• Establishing the context of the risk assessment,
• Identifying hazards and determining possible risk scenarios (unwanted events),
• Evaluating risks and assigning ratings (classification),
• Recording the risk analysis in a risk register,
• Managing risks according to their classification (prioritizing for action),
• Identifying and implementing control measures (through the application of the

Hierarchy of Controls) to ensure that risks are managed to levels that are as low as is

reasonably practicable (ALARP),

• Developing action plans for reducing risk levels (where possible),
• Verifying the completion of actions,
• Re-evaluating the risks and classifications as appropriate, and
• Reviewing and updating the risk register.

8.1 Baseline Risk Assessments.

measures as required to mitigate such hazards and risk scenarios associated with the overall

project scope as required by Construction Regulations 5(1)(a). The Risk Assessment process

shall be facilitated by a team of competent persons, including subject matter experts as

required. The Baseline Risk Assessment shall be reviewed approved by project management

prior to implementation.

When carrying out a Risk Assessment, Hazard (Energy) Types must be specified in

accordance with the categorization detailed in Table 8-1 below. Risk scenarios must be

described indicating the way a person may come into contact with, or be exposed to, a

specific hazard. An initial risk rating must be assigned to each risk scenario without taking

any control measures into consideration. Control measures for managing the risks to levels

that are as low as is reasonably practicable must then be identified for implementation on

the project, and a residual risk rating must be assigned to each risk scenario taking the

identified control measures into consideration.

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

Table 8-1: Hazard (Energy) Types

specified in the register. For the significant risks in particular, action plans will be developed

for reducing the risk levels (where possible). The project Risk Register will be reviewed and,

if necessary, updated on an annual basis during construction as well as when changes are

made to a design and/or the construction scope, schedule, methods, etc. that result in a

change to the risk profile and following an incident.

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

in the contractor's Risk Assessments are taken into consideration when developing,

implementing and maintaining the various elements of the contractor's health and safety

management system for the project (e.g. Competence, training and awareness

requirements). All persons potentially affected must be made aware of the hazards, risk

scenarios and control measures identified in the contractor's Risk Assessments. The

contractor shall develop its own Risk Register that comprises of all significant risks (i.e. Risks

rated as major or catastrophic) identified when developing their Risk Assessments.

8.2 Task-Based Risk Assessments.

must be reviewed and approved by the PrCHSA or designated personnel prior to the

commencement of any work. The risk assessment process must be facilitated by a

competent person who has been appointed in writing in terms of the Construction

Regulations 9(1). The contractor's site management representatives, supervisory personnel,

technical experts (as required) and workforce personnel directly involved with the task being

examined must participate in the Risk Assessment process. An attendance register must be

completed and retained. It must be noted that under no circumstances may a contractor’s

participation of all people referred to above is mandatory. A Task-Based Risk Assessment

must at least:

• Be accompanied by a Safe Work Procedure (describing in sufficient detail how the

specific job or task is to be performed in a logical and sequential manner),

• Provide a breakdown of the job or task into specific steps,
• Identify the hazards and potential risk scenarios associated with each step,
• Include consideration of possible exposure to noise, heat, dust, fumes, vapours,

gases, chemicals, radiation, vibration, ergonomic stressors, or any other occupational

health hazard or stressor,

• Describe the control measures that will be implemented to ensure that the risks are

managed to levels that are as low as is reasonably practicable, and

• Assign an initial risk rating (without taking any control measures into consideration)

and a residual risk rating (taking the identified control measures into consideration) to

each risk scenario.

• On an annual basis (as a minimum),
• When changes are made to a design and/or the construction scope, schedule,

methods, and

• Following an incident.

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

8.3 Pre-Task Hazard Assessments.

carrying out an activity. Any deviation from what was discussed during the Daily Safe Task

Instruction (DSTI) (prior to the activity commencing), or anything that was not discussed,

constitutes a change. Before carrying out the task that involves the identified change, a few

minutes must be spent identifying the hazards and risks associated with that task as well as

suitable control measures.

8.4 DSTI/Continuous Risk Assessment.

A Daily Safe Task Instruction (DSTI) is a simple and effective tool for the management of

hazards and risks within the workplace. It enables supervision, work teams and individual

employees to quickly assess a situation for hazards and to introduce controls to make the

situation safe. A DSTI is based on a simple checklist/evaluation tool that is completed prior

to commencing work. It can be made task specific, rather than using a generic one for all

activities.

work related tasks as well as at the end of the shift to record any incidents, changes that

occurred during the shift, and lessons learnt. Due consideration must be given to changes in

the work environment e.g. terrain, weather and health hazards when conducting the DSTI.

supervision shall ensure the existing Task-Based Risk Assessment is amended and revised,

as necessary. All visitors to a particular work area must also sign the DSTl for that area as

acknowledgement of identified hazards.

8.5 Issue-based Risk Assessment.

appropriate for the management of change in the workplace, for example:

• When a near-miss incident occurred,
• New machinery/equipment is introduced into the workplace,
• Processes or procedures change, and
• New knowledge comes to light, to name a few.

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

conducted. The outcomes of all Issue-Based Risk Assessments will be incorporated into the

management tools and methods. This can typically include critical health and safety risks,

strategic business management, project risk workshops, HAZOP studies, HAZCON studies,

change management and safety in design issues where controls are required to achieve

8.7 Risk Assessment Monitoring and Reviews.

personnel prior to the commencement of any work. Safe work procedures shall include

reference to:

• The specific method statements,
• Control measures to mitigate or reduce risk,
• Supervisory requirements, including level and frequency,
• Responsibilities of competent persons,
• Responsibilities of legal appointees,
• Required personal protective equipment,
• Required plant, tools, and equipment,
• Inspection regime relating to plant, tools, and equipment,
• Medical certificates of fitness,
• Relevant risk assessments, and
• Emergency management procedure, and any special arrangements required for the

task.

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

ensure the effective implementation, maintenance and continual improvement of the

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HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

contractor's health and safety management system on the project. For each role that carries

health and safety accountability and/or responsibilities (including legislative requirements), a

role description detailing the accountability and/or responsibilities must be documented.

All health and safety appointments (i.e. the assignment of specific health and safety

responsibilities to individuals in accordance with legal or project requirements) must be done

in writing. Documented proof of each appointment (i.e. a signed appointment letter) must be

retained. The contractor should not discharge any legal responsibilities to employees who are

not legally appointed.

health and safety related appointments and delegations for the project.

maintained. All roles that carry health and safety accountability and/or responsibilities must

be included, and all individuals that carry health and safety appointments must be clearly

identified.

appropriate for the nature and scale of the work to be carried out. The contractor is solely

responsible for carrying out the work under the contract whilst having the highest regard for

the health and safety of all persons on the project site. Health and safety are the

responsibility of each individual on the project site, but in particular, it is the responsibility of

the contractor's management team who must set the tone.

contractor's managers and supervisors at all levels must demonstrate their commitment and

support by adopting a risk management approach to all health and safety issues. These

individuals must consistently take immediate and firm action to address violations of health

and safety rules and must actively participate in day-to-day activities with the objective of

preventing harm. The contractor's management representatives are responsible and

accountable for health and safety performance on the project. Key responsibilities include

the following:

• Preparing, implementing, and maintaining a risk-based Health and Safety

• Establishing, implementing, and maintaining health and safety systems and

procedures to ensure that all work is carried out in compliance with the requirements

of this specification, the contract, and all applicable legislation,

• Establishing, implementing, and maintaining effective hazard identification and risk

management processes and procedures to ensure that all reasonably foreseeable

hazards are controlled to minimize risk,

• Providing the resources necessary to meet the requirements of this specification,

Page | 24

HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

• Ensuring that all contractor employees have clearly defined responsibilities regarding

health and safety, and that these responsibilities are clearly communicated and

understood,

• Establishing, implementing, and maintaining a system for ongoing training and

assessment of skills and competence,

• Establishing, implementing, and maintaining procedures to ensure that only qualified

and competent personnel are permitted to work on the project site,

• Establishing, implementing, and maintaining effective communication and consultative

processes concerning health and safety for the duration of the contract,

• Maintaining operational control for the protection of all persons on the project site as

well as the public,

• Establishing, implementing, and maintaining effective emergency preparedness and

response procedures,

• Establishing, implementing, and maintaining effective management of change

processes and procedures,

• Establishing, implementing, and maintaining effective incident reporting, investigation

and recording processes and procedures,

• Establishing, implementing, and maintaining effective auditing and inspection

processes and procedures, and

• Formally reviewing the contractor's Health and Safety Management System annually

to ensure that the system continues to be effective in managing health and safety

performance and meeting project requirements.

cost associated with any work stoppage due to non-compliance with a health and safety

requirement shall be in the contractor's account.

11.1 Contractor Construction Manager.

responsible for the successful and safe completion of all work to be carried out by

contractors as required by the Construction Regulations 8(1). The Construction Manager

shall be responsible for:

• Ensuring that a Health and Safety Policy that clearly states the contractor's values and

objectives for the effective management of health and safety on the project is in place

and is communicated to all contractors and their employees,

• Ensuring that all applicable legal and project health and safety requirements are

always identified and complied with,

• Ensuring that effective hazard identification and risk management processes are

established and implemented for all work to be carried out by contractors,

• Participating in (and approving) all Task-Based Risk Assessments conducted for the

work to be carried out by contractors,

Page | 25

HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

• Driving the achievement of agreed health and safety objectives,
• Ensuring that the necessary resources are made available for the effective

implementation of the contractors’ Health and Safety Management Plans,

• Ensuring that all work is adequately and competently supervised,
• Ensuring that all contractors’ employees have clearly defined responsibilities regarding

health and safety (assigned in writing), and that these responsibilities are clearly

communicated and understood,

• Ensuring as far as is reasonably practicable that contractors and their employees are

competent to perform their roles and have received appropriate workplace health and

safety training and instruction,

• Managing all appointed contractors regarding health and safety performance,
• Establishing and maintaining effective communication and consultative processes to

ensure that contractors and their employees are kept up to date regarding health and

safety information (e.g. Incidents and lessons learnt, leading practices, hazards, risks

and control measures, etc.) and that feedback is provided promptly regarding issues

and/or concerns raised,

• Participating in the project's Visible Felt Leadership (VFL) programme,

• Chairing monthly Contractor Health and Safety Meetings and attending monthly Site

• Implementing programmes that encourage continual improvement and providing

recognition for suggestions made by contractors’ employees,

• Implementing contractors’ Health and Safety Management Plans and associated Safe

The Contractor’s Health and Safety Manager shall be duly registered with the SACPCMP as

• Design Health and Safety Management Systems specific to the need of the project,

organizational and specific construction project management system,

• Facilitate and coordinate preparation of site-specific Health and Safety Management

the Project Health and Safety Specification,

• Facilitating and chairing of monthly health and safety meetings,
• Ensure identification of hazards and risks relevant to the construction project through

regular coordinated site inspections,

• Attend and participate in all project meetings,
• Use of trend analysis to identify system deficiencies and incident trends, outline

relevant improvements,

• Manage necessary changes on the contractor’s Health and Safety Management Plan,
• Manage the reporting, investigation and recording of project related incidents,
• Manage and maintain health and safety communication structures and systems,

including distribution of health and safety specific documents to subcontractors,

• Monitor, measure and report on health and safety system performance through

facilitating health and safety audits,

• Analysis of audit results and trends to ensure continuous improvement,
• Manage and evaluate processes for reporting non-compliance issues and

implementation of identified appropriate corrective and preventative actions.

• Manage health and safety during defects liability period,
• Prepare health and safety close out report for the contractor.

The Contractor’s Health and Safety Manager shall possess qualifications and have acquired

the necessary experience as follows:

Page | 27

HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

• Minimum of 10 years’ experience in development, implementation and maintenance of

• Minimum National Diploma or Advanced Diploma/BTech in Safety Management or

Bachelor’s degree in Environmental Health or NEBOSH International Diploma or an

equivalent qualification.

The Contractor’s Health and Safety Officer shall be duly registered with the SACPCMP as

responsible for the following:

• Reviewing all applicable legal and project health and safety requirements and

providing guidance to the contractor's management personnel to ensure continual

compliance,

• Assisting with the implementation of effective hazard identification and risk

management processes for all work to be carried out by the contractor,

• Participating in all Task-Based Risk Assessments conducted for the works to be carried

out by the contractor and ensuring that identified control measures are implemented,

• Conducting contractor’s health and safety induction training for all contractor’s

personnel,

• Compiling and maintaining all health and safety related documents and records

required of the contractor,

• Communicating relevant health and safety information to contractor’s personnel (e.g.

incidents and lessons learnt, leading practices, hazards, risks, and control measures,

etc.),

• Carrying out Safety Observations and Coaching,
• Evaluating the content of the DSTI's conducted by the contractor's appointed

supervisor and attending at least one DSTI each day,

• Attending the contractor's site health and safety meetings,
• Assisting with the implementation of the contractor's Health and Safety Management

adequately equipped to enable him to perform his duties effectively, which include the

following:

• A computer with access to all necessary systems, including access to e-mail and the

internet, and

• A mobile telephone on contract or with adequate pre-paid airtime.

as CHSM and/or CHSO respectively, must have the following minimum competences:

• Experience and appropriate training regarding implementing and maintaining a Health

and Safety Management System compliant with national legislation or an international

standard,

• Experience and appropriate training regarding construction related hazard

identification and risk management processes,

• Competence, experience, and relevant training regarding incident investigation

procedures and causation analysis,

• Health and safety auditing experience and training,
• A valid First Aid certificate of competency,
• Fire prevention and protection training, and

contractor must forward a copy of the candidate's resume to the PrCHSA or designated

personnel for review and acceptance. A proposed candidate may be rejected should he not

meet the experience and/or qualification requirements, or due to poor work performance on

previous projects.

Page | 29

HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

11.3 Contractor Construction Supervisors.

by an adequate number of qualified, competent and appointed Construction Supervisors

who have experience in the type of work being carried out as required by the Construction

Regulations 8(7). No work may be carried out without an appointed Construction Supervisor

being physically present in the work area and during completion of the Daily Safety Task

• Ensuring that all work carried out under his supervision is done so in accordance with

the requirements of all applicable legislation, rules, standards, specifications, plans

and procedures,

• Participating in Task-Based Risk Assessments including other relevant risk

assessments,

• Ensuring that all employees under his supervision are made aware of the hazards, risk

scenarios and control measures identified in relevant risk assessments,

• Ensuring that the control measures stipulated in all relevant risk assessments are in

place and are implemented fully for all work carried out under his supervision,

• Ensuring that all employees under his supervision conduct pre-task hazard

assessments, when necessary,

• Driving the achievement of health and safety objectives set for his team,
• Ensuring that the necessary written appointments are in place for each employee

under his supervision (e.g. First aider, mobile crane operator, etc.),

• Ensuring that all employees under his supervision attend all required training,
• Ensuring that no employee carries out any work that he is not competent to perform

or has not been appointed to perform,

• Identifying training needs within his team,
• Carrying out Safety Observations and Coaching,
• Conducting Toolbox Talks with his team,
• Leading a Daily Safe Task Instruction discussion with his team,
• Attending Health and Safety Meetings as required,
• Maintaining a Health and Safety Management Information Notice Board in the work

area for which he is responsible,

• Recording, daily, a description of the day's activities as well as a breakdown (by

occupation) of the personnel on site under his supervision (e.g. 5 bricklayers, 2

carpenters, 3 welders, 22 general workers, and 1 supervisor),

• Ensuring that all Safe Work Procedures applicable to the work carried out under his

supervision are adhered to and are fully implemented,

• Maintaining discipline and taking the necessary action whenever an employee under

his supervision does not adhere to a rule or requirement,

• Carrying out Planned Task Observations,
• Ensuring that emergency response procedures are understood by all employees under

his supervision and that these procedures are followed in the event of an emergency,

Page | 30

environmental impact.

property damage but had the potential to cause an injury, illness, environmental or property

damage.

An event (or a continuous or repetitive series of events) that results or has the potential to

result in a negative impact on people (employees, contractors, service providers and

visitors), the environment, operational integrity, assets, community, process, product, legal

liability and/or reputation.

Page | 26

HO1436-SP-0001HealthandSafetySpecification(WitbankDepot)

• Ensuring that mandatary agreement in terms of OHSA Section 37(2) is in place as well

as principal contractor and contractor appointment in terms CR 5(1)(k) and CR

7(1)(c)(v) respectively have been signed and is in the health and safety file, and

• Ensure that the letter of good standing in terms of COIDA is up to date and is in the

health and safety file as well as the proof of public liability insurance as required with

the bonds for the contract.

11.2 Contractor Health & Safety Manager and Officer.

{"closingDate":"01 October 2025"}

a. Evaluation of the geology and hydrogeology of the site.

h. Evaluation of geotechnical properties of tested soils.

preference to mate

quality control measures like material testing.

maintenance and operational

activities. They may be surfaced with asphalt, gravel, paving

Document Number: PL 889 P a g e 8 | 23

Standard Title: Earthworks

b. has a tertiary qualification (Degree or Bachelor of

Technology or Advanced Diploma or National Diploma) in

civil engineering, and

c. is generally recognized as having the necessary experience

and training to undertake rational assessments or rational

designs in the field of civil engineering.

a. is registered as a Professional Natural Scientist in terms of

the Natural Scientific Professions Act, 2003 (Act No. ), and has a BSc (Hons) degree or higher qualification

in engineering geology,

or

registered as a Certificated Natural Scientist and has a

recognized 3-year qualification or equivalent qualification

at NQF 7 or higher and

b. and has suitable experience in geotechnical site

investigations or foundation design (or both)

subjected to a combination of direct actions and an increase in soil

moisture content, experiences sudden or rapid settlement.

roads situations such as construction sites. They are specifically built for

moving heavy loads such as trucks transporting materials or

equipment.

C3 A moderately strong cement-treated granular material, where:

C = Cemented material and

3= strength class (typically unconfined compressive strength

between 3 and 6 MPa)

C35 Structural grade concrete, suitable for load-bearing applications

with a compressive strength of 35 MPa (megapascals) at 28 days,

testing using standard concrete cute (150 mm)

Type 1 masonry Building not used for storage or industrial purposes, and with

building masonry walls that are not supported by steel, concrete or

reinforced masonry columns

Pipelines (TPL) facilities and along the pipeline routes within TPL’s servitude . It encompasses

earthworks activities such as site preparation, excavation, grading, backfilling, and specific

requirements for stabilization and compaction. Additionally, it addresses other related aspects,

including trench safety, material specifications where applicable, design requirements, and

quality control measures like material testing.

1.2. Applicability

This specification is applicable to all Transnet Pipelines facilities, along the pipeline within TPL’s

servitude and the service roads/ access routes to the block valves chambers and the pipeline.

1.3. Reference Documents

c. Excavation or boring in soil or rock and systematic description of the soil and rock

profiles.

d. Determining the depth of any fill that might be present.

e. In-situ assessment of geotechnical properties of materials.

f. Recovery of samples of soil or rock examination, identification, recording, testing

or display.

g. Testing of soil or rock samples to quantify properties relevant to the purpose of

the investigation.

h. Evaluation of geotechnical properties of tested soils.

i. Reporting of the results.

j. Providing recommendations and conclusions

2.4.1 Geotechnical Assessment Requirements

Table 2: Materials Testing

Tests Required Material Classification TRH14 Test Method

G4 g5 g6 g7 g8 g9 g10

Grading (sieve x x x x x x SANS 3001-GR1

analysis)

SANS 3001-GR2

SANS 3001-GR3

Moisture x x x x x x x SANS3001-GR20

1. General ........................................................................................................... 5

1.1. Scope ............................................................................................................ 5

1.2. Related Specifications & Regulation .............................................................. 5

1.3. Definitions ...................................................................................................... 5

2. Bedding/padding material ........................................................................ 6

2.1. Material Quality .............................................................................................. 6

2.2. Grading .......................................................................................................... 7

2.3. Testing of Material ......................................................................................... 7

3. Bedding and padding bars ........................................................................ 7

4. Padding ............................................................................................................ 8

5. Pipeline construction padding machine ............................................ 8

6. Imported bedding and padding ............................................................... 9

7. Padding sand ................................................................................................. 9

8. Standard crossing conditions and requirements ..................... 11

8.1. Minor Road Crossings (Road reserve less than 20m) ................................. 11

8.2. Major Road Crossings (Road reserve greater than 20m) ............................ 11

8.3. Railway Tracks and Canals Crossings ........................................................ 12

8.4. Underground Services (Cables, Pipes, etc.) ................................................ 12

Document Number: PL 890 P a g e 4 | 13

Standard Title: Bedding and Padding Specification

©Transnet SOC Ltd

pipe.

b) The diameter of the largest Pad sand particles shall not be greater than

1.5mm.

2.3. Testing of Material

a) Grading tests shall be performed for the following:

i. Each new borrow pit area; and / or

ii. At any time, the source of material is changed.

iii. Samples of bedding / padding material shall be taken twice daily from

the trench for testing.

b) The test result shall be subject to the approval of TPL Project Engineer.

Occupational Safety and Health Administration – OSHA 2226

structures shall be cleared in accordance with the requirements of SANS 2001 – BS1. The area

shall also be stripped of all remaining vegetation and surface soil to depth of up to 150 mm.

Unsuitable material shall be disposed of as specified in 2.3.

2.2 Conservation of Topsoil

3.1. All excavations must be conducted in compliance with SANS 10400-G and the

Occupational Safety and Health Administration (OSHA- Trenching and Excavation

Safety) standards.

3.2. Excavation work shall be so executed that material from excavations shall be used in

preference to materials from borrow pits and other sources.

3.3. Support systems like shoring, bracing, or underpinning must be provided when

needed to ensure the stability of adjacent structures, including nearby buildings,

walls, sidewalks, and pavements, during excavation.

3.4. A protective system is not required when excavation is made entirely in stable rock

or when an excavation is less than 1.52 meters deep and a competent person has

examined the ground and found no indication of a potential cave-in.

3.5. Material shall be transported directly to its final position without being stockpiled, and

if stockpiling is unavoidable, materials intended for different uses shall be stockpiled

separately.

3.6. No mechanical driven equipment may be used within the area of the pipeline

servitude/s unless otherwise authorised by the Transnet Pipelines Servitude Officer.

3.7. No blasting is allowed within the pipeline servitude. Application to carry out blasting

within 500m of the pipeline must be made to the Transnet Pipelines Servitude office

in writing in terms of paragraph 17.1 chapter 10 of the regulations embodied in the

Explosives Act and Regulations (Act ) as amended.

after topsoiling has been completed. On completion of planting, the planted area shall be

neatly trimmed and well-watered and not allowed to dry out until it is established, or for the

period required in the scope of work.

a. A 150 mm layer at the bottom of the excavation, ripped and recompacted to 90 %

b. A minimum of three layers of G6 quality material compacted to 98 % Mod AAHSTO

in layers not exceeding 150 mm.

c. A 50 mm thick blinding where applicable.

Figure 1: Typical Detail – Earthworks Section Under Concrete

7.2 Block Valve Chambers

Unless otherwise specified by the Engineer, the typical earthworks for a block valve (BV)

chamber shall include the following:

a. A 150 mm layer of in-situ material ripped and recompacted to 93% Mod AASHTO.

b. A minimum of two layers of G6 material compacted to 98% Mod AASHTO in layers not

exceeding 150mm . Provided the in-situ material is suitable, it may be utilized.

c. A 2mm thick HDPE liner .

d. A maximum particle of 3mm is allowed beneath the HDPE liner. If the excavated soil

is unsuitable , a stabilised sand blinding 50 mm (minimum) should be placed.

7.3 Buried Pipelines and Prefabricated Culverts

Document Number: PL 889 P a g e 16 | 23

Standard Title: Earthworks Specification

©Transnet SOC Ltd

functional requirements.

7.4.1.1 In areas subjected to loads from road traffic , the backfill shall have a PI that does

not exceed 12 and a minimum CBR of 15% at specified density if the backfill is to be

placed in the upper 150mm of the subgrade . If placed lower in the subgrade , the

backfill must have a minimum CBR of 7%.

Document Number: PL 889 P a g e 17 | 23

Standard Title: Earthworks Specification

©Transnet SOC Ltd

7.4.1.2 The road shall be suitably designed to withstand the maximum load imposed by all

operational vehicles required for depot and/or servitude activities, and to allow for

travel with reasonable ease and safety at a speed of 15 km/hr within the depot.

7.4.1.3 Where specified , a wearing course , complying with the following , shall be provided

over the foundation layer:

a. Thickness (minimum) : 150 mm

b. Percentage by mass passing the 0.075 mm sieve : 10 to 40.

c. PI : 8-17

d. Compaction : 93 % Mod AASHTO maximum dry density in the case of cohesive

soil or 98 % in the case of non-cohesive soil.

e. Minimum CBR after compaction : 15

7.4.1.4 In all cases, effective drainage of the road shall be provided to prevent ponding.

roads shall include:

a. Subbase layer: 150 mm G7 compacted to 93% Mod AASHTO

b. Lower subbase: 150 mm C3 compacted to 95% Mod AASHTO

c. Upper base layer: 150 mm G1 compacted to 98% Mod AASHTO

d. Surface layer: 40 mm asphalt continuously graded

7.4.2 Gravel/ Haul Roads

G1 Graded crushed Dense - graded unweathered crushed

stone; Maximum size 37.5 mm, stone

86 - 88 % apparent relative density; Soil fines

Pi < 4

G2 Graded crushed Dense - graded crushed stone; Maximum

size 37,5 mm;100 - 102 % stone

Mod. AASHTO or 85 % bulk relative density;

Soil fines PI < 6

G3 Graded crushed Dense -graded stone and soil binder;

Maximum size 37.5 mm,

stone 98 - 100 % Mod. AASHTO: Soil fines PI < 6

G4 Crushed or natural Minimum CBR = 80 % @ 98 % Mod.

AASHTO; Maximum size 37.5 gravel

mm, PI < 6

G5 Natural gravel Minimum CBR = 45 % @ 95 % Mod.

AASHTO; Maximum size 63 mm

or 2/3 of layer thickness, Density as per

prescribed layer usage, PI < 10

G6 Natural gravel Minimum CBR = 25 % @ 95 % Mod.

AASHTO; Maximum size 63 mm

or 2/3 of layer thickness; Density as per

prescribed layer usage; PI < 12;

G7 Gravel/ soil Minimum CBR = 15 % @ 93 % Mod.

AASHTO; Maximum size 2/3 of

layer thickness; Density as per prescribed

layer usage; PI < 12

G8 Gravel/ soil Minimum CBR = 10 % @ 93 % Mod.

AASHTO; Maximum size 2/3 of

layer thickness; Density as per prescribed

layer usage; PI < 12

Document Number: PL 889 P a g e 21 | 23

Standard Title: Earthworks Specification

©Transnet SOC Ltd

2.1. Material Quality

a) Screened and suitable excavated material from site or trench that meets

this specification, may be utilized for bedding and padding if certified by

a TPL Engineer.

b) Material used for Bedding and Padding shall comply with the following:

i. Free of organic matter. Topsoil shall not be used for bedding and

padding.

ii. Free of clods or peat.

iii. Free of physical or chemical contamination or hazardous materials

including arsenic, cyanide, lead, mercury, selenium, and carbonaceous

material such as coke, ash, or breeze.

iv. Material shall be free flowing – non-cohesive: i.e., material which is

cohesive shall be excluded for Bedding and Padding purposes.

c) Crusher run is not acceptable. However, site specific materials such as

sugar dolerite and sandstone that have been crushed and screened and

meet the requirements of this specification may be submitted to the

{"name":null,"email":null,"phone":null,"department":"ON CONNECTION TYPE. FROM MUNICIPALITY","address":null}

Supply to fire

System.

Fire water 27-FW-A-150-CS-9505

11364-A1053

To pump house

H

Designer project

No specific requirements found

B-BBEE Minimum Level: 200

36 the 110% must be at 66minutes

Usage. Fire water 27-FW-A-25-GCS-9568 37 tank shell cooling ring to 11364-A1053

12000L/min 25 BUND POURER SYSTEM SHOWN

At zone 1.

L: 110% note 36 27es 26 demolish existing meter and 27ls 27ua 27ua ll: 30% p182 181b 181B-C-1 181B-A valve. 27Pi 27pi 27 foam premix sampling point 182-B 182-A 27xv 27xy 27xy 27xy 27xy downstream at minimum pipe

A2 25 F1 TBD LENGTH REQUIRED 27-FW-A-450-CS-9553 DE P182 P182-C-4 P182-C-1 P182-B-1/ P182-D-1 27-FW-A-350-CS-9558 DIESEL RETURN C-2 A1 25 DOWNSTREAM OF BPP.F 27-DIE1-A-25-CS-9564 15 SO 15 V026 V024 SO V1 27-P181-A-B 28 FEED TO PUMPHOUSE SPRINKLER 27-T181B V119 DIESEL ENGINE SYSTEM (GLASS BREAK BULB) 450 450 x 400 300 x 350 27-FW-A-350-CS-9556 350 350 27LI DIESEL TANK SO FOR FUTURE WORK IF REQUIRED. F1 181B C TBD m3 B1 25 DIESEL SUPPLY 29 VERIFY IF TANK CONNECTION OF 27-DIE1-A-25-CS-9565 V025 V027 V023 (EFFECTIVE) TF 27-P181-A-B EXISTING TOP FOAM POURER SO SO V120 DIESEL ENGINE CAN BE REUSED.

27-P182A 15 d1 15 note 12 so 30 add line spec breaks during

Standby fire pump v033 note 17 detailed design. Note 16 wt

12000L/min 27PS 31 FLOAT VALVE MAINTAINABLE

183 from the roof manhole. 27Pi 15 lc v121 27es 33 sized for pump minimum flow 27pi 183-C 27pi p183 requirement. 183-A 183-B l: 110% note 36

27Ls 27ua 27ua 34 add drain & vent valves ll: 30% 27xv 27xy instr. 182B 182B-C-1 182B-A during models review. 27-FW-A-50-CS-9554 m p183 P183-C-1 15 glasses to be 15 35 sight so 15 so piping so v031 v032 v029 accesible from grade level. V034g 15 a2 25 f1 tbd

A1 25 diesel return 36 the 110% must be at 66minutes

USAGE. FIRE WATER 50 50 x 32 32 x 50 50 50 V1 27-DIE1-A-25-CS-9566 27-P182-A-B 27-T182B 11364-A1052 C V122 DIESEL ENGINE 37 TANK SHELL COOLING RING TO 27-FW-A-50-CS-9557 27LI V030 V035 FULL TANK FROM MUNICIPAL SUPPLY V028 DIESEL TANK SO CIRCLE TF F1 CIRCUMFERENCE. TANK ROOF SO 182B SO

TBD m3 B1 25 DIESEL SUPPLY COOLING SYSTEM TO BE A 27-DIE1-A-25-CS-9567 27-P183 (EFFECTIVE) 27-P182-A-B COMPLETE RING ON THE APEX.

JOCKEY PUMP V123 DIESEL ENGINE 38 REMOVE VALVE AND BLANK 50 L/min D1 15 NOTE 12 SO NOTE 15 EXISTING SUPPLY TO FIRE NOTE 17 WT SYSTEM. NOTE 16

Fire water 27-FW-A-150-CS-9505 15 lc 11364-A1052 v124 50

Foam pre-mix 27-FMP-A-150-CS-9655 27-FMP-A-150-SS-9671 33 sized for pump minimum flow 11364-A1056 27xso 27xso requirement.

From valve bank 1 i.F 189A-G 189B-G 34 add drain & vent valves

Zone 12 35 duringsight glassesmodelstoreview.BE 27Bgu 27bgu

189A 189bg cs ss accesible from grade level. 36 the 110% must be at 66minutes lhs rhs usage.

DN-122 DN-122 37 tank shell cooling ring to

SET @ 187A2 187A2-C-1 187A2-C-2/ 187A2-D-1 DN-51 B-1 RESERVOIRS. TPL TO CONFIRM SHELL COOLING xxx kPag WITH LOCAL FIRE DEPARTMENT

TP-51 on connection type.

Xx

Fire water cs ss BP-58 4 twin booster with 65 dia. Threaded male 100 11364-A1054 27-FMP-A-100-CS-9759 note 23 BP-57 xx instantaneous coupling for

Shell cooling using 27-P184. 27-FW-A-150-SS-9659 cs ss 14 foam concentrate sampling 150 27-FMP-A-150-CS-9762 note 23 DN-61 point.

V100 150 i.F Safe closed unless

So pcv187c2 shell cooling otherwise noted.

25 bund pourer system shown 27xv 27xy 27xy 27xy

S at zone 1.

SET @ 187C3 187C3-C-1 187C3-C-2/ 187C3-D-1 DN-91 B-1 26 DEMOLISH EXISTING METER AND xxx kPag TP-91 XX VALVE. BP-98 27 FOAM PREMIX SAMPLING POINT

Xx downstream at minimum pipe see typical b.P Detail BP-97

F 27-FMP-A-150-CS-9766 150 xx lengthdownstreamrequiredof bpp. BP-96

V101 150 FO005 28 FEED TO PUMPHOUSE SPRINKLER XX SYSTEM (GLASS BREAK BULB) SO PCV187C3 BP-95 ZONE 9 TANK 9 FOR FUTURE WORK IF REQUIRED. SET @ 25 XX XX BP-92 BP-94 FOAM PRE-MIX xxx kPag TRV306 T-09 29 VERIFY IF TANK CONNECTION OF 11364-A1055 EXISTING TOP FOAM POURER XX XX BP-91 BP-93 TO SPILL BASIN CAN BE REUSED. 27XV 27XY 27XY 27XY

S 188 188-C-1 188-C-2/ 188-D-1 30 add line spec breaks during set @

25 SO xxx kPag B-1 DETAILED DESIGN. V104 31 FLOAT VALVE MAINTAINABLE 27-FMP-A-150-CS-9766

V102 80 fo006 during models review.

So pcv188 35 sight glasses to beg accesible from grade level.

27Xv 27xy 27xy 27xy 36 the 110% must be at 66minutes s

Set @ 189 189-C-1 189-C-2/ 189-D-1 foam pre-mix usage. B-1

xxx kPag 11364-A1055 37 TANK SHELL COOLING RING TO

Cooling reservoirs. Tpl to confirm cs ss DN-12 100 with local fire department

27-FMP-A-100-CS-9769 note 23 27-FMP-A-100-SS-9663 on connection type.

V106 100 i.F 4 twin booster with 65 dia.

So pcv187d2 shell threaded male

150 RETURN LINE TO DISCHARGE 27-FMP-A-150-CS-9770 27-FMP-A-150-CS-9770 300mm ABOVE TANK FLOOR .

V107 150 fo008 9 signage to show 100% level

So pcv187d3 (which is 110% level) and 0%

Cs ss level and corresponding 27xv 27xy 27xy 27xy

S 187e2 187E2-C-1 187E2-C-2/ 187E2-D-1 note 23 27-FW-A-65-SS-9664 level. Set @

B-1 10 DESICCANT BREATHER FOR TANK xxx kPag

I.F To be accessible from apex roof note 37 ground level.

Cooling DN-22 cs ss 11 low-level nozzle to be flush

100 with tank floor for cleaning 27-FW-A-100-CS-9771 notenotenote 232323 27-FW-A-100-SS-9665 tank from contaminated shellc v108 100 i.F Cooling foam.

So pcv187e2 12 add signage on tank

Indicating tank levels at 60 zone 2 minutes, 105 minutes and

TP-21 150minutes.

Note 25 DN-21 BP-15 tank 1 tank 2 tank 3 tank 4 13 coupling for emptying tank

Using 27-P184. 27xv 27xy 27xy 27xy BP-12 T-01 T-02 T-03 T-04 BP-14 s 14 foam concentrate sampling 187f1 187F1-C-1 187F1-C-2/ 187F1-D-1 set @

B-1 BP-11 BP-13 POINT. xxx kPag

Cs ss cooling DN-32 20 motorized expanding plug 100 27-FMP-A-100-CS-9773 notenote 2323 27-FMP-A-100-SS-9667 shell valve.

COOLING 21 6 mm HOLE TO BE DRILLED IN

V110 100 i.F Valve disc.

So pcv187f2 22 flexible suction hose

Zone 3 completecouplers withto matchkamlockfoam TP-31

Note 25 DN-31 BP-15 drum connection outlet. Length to suit placement ofe tank 1 tank 2 tank 3 tank 4

BP-12 T-01 T-02 T-03 T-04 BP-14 foam drum outside of pump house. Stowage mechanism

BP-11 BP-13 for hose to be installed

SET @ 187G2 187G2-C-1 187G2-C-2/ 187G2-D-1 NOTE 23 27-FW-A-65-SS-9668 B-1 25 BUND POURER SYSTEM SHOWN xxx kPag AT ZONE 1. I.F

Note 37 26 demolish existing meter and

Cs ss apex roof DN-42 valve.

100 cooling 27 foam premix sampling point 27-FMP-A-100-CS-9774 note 23 27-FMP-A-100-SS-9669 shell downstream at minimum pipe

Downstream of bpp.F Foam premix v111 100 i.F Cooling length required so pcv187g2 11364-A1054 DN-41 28 feed to pumphouse sprinkler to ring main zone 4 system (glass break bulb)

TP-41 BP-15 for future work if required. Note 25 foam pre-mix tank 1 tank 2 tank 3 tank 4 29 verify if tank connection of

11364-A1054 BP-12 BP-14 existing top foam pourer

From ring main T-01 T-02 T-03 T-04 can be reused.

BP-11 BP-13 30 add line spec breaks during

Fire water 27-FW-A-150-CS-9775 requirement. Fire water 11364-A1058 34 add drain & vent valves 11364-A1054 to valve bank 2 sheet 2 during models review. From ring main

Foam pre-mix 35 sight glasses to be 27-FMP-A-150-CS-9776G 11364-A1058 accesible from grade level.

To valve bank 2 sheet 2 36 the 110% must be at 66minutes

Foam pre-mix usage. 27-FMP-A-150-CS-9777

11364-A1058 37 tank shell cooling ring to

To valve bank 2 sheet 2 circle full tank

Circumference. Tank roof fire water 27-FW-A-150-CS-9778 cooling system to be a fire water 11364-A1058 complete ring on the apex.

11364-A1054 to valve bank 2 sheet 2 38 remove valve and blank

From ring main foam pre-mix 27-FMP-A-150-CS-9779 existing supply to fire

11364-A1058 system.

To valve bank 2 sheet 2

Foam pre-mix 27-FMP-A-150-CS-9780

11364-A1058

To valve bank 2 sheet 2

H

Designer project: scale checked: approved: references revisions project name

Dwg number description rev date by chk description witbank fire 1 : 1 bj bj - - a 2025-07-14 hs bj issued for acceptance resp. Eng TRANSNET pipelines witbank drawn REF. - - b 2025-07-25 hs bj p.J Reviewed comments from 22/07

• • C 2025-08-04 hs bj issued for acceptance after design review meeting traced date proj. Manager witbank fire cad file: design-drawn: date:

Ho1436-tpl_2024_09_0008 d 2025-11-05 hs bj as-built of municipal supply - checked approved - hs 2025-07-14 - _77334_rfp-fat-0001 hs e 2026-01-06 hs bj 3d model review comments included - - client title:

SCALE - - GREYJONES (PTY) LTD. ROLE NAME SIGN DATE PROCESS & INSTRUMENTATION DIAGRAM- PROJECT No: DRAWING No: REV: - - TPL DRAWING No. REV

• • Valve bank 2-SHEET 1 11364 11364-A1057 e    a1 drawing approval status - - HO1436-WIR-PR-PI-0006

1 2 3 4 5 6 7 8 9 10 11 12

See typical b.P Detail BP-77 xx detailed design. Zone 7

31 float valve maintainable xx xx 150 BP-73 BP-76 from the roof manhole. 27-FMP-A-150-CS-9780 tank 7 xx xx 33 sized for pump minimum flow

Fire water v117 150 fo010 BP-72 T-07 BP-75 requirement. 27-FW-A-150-CS-9775

Xx 11364-F-27-PID-A1057 so pcv187i3 xx 34 add drain & vent valves BP-71 BP-74

From valve bank 2-SHEET1 during models review.

Foam pre-mix 35 sight glasses to be

G 11364-F-27-PID-A1057 27-FMP-A-150-CS-9776 accesible from grade level.

From valve bank 2-SHEET1 36 the 110% must be at 66minutes

Foam pre-mix usage. 27-FMP-A-150-CS-9777

11364-F-27-PID-A1057 27-FMP-A-150-CS-9780 37 tank shell cooling ring to

From valve bank 2-SHEET1 circle full tank

Circumference. Tank roof fire water 27-FW-A-150-CS-9778 cooling system to be a

11364-F-27-PID-A1057 complete ring on the apex.

From valve bank 2-SHEET1 38 remove valve and blank

Foam pre-mix 27-FW-A-150-CS-9779 existing supply to fire

11364-F-27-PID-A1057 system.

From valve bank 2-SHEET1

Foam pre-mix 27-FMP-A-150-CS-9780

11364-F-27-PID-A1057

From valve bank 2-SHEET1 valve bank 2 continued

H

Designer project: scale checked: approved: references revisions project name

Dwg number description rev date by chk description witbank fire 1 : 1 bj bj - - a 2025-07-14 hs bj issued for acceptance resp. Eng TRANSNET pipelines witbank drawn REF. - - b 2025-07-25 hs bj p.J Reviewed comments from 22/07

• • C 2025-08-04 hs bj issued for acceptance after design review meeting traced date proj. Manager witbank fire cad file: design-drawn: date:

Ho1436-tpl_2024_09_0008 d 2025-11-05 hs bj as-built of municipal supply - checked approved - hs 2025-07-14 - _77334_rfp-fat-0001 hs e 2026-01-06 hs bj 3d model review comments included - - client title:

SCALE - - GREYJONES (PTY) LTD. ROLE NAME SIGN DATE PROCESS & INSTRUMENTATION DIAGRAM- PROJECT No: DRAWING No: REV: - - TPL DRAWING No. REV

• • Valve bank 2-SHEET 2 11364 11364-A1058 e    a1 drawing approval status - - HO1436-WIR-PR-PI-0007

1 2 3 4 5 6 7 8 9 10 11 12

REV DATE BY CHK DESCRIPTION WITBANK FIRE As indicated BJ BJ - - A 2025-11-21 NP BJ ISSUED FOR INFORMATION RESP. ENG TRANSNET PIPELINES WITBANK DRAWN REF. - -

• • Traced date proj. Manager witbank fire cad file: design-drawn: date:

Ho1436-tpl_2024_09_0008 - checked approved - np 2025-11-21 - _77334_rfp-fat-0001 np - - client title:

SCALE - - GREYJONES (PTY) LTD. ROLE NAME SIGN DATE PROPOSED SITE PLAN OF NEW FIRE SYSTEM PROJECT No: DRAWING No: REV: - - TPL DRAWING No. REV

• 11364 11364-A1051 a    - a1 drawing approval status - -

1 2 3 4 5 6 7 8 9 10 11 12

Notes

1. Site survey date 2025/07/18

Legend

Fh fire hydrant

Gr guard rail

LP light pole

Mh manholea

Rtla road tanker loading

WALL APPROXIMATELY 2.80m HIGH AREA

Dt4 12mm peg in

Open drain clogged with debris open drain clogged with debris

DEMOLISHED DT8 BUND E ZONE 8 AREA 895 m2

NEW CARPORT MAST INLET PIPE BUND OVERFLOW BUND D 29-153 15m APPROXIMATELY DT14 DRIVEWAY TOWER AREA 895 m2

MMRisk (Pty) Ltd were contracted by Transnet Pipelines (Pty) Ltd (‘TPL’), to conduct the Major Hazard

Installation (MHI) Risk Assessment of their Witbank Depot (‘Site’) in Emalahleni, Gauteng Province, South

Africa.

The risk assessment is an update of a previous risk assessment completed in August 2018.

The site is a depot receiving and distributing 50 ppm Diesel (D50), 95 Octane Unleaded Petrol (ULP 95) and

93 Octane Unleaded Petrol (ULP 93) to its external customers. The site receives diesel and petrol via pipeline

from the TPL Kendal Depot, which passes through a series of pipes and valves in the manifold before being

distributed to the nearby external clients, Shell and Engen depots. Any fuel that is intermixed when changing

the product in the pipeline is transferred to and stored in bulk intermix tanks. The site also has 5 bulk

aboveground clean petroleum products holding tanks.

As per the MHI Regulations of 2022 promulgated on 31st January 2023, the site is classified as a Medium

Hazard establishment. As such, the following requirements apply:

• An MHI Risk Assessment (this document);
• A Major Incident Prevention Policy (MIPP);
• A Process Safety Management System (PSM) (described in the MIPP but not submitted to the

authorities); and

• An Emergency Plan.

MMRisk are accredited by the South African National Accreditation System (SANAS, number MHI0037) and

approved by the Department of Employment and Labour to conduct Major Hazard Installation (MHI) Risk

Assessments (AIA approval Number CI MHI 0013, approval certificates attached in Appendix A).

Site activities

The Witbank TPL depot is a deport receiving and distributing petroleum products (Diesel and Unleaded Petrol).

The site receives diesel and petrol via 12-inch pipelines from the TPL Kendal Depot at a maximum operating

pressure of 8 bar and a flow rate of 11,300 litres/min. The duration of fuel receipt and distribution on site is

approximately 2 to 3 days per week.

The diesel and petrol received via pipeline are directed to the pipe manifolds and transferred to the external

clients while fuel that is intermixed when changing the product in the pipeline is transferred to and stored in 4

(four) bulk intermix tanks onsite. Any fuel that cannot be received by a client is transferred to and stored in 5

(five) bulk storage tanks.

The fuel that is stored in intermix tanks is then dispatched from site via road tanker and transported to the

Tarlton TPL depot for re-fractioning.

A simplified block flow diagram of the processes occurring onsite is shown in Figure 2.2.

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Figure 2.2: Process block flow diagram

Individual risk results

The individual risk contours illustrated in the figures below are of the type ‘Location Specific Individual Risk

(LSIR)’ contours. These show the chance of death of a theoretical person if they are positioned at a particular

location 24 hours per day, 365 days per year. LSIR is an overstatement of risk which is widely accepted as

sufficiently conservative. In reality, workers will spend the length of a shift per day and not the entire day.

However, when a worker is off, another worker may replace the worker in performing task(s), therefore, overall,

it can be considered that there is an individual at that particular point or area, all of the time.

The risk acceptability criteria are described in Section 3.5.1 and the individual risk profiles for the site are

illustrated in Figure 8.1.

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Individual risk for those located outdoors

Figure 8.1 illustrates individual risk of death for those located outdoors; being located outdoors implies a lack

of shielding for thermal radiation exposure, as would be the case for those located indoors. Only the estimated

consequences of a tank overfill event have been included in this report. The frequency of occurrence has been

excluded and as a result, the risks associated with this event have not been evaluated and are not included in

the figure below. The contours extend as follows:

Individual risk

Associated tolerability Observations

contour

1 x 10-3 / year Inside these contours risk is intolerable

This contour is not reached.

(blue contour) to workers.

The 1 x 10-4 contour envelopes the transfer tanks, the

pipe manifold, and the point where the incoming

pipeline from Kendal surfaces.

1 x 10-4 / year Inside this contour risk is intolerable to This contour appears over these areas due to the

(red contour) members of the public. relatively high frequency of small pump leaks leading to

flammable pools and associated pool fires restricted to

the contained areas. This contour does not extend

offsite.

The 1 x 10-5 contour envelopes the pipeline manifold, a 1 x 10-5 / year This contour indicates threshold of

portion of the road tanker gantry and the intermix tanks

(orange contour) tolerability for workers. pipework. This contour does not extend offsite.

The 1 x 10-6 contour extends over the abovementioned

1 x 10-6 / year This contour is the threshold for areas to a greater degree as well the bulk storage tanks

(yellow contour) tolerability for members of the public. onsite and the control room. This contour does not

extend offsite.

The 3 x 10-6 extends over the areas mentioned above to

a greater degree.

At this level, risk is broadly acceptable, 3 x 10-7 / year

but an indicator of appropriateness of The 1 x 10-8 and 1 x 10-9 / year contours also extend (green contour) land-use (see Section 8.5) over the areas mentioned above to a greater degree

than the 3 x 10-6. These contours extend slightly offsite

over the north and eastern site boundaries.

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Figure 8.1: Individual risk contours for personnel located outdoors

Conclusion:

Onsite, the risk contours extend such that the risk is considered tolerable if the site can prove that it is As Low

As Reasonably Practicable ‘ALARP’ for personnel especially at the pipe manifold. Offsite, the risk is considered

Broadly Acceptable.

Risk Judgement and Treatment are discussed in Section 8.4.

Societal risk results

Societal risk considers populations around the site to determine risk tolerability. In this study, this is presented

in the form of an FN-Curve, which illustrates scenarios with the potential to cause death, as well as considers

the frequency of each scenario. The frequencies of the scenarios are then summed to show a cumulative risk

of death, i.e., the frequency (F) of causing N or more fatalities against the number of fatalities, N.

As illustrated in Figure 8.2 there are tolerability limits as suggested by SANS 1461:2018 (see Section 3.5.2),

as illustrated by the red and blue sloped lines. Above the red line is the region where societal risk is intolerable;

below the blue line is the region where societal risk is broadly acceptable. Between these lines is the region

where risk can be tolerated if it is proven to be ALARP (see Section 3.5.2).

Description of the site’s FN curve (societal risk results)

Day time societal risk is based upon activities onsite which take place only during the day and upon day-time

population levels, and similarly night time risk is based upon activities taking place at night and also on

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populations of people during the night. The FN curve given below is a combination of day time and night time

risk.

Figure 8.2 shows that the maximum number of fatalities (on and off site) which can occur from a single event

occurring onsite is approximately 1 person; the associated frequency of this one large event is relatively low, at

approximately 1 x 10-4 / year. This corresponds to one of the high-impact, low-frequency events occurring at

the site.

Societal risk for the site lies predominantly below the blue line, indicating risk which is Broadly Acceptable.

Figure 8.2: FN Curve illustrating societal risk level of the site

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Top contributors to societal risk

Because Societal risk was assessed to Broadly Acceptable both to members of the public and personnel the

top contributors to societal risk were not analysed further.

Conclusion:

Societal risk was assessed to be Broadly Acceptable.

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Conclusions

The following conclusions were drawn from the analysis, divided into various topics in the table which follows:

Topic Conclusion(s)

The following have been identified as potential major hazard installations at the site:

The identification of different Diesel Pipe Manifold, Pumps, Holding Tanks, Loading Road Tankers. Petroleum

hazardous installations within products are received and distributed onsite such that the site is classified as a

the premises Medium Hazard establishment as per the MHI Regulations promulgated on 31st

January 2023.

The 1% fatality probability consequence contours associated with the installations

onsite would extend as follows:

• Tank T6: 29 metres (pool fire);
• Tank T8: 28 metres (pool fire);
• Incoming diesel pipeline: 26 metres (pool fire)
• Incoming petrol pipeline: 30 metres (pool fire)

The maximum extent of the 1

• Diesel road tanker loading: 18 metres (pool fire)

% consequence-based lethality

• Petrol road tanker loading: 19 metres (pool fire)

(effect) zone from major

• According to the UK HSE Process Safety Leadership Group final report for

hazards Safety and Environmental Standards for Fuel Storage Sites[1], the following

distances are considered to be a conservative estimate of the hazard

zones for tank overfill scenarios (i.e., a Buncefield-type event).

• 2 bar overpressure: 250 metres
• 250 mbar: 400 metres
• Flammable vapour cloud: 437 meters

The individual risk at the pipe manifold was assessed to be tolerable provided that

The level of risk posed by the

the site can prove that it is ‘ALARP’ to personnel onsite. and broadly acceptable for

facility to various populations

members of the public.

Individual risks were assessed to be tolerable for personnel onsite at the pipe

The assessment of the risk as manifold provided that it is As Low As Reasonably Practicable ‘ALARP’.

acceptable or tolerable

provided ALARP or intolerable Societal risk was assessed to be Broadly Acceptable for both personnel and

members of the public.

Suggestions for risk reduction

Risk reduction measures are discussed in Section 8.4.2 and the Recommendations /

including preventative and

Risk Reduction Measures Section 11.

mitigative measures

Only the estimated consequences of a tank overfill event have been included in this

Any specific technical

report. The frequency of occurrence has been excluded and as a result, the risks

uncertainties or sensitivities

associated with this event have not been evaluated.

The suggested land-use Land-use planning restricted development distances are discussed in Section 8.5:

planning restricted

development distance and the Land Use Planning and no incompatible land-uses exist at present. The zones remain

risk zones within the site boundaries.

1 UK Health and Safety Executive, Process Safety Leadership Group, Final Report, 2009.

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Topic Conclusion(s)

Any organisational measures

The Recommendations in Section 11 contains suggestions of organisational

that may be required. (MHI

measures which may be required.

Reg 5 (5) (b) (xii))

Recommendations / risk reduction measures

Based on the risk analysis herein, the following recommendations are made:

Recommendation

Number:

Recommendation The site is a Medium Hazard Establishment according to new set of MHI regulations

wording: promulgated 31st January 2023.

According to the MHI Regulations of 2022 promulgated on 31st January 2023, due

to the overall storage of petroleum products of approximately 14,000 tons

(considering Diesel and Petrol densities) the establishment is classified as a Medium

Hazard Establishment.

As such, the following requirements apply:

Rationale:

• An MHI Risk Assessment (this document);
• A Major Incident Prevention Policy (MIPP);
• A Process Safety Management System (PSM) (described in the MIPP but

not submitted to the authorities); and

• An Emergency Plan.

Carry out advertisement (if not previously advertised) and carry out notification as

required by the MHI Regulations.

Priority: High

Recommendation

Number:

Communicate the results of this risk assessment with Local Municipality Emergency Recommendation

Planning to strengthen their emergency planning strategies should an incident occur

wording:

onsite.

There would be a domino impact which would extend offsite due to elevated thermal

radiation emitted from various petrol and diesel installations. Informing the local

Rationale: emergency planning would prepare them in case of an emergency.

[This would form part of MHI notification Process).

Priority: High

Recommendation

Number:

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Recommendation Confirm with the municipality of Emalahleni if the Dangerous Goods Certificate is not

wording: required for such a particular site.

Rationale: This would ensure that the site remains compliant with the local authorities.

Priority: High

Recommendation

Number:

Recommendation

Consider the installation of hydrocarbon gas detectors in the bulk tank bunds.

wording:

Installation of this instrumentation may allow for early detection of flammable

Rationale:

vapours released thus potentially reducing the impact should ignition occur.

Priority: Medium

Recommendation

Number:

Recommendation Consider the installation of Close Circuit Television (CCTV) at strategic points

wording: around the site.

Installation of CCTV may allow for monitoring of areas not frequently patrolled (such

Rationale:

as the tank bunds) with may allow for early detection of overfilling events.

Priority: Medium

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Table of Contents

Executive Summary ........................................................................................................................................ 4

1 Introduction ........................................................................................................................................... 15

1.1 Scope of Risk Assessment ........................................................................................................... 15

1.2 The Site Visit ................................................................................................................................ 15

1.3 Legal Aspects .............................................................................................................................. 16

1.4 Methodology of Risk Assessment ................................................................................................. 17

2 Descriptions .......................................................................................................................................... 18

2.1 Site Location ................................................................................................................................ 18

2.2 Company’s Main Activities / Non-technical Process Description ................................................... 22

2.3 Detailed Process Description ........................................................................................................ 23

2.4 Staff Complement and Shift Patterns ............................................................................................ 25

2.5 Meteorological Tendencies ........................................................................................................... 26

2.6 Special Features Around Site ....................................................................................................... 30

2.7 Relevant Topography of the Area ................................................................................................. 30

3 Methodology for Risk Analysis and Assessment .................................................................................... 31

3.1 Methodology for Inherently Safer Operation .................................................................................. 32

3.2 Methodology for Hazard Identification ........................................................................................... 32

3.3 Methodology for Consequence Analysis ....................................................................................... 32

3.4 Methodology for Frequency Analysis ............................................................................................ 36

3.5 Methodology for Risk Summation and Assessment ....................................................................... 37

3.6 Methodology for Risk Treatment ................................................................................................... 41

4 Hazard Identification ............................................................................................................................. 42

4.1 Hazardous Materials Onsite .......................................................................................................... 42

4.2 Any Significant Incidents which have Happened in the Past at the Site and Lessons Learned ....... 42

4.3 Major Accidents at Related Facilities ............................................................................................ 42

4.4 Containment Systems for Analysis ................................................................................................ 43

4.5 Description of Safety Systems ...................................................................................................... 44

4.6 Isolation Systems and Associated Release Durations ................................................................... 45

5 Hazard Analysis .................................................................................................................................... 46

5.1 List of Scenarios Modelled for each Containment System ............................................................. 46

5.2 Description of Causes, Consequences, Preventive and Mitigative Measures ................................ 46

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5.3 Organisational Measures in Place at the Site ................................................................................ 47

5.4 Requirements in Terms of Environmental Conservation Act, 1989 ................................................ 47

6 Consequence Analysis .......................................................................................................................... 48

6.1 Scenarios Included in Risk Analysis .............................................................................................. 48

6.2 Key Process Data for Major Scenarios .......................................................................................... 48

6.3 Consequence Analysis of Materials at the Witbank Depot............................................................. 48

6.4 Worst Case Effects at the Depot ................................................................................................... 48

7 Frequency Analysis ............................................................................................................................... 58

7.1 Failure Data Used, Final Frequency and Estimation of the Probability of a Major Incident .............. 58

8 Risk Results .......................................................................................................................................... 59

8.1 Interpreting the Risk Results ......................................................................................................... 59

8.2 Individual Risk Results .................................................................................................................. 59

8.3 Societal Risk Results .................................................................................................................... 61

8.4 Risk Judgement and Treatment .................................................................................................... 64

8.5 Land Use Planning ....................................................................................................................... 65

9 Emergency Response Data ................................................................................................................... 67

9.1 Emergency Response Management at the Site ............................................................................ 67

9.2 Suitability of ERP against Risk Assessment Results ....................................................................... 67

9.3 Emergency Response Plan Evaluation .......................................................................................... 67

10 Conclusions .......................................................................................................................................... 68

11 Recommendations / Risk Reduction Measures ...................................................................................... 70

12 References ............................................................................................................................................ 72

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1.1 Scope of Risk Assessment

MMRisk (Pty) Ltd were contracted by Transnet Pipelines (Pty) Ltd (‘TPL’), to conduct the Major Hazard

Installation (MHI) Risk Assessment of their Witbank Depot (‘Site’) in Emalahleni, Gauteng Province, South

Africa.

The risk assessment is an update of a previous risk assessment completed in August 2018.

The site is a depot receiving and distributing 50 ppm Diesel (D50), 95 Octane Unleaded Petrol (ULP 95) and

93 Octane Unleaded Petrol (ULP 93) to its external customers. The site receives diesel and petrol via pipeline

from the TPL Kendal Depot, which passes through a series of pipes and valves in the manifold before being

distributed to the nearby external clients, Shell and Engen depots. Any fuel that is intermixed when changing

the product in the pipeline is transferred to and stored in bulk intermix tanks. The site also has 5 bulk

aboveground clean petroleum products holding tanks.

As per the MHI Regulations of 2022 promulgated on 31st January 2023, the site is classified as a Medium

Hazard establishment. As such, the following requirements apply:

• An MHI Risk Assessment (this document);
• A Major Incident Prevention Policy (MIPP);
• A Process Safety Management System (PSM) (described in the MIPP but not submitted to the

authorities); and

• An Emergency Plan.

MMRisk are accredited by the South African National Accreditation System (SANAS, number MHI0037) and

approved by the Department of Employment and Labour to conduct Major Hazard Installation (MHI) Risk

Assessments (AIA approval Number CI MHI 0013, approval certificates attached in Appendix A).

1.2 The Site Visit

A site visit was conducted on 29th August 2023 for purposes of information gathering. MMRisk representatives,

Motlatsi Mabaso, Lesedi Lebea, and Roshuma Mafukaduvha, met with a number of TPL representatives during

the site visit. The following TPL representatives were present during the site visit:

Name Title / Role

Peter Lebono Mechanical and workshop manager

Siyabonga Mnikathi TPL – Mechanical Specialist

Papa Moratwe Senior Fire Specialist

Shaun Groenewald Electrical Fitter

During the visit, technical information and information on the surroundings was gathered by way of note-taking.

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MMRisk staff drove around the site to familiarise themselves with the neighbours, paying particular attention to

other potential MHI sites around the site.

Prior to the site visit, several documents detailing depot operations were requested and received.

1.3 Legal Aspects

1.3.1 MHI Regulations of 2022

On 31st January 2023, a new set of MHI Regulations were promulgated via Government Gazette Volume 691

Number 47970. The regulations are called the MHI Regulations of 2022. This MHI Risk Assessment has been

completed in line with the requirements of the Major Hazard Installation Regulations of 2022 and in line with the

following requirements:

• The South African National Standard (SANS) 1461:2018 ‘Major Hazard Installation – Risk

Assessments’; and

• South African National Accreditation System (SANAS) Technical Requirement document TR54.

1.3.2 MHI Classification According to MHI Regulations 2022

According to the MHI Regulations of 2022, due to the overall storage of petroleum products of approximately

14,000 tons (considering Diesel and Petrol densities) the establishment is classified as a Medium Hazard

Facility.

As such, the following requirements apply:

• An MHI Risk Assessment (this document);
• A Major Incident Prevention Policy (MIPP);
• A Process Safety Management System (PSM) (described in the MIPP but not submitted to the

authorities); and

• An Emergency Plan.

1.3.3 Definition of MHI in the Occupational Health and Safety Act No. 85, 1993 as a Basis for

Declaring MHI Status

MMRisk may also use risk contours as a basis to declare a site as an MHI if dangerous chemicals stored onsite

are below the relevant threshold (such that the site would be exempt under the MHI Regulations, 2022).

This is in line with the Definitions Clause 1 (1) (xxvi) (b) of the Occupational Health and Safety Act No. 85, 1993

which defines a major hazard installation as “... an installation where any substance is produced, processed,

used, handled or stored in such a form and quantity that it has the potential to cause a major incident...”.

If the assessment shows that the 1 x 10-4 per annum contour (intolerable risk to members of the public) extends

beyond the site boundary, then the site will be assessed to be a Major Hazard Installation even if the quantities

stored onsite are below the thresholds indicated in the MHI Regulations, 2022.

Furthermore, the following guidelines shall be used to determine whether the site is an MHI or not.

• Toxics – the 50% lethality level, using probits or the UK HSE SLOD values.

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• Fires (pool fires, jet fires, fireballs / BLEVE)– the 50% lethality or a radiation level of 20 kW/m2 with 20

s exposure time.

• Flash fires – the maximum extent of the lower flammable limit (LFL).
• Explosions (VCE)– the 35 kPa (0.35 bar or 5 PSI) overpressure level.

If any of the above criteria extends over Level 3 and 4 sensitivity developments as per Land Use Planning clause

4.10 of SANS 1461:2018, the site will be declared a Major Hazard Installation.

1.4 Methodology of Risk Assessment

The assessment has been conducted in line with the requirements of South African National Standard (SANS)

1461:2018 Major Hazard Installation – Risk Assessments. The standard was published in June 2018; it is now

the industry best practice for the compilation of MHI Risk Assessments. All MHI AIAs are now required to

perform MHI Risk Assessments according to the requirements of the standard.

The standard provides requirements for the following as part of MHI Risk Assessments:

• Defining the scope of work;
• Gathering relevant data;
• Hazard identification;
• Hazard analysis;
• Consequence analysis;
• Risk calculations (including individual and societal risk);
• Risk judgement criteria;
• Risk treatment;
• Land-use planning;
• Emergency response data (analysing information from the Client);
• Conclusions and recommendations.

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2 descriptions

2.1 Site Location

The site is located at 10 Schonland Drive, Ferrobank, Emalahleni, Mpumalanga Province. The GPS coordinates

of the site are 25° 51'46.36"S, 29°09'58.74"E.

The site is located in an area which is predominantly industrial with residential areas nearby. Establishments

surrounding the site are shown in Figure 2.1 and described below the figure.

1: Shell Witbank Depot 5: Tam Alloys (Beneficiation Plant)

2: Mpumalanga Training Trust (School) 6: Schonland Drive

3: Ackerville Township (Residential Area) 7: Shoping Centre

4: Bushveld Vanchem (Beneficiation Plant) 8: Van Eck Drive

Figure 2.1: The site and its surroundings

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2.1.1 Population Estimates for Surrounding Areas

2.1.1.1 Categories of Populations Present around the Site

An important contributor to risk for a site is an estimate of populations both for the site itself, and for surrounding

facilities and residential areas. MMRisk used estimates from a combination of sources such as from Statistics

South Africa (StatsSA Living Conditions Survey 2014/15[2]) as well as from the TNO Green Book[3].

To illustrate where the various population estimates are applied, MMRisk uses code names, and these are

described in Table 2.1.

Table 2.1: Population estimates for surrounding populations

MMRisk

Population categories People per hectare

code

Industrial Areas4:

Low density of personnel 5 IS

Medium density of personnel 40 IM

High density of personnel 80 IL

Remote Area 1 R

Nature Area 0 N

Shopping Centres or Shopping Streets:

Very small scattered 10 per shop SV

Small 100 SS

Medium 500 SM

Large >1,000 SL

Office:

Small 10 people OS

Medium 100 people OM

Large 1,000 people OL

Police Station

6 people per hectare

Standard PS

86% indoors

Hotel and Catering:

Small 10 people HS

Medium 50 people HM

Large 250 people HL

Important Auto Routes (50% outdoors day and

night, assume 2 people per car)

Normal circulation 20 cars/km/lane RN

Heavy Traffic 100 cars/km/lane RT

Variable depending on time of day.

Taxi Ranks Peak time assume 20 taxis present at a time, with TR

15 passengers per taxi.

Assume one full train present at peak time, 12

Passenger Train Stations TS

carriages (1,800 passengers per full train)

2 StatsSA, Statistics South Africa, Statistical Release P0310, Living Conditions of Households in South Africa, An analysis of household

expenditure and income data using the LCS 2014/2015, January 2017.

3 The Netherlands Organisation (TNO) of Applied Scientific Research, Methods for determination of possible damage to people and objects

resulting from release of hazardous materials, CPR 16E, 1992.

4 At night time MMRisk applied 1⁄2 the population density, with the exception of “IL” facilities.

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MMRisk

Population categories People per hectare

code

Residential Areas (StatsSA data)5

Urban Informal 5.6 people per household DI

Urban Formal 5.97 people per household DF

120 people per hectare

Busy housing district: low buildings and

(36% indoor during the day, 92% indoor during the DA

flats

night)

80 people per hectare

Quiet housing district, scattered flats (36% indoor during the day, 92% indoor during the DQ

night)

School / University (Advanced Education)

Small 200 persons SUS

Medium 500 persons SUM

Large 1,000 persons SUL

2.1.1.2 Presence of Persons Indoors and Outdoors

The following have been applied with regards to the presence of persons indoors vs outdoors, based on

recommended methodology from the TNO Green Book [3]:

Table 2.2: Presence of persons indoors and outdoors per category

Persons present during the day Persons present during the night

Population % of total

% of total persons Percentage Percentage Percentage Percentage category persons

present indoors outdoors indoors outdoors

present

Assume 50% are

children away at

school.

Formal

residential 93% 7% 100% 99% 1%

Remaining adults will

areas

be present according

to the prevailing

unemployment rate.

Assume 50% are

children away at

Informal school.

residential

50% 50% 100% 99% 1%

and deprived Remaining adults will

areas be present according

to: 100 – prevailing

unemployment rate %.

Industrial 20% if there

areas and is a night

100% 93% 7% 99% 1%

other places shift, 0%

of work otherwise.

5 Presence during the day based on SA’s employment rate at the time of writing, as well as an assumption that 50% of residents would be

children who would be away at school.

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2.1.2 Nearby Residential Areas

Ackerville township is the closest residential area to the site; details are provided in Table 2.3 below.

Table 2.3: Nearby residential areas

Illustrated by Distance from Population and MMRisk Code (see

Facility/ Area Direction

number site (m) Table 2.1 for MMRisk Code)

Ackerville Township 3 59 South-east DI

2.1.3 Nearby Industrial Facilities

The site is located in a residential area but there a few industrial facilities nearby. The surrounding industrial

facilities are shown with details given in Table 2.4. For those facilities, the assumed population statistics are

also provided in the table.

Table 2.4: Industrial facilities located close to the site

Indicated

Distance from MHI Population and MMRisk code

Facility/ Area by Direction

site (m) facility? (see Table 2.1 for MMRisk code)

number:

Bushveld Vanchem Possible

4 340 North West IM

(Beneficiation Plant) MHI

Tam Alloys Possible

5 450 North West IM

(Beneficiation Plant) MHI

Shell Witbank Depot 1 350 North Yes IS

2.1.4 Nearby Major Transportation Routes

Details of the closest major transportation routes to the site are provided in Table 2.5 below.

Table 2.5: Nearby major roads

Illustrated by Distance from Population and MMRisk Code (see Table 2.1

Facility/ Area Direction

number site (m) for MMRisk Code)

Adjacent to site

Schonland Drive 6 East RN

boundary

Van Eck Drive 8 197 West RN

2.1.5 Nearby Sources of Additional Risk

The Shell depot to the north of the site is a Major Hazard Installation and may pose additional risk to the site.

Tam Alloys located north west from the site and Bushveld Vanchem, also located north west from the site are

also possible MHIs which may pose possible risk to the site.

2.1.6 Vulnerable Developments / Sensitive Receptors

Details of areas which may be sensitive receptors are provided in table 2.6 below.

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Table 2.6: Vulnerable developments

Illustrated by Distance from Population and MMRisk Code (see Table 2.1

Facility/ Area Direction

number site (m) for MMRisk Code)

Ackerville

3 59 East DI

Residential area

Mpumalanga

Training Trust 2 197 South SUS

(school)

Shopping Centre 7 87 North SV

2.2 Company’s Main Activities / Non-technical Process Description

The Witbank TPL depot is a deport receiving and distributing petroleum products (Diesel and Unleaded Petrol).

The site receives diesel and petrol via 12-inch pipelines from the TPL Kendal Depot at a maximum operating

pressure of 8 bar and a flow rate of 11,300 litres/min. The duration of fuel receipt and distribution on site is

approximately 2 to 3 days per week.

The diesel and petrol received via pipeline are directed to the pipe manifolds and transferred to the external

clients while fuel that is intermixed when changing the product in the pipeline is transferred to and stored in 4

(four) bulk intermix tanks onsite. Any fuel that cannot be received by a client is transferred to and stored in 5

(five) bulk storage tanks.

The fuel that is stored in intermix tanks is then dispatched from site via road tanker and transported to the

Tarlton TPL depot for re-fractioning.

A simplified block flow diagram of the processes occurring onsite is shown in Figure 2.2.

Figure 2.2: Process block flow diagram

A detailed description of the processes taking place onsite is provided in Section 2.3: Detailed Process

Description.

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2.3 Detailed Process Description

Details of the main activities onsite is provided in this section; this section makes reference to the site layout

diagram in appendix F. For each process / equipment, the associated safety systems are described in tabular

form.

2.3.1 Material Receipt – Pipeline

Diesel and petrol onsite are received via pipeline from the TPL Kendal Depot and routed to manifolds. The

details of the feed pipeline are provided in the table blow.

Table 2.7: Fuel receipt via pipeline

% time

Pipeline Delivery Flowrate Line

hazard Feed pressure Limited area

Source frequency (L/min) diameter

onsite

24 hours, 2-3 12

Kendal 11, 300 43 8 bar Pipe manifold area

days a week inches

Safety Systems

System Implication on modelling Probability of failure (SANS 1461)

Bunding Limits sizes of pools formed -

Control room intervention

(SCADA – Offsite and onsite Estimated maximum 10-minute release duration 0.01

control)

2.3.2 Bulk Tanks

Details of the bulk tanks on site are summarised in the table below.

Table 2.8: Tank listing

Gross capacity Tank height

Tank number Product

m3 m

T1 Intermix 169 6

T2 Intermix 169 6

T3 Intermix 169 6

T4 Intermix 169 6

T5 ulp 93 2200 13

T6 ulp 93 3700 12

T7 ulp 95 3700 12

T8 Diesel 3700 12

T9 Diesel 3700 12

The following safety systems apply for the main product storage tanks:

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Table 2.9: Safety system descriptions for product tanks

System Present? Description of operation Sub-system

Detection only

Detection and alarm

Level control (with control room

intervention)

Radar level transmitters with indication, high-high

Full Level control (High

YES level automatic feed shut off on tanks to reduce risks

and Hi-Hi)

from overfilling. Overflow switch associated with ESD.

Pressure and vacuum relief vents are present. These

vents are located at the top of the tanks and are of a

Overflow vent - YES ‘goose-neck’ configuration. During overflow, liquid

would flow out onto the roof of the respective tank

and then cascade to the bund floor.

Inlet and outlet

• YES Automated valves for inlet and outlet isolation.

valves

Bunds - YES All bulk tanks are contained within a bunded area.

Fire protection

• YES Refer to Section 4.5.

systems

2.3.3 Main Pumps

Details of the pumps are found below.

Table 2.10: Main pumps details

Numbering Type of pump Discharge Pressure (bar) Discharge flowrate (m3/hr)

Transfer Pumps Centrifugal (3 pumps) 1.5

Intermix Pumps Centrifugal (4 pumps) 1.5

Variable

Accumulation

Centrifugal (2 pump) 1.5

Tanks Pumps

Road Tanker

Centrifugal (1 pump) 1

Loading Pump

Safety Systems

Probability of failure

System Implication on modelling

(SANS 1461)

Bunding Limits sizes of pools formed -

Estimated maximum 10-minute

Control Room intervention 0.01

release duration

2.3.4 Material Dispatch from Site - Pipeline

Products are dispatched from the site via pipeline to the external clients (Engen and Shell).

Details of pipeline dispatch from site to the clients are contained in the table which follows.

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Table 2.11: Details of pipeline dispatch

Flowrate

Dispatch to Line diameter Estimated % time in use

(L/min)

Shell and Engen 11,300 8 inches 43

Safety Systems

Probability of failure

System Implication on modelling

(SANS 1461)

Estimated maximum 10-minute release

Control Room intervention 0.01

duration

2.3.5 Material Dispatch from Site – Road Tanker

Products from the intermix tanks are dispatched to the Tarlton TPL depot for re-fractionation. This is described

in the table which follows:

Table 2.12: Details of road tanker loading

Products Time to fill truck % Hazards present Truck size

The site reports an average of: 3 road

Petrol and Diesel 45 minutes 42 m3

tankers quarterly

Safety Systems

Probability of failure (SANS

System Implication on modelling

Hand brakes and chocks to prevent - -

tanker rollaway

Earthing couplings - -

Driver presence during filling (manual

Estimated 2 minute release duration 0.1

intervention)

Breakaway couplings (standard Limits release duration to approximately 5

0.06

installation) seconds

Kerbed area – with a drainage Limit the size of a pool fire -

2.4 Staff Complement and Shift Patterns

The site operates 24 hours per day and 7 days per week throughout the year with the shift patterns and staff

distributions shown below.

Table 2.13: Staff locations and number of employees per location

Staff complement and shift pattern

Operating hours: 24 hours, 7 days per week

Number of shifts: 3

Shift 1: 10h00 to 18h00

Shift 2 18h00 to 02h00

Shift 3: 02h00 to 10h00

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Admin Staff hours: 07h00 to 16h00

Staff Distribution

Locations: Number of personnel:

1. Mechanical 3

2. Admin 1

3. Depot manager 1

4. Cleaning 3

5. Security 2 + (2 offsite)

6. Control room operator 2

2.5 Meteorological Tendencies

The weather conditions around the site, which are used for risk analysis, were obtained from South African

Weather Service data, as analysed and summarised in the websites: meteoblue.com and weatherbase.com.

The closest Weather station to the site, and its SA Weather Service reference number are: Witbank, Reference:

5153208. The distance of the weather station from site is approximately 3.46 kilometres north-east.

2.5.1 Ambient Temperature, Pressure, Humidity and Rainfall

Ambient Temperature and Pressure

• On average, the warmest months are October to March (22 to 25oC average high temperatures).

• On average, the coolest months are April to September (10 to 16oC average low temperatures).

• Average annual maximum temperature: 23.5oC.

• Average annual minimum temperature: 9.4oC.

• Average annual temperature: 16.2oC.

• Air Pressure was calculated based on the site’s elevation above sea level, using the webpage:

www.mide.com/pages/air-pressure-at-altitude-calculator.

Based on the site’s elevation above sea level (1,627 m) the ambient pressure was taken to be = 0.82

atm.

Humidity

Humidity is of interest because it affects the rate at which thermal radiation transfers from a flame to a target,

such as a person, building or piece of equipment. The more humid the conditions, the more radiation is

absorbed by the water vapour and the less radiation is felt by the target.

• On average, November to April are the most humid months (Ave. 57 to 69 % humidity).

• On average, May to October are the least humid months (Ave. 50 to 59 % humidity).

• The average annual percentage of humidity is: 60.3 %.

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Rainfall

Similar to humidity, the presence of rain is of interest because water droplets absorb some radiation.

• On average, October to April are the wettest months, with average precipitation of between 48 and

121 mm.

• On average, May to September are the driest months with some months having no precipitation and

others having an average of between 5 to 24 mm precipitation.

• Average total annual precipitation is 691 mm.

2.5.2 Wind Statistics

Wind statistics were based on observations over a 30-year period of hourly weather model simulations,

recorded at Witbank weather station. Wind statistics were obtained from https://www.meteoblue.com.

Wind statistics were taken into account in the risk modelling. Considering the yearly average wind direction

distribution, the majority of wind tends to blow from south to north. The wind rose is shown in Figure 2.3.

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Figure 2.3: Wind statistics at site

2.5.3 Weather Conditions Used for Modelling in this Assessment

2.5.3.1 Introduction to Weather Stability Classes

As required in SANS 1461:2018, several weather conditions have been used in the modelling of consequence

and risk in this assessment. The choice of weather conditions is in the form of so-called ‘Pasquill stabilities’;

Pasquill stabilities are measures of ‘the tendency of the atmosphere to resist or enhance vertical motion’ [6].

Stability is a function of the vertical change in temperature of the air, the wind speed and the type of surface

over the area of interest. Stabilities are characterised into the following categories:

6 AirWare Online Reference Manual: Pasquill Stability Classes, Release Date 2007 06, Revision Level 1.1. Retrieved from

http://www.ess.co.at/MANUALS/AIRWARE/stability_class.html on 23 March 2018.

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• Neutral: mechanical turbulence is neither enhanced nor inhibited;
• Unstable: Where turbulence is enhanced; and
• Stable: Where the atmosphere inhibits mechanical turbulence.

Stability classes (Pasquill classes) can be defined for various meteorological instances, as functions of wind

speed and solar radiation. Commonly, six Pasquill stability classes are defined:

Table 2.14: Pasquill Stability Classes and descriptions

Stability class Description of stability

1. A Very Unstable
2. B Unstable
3. C Slightly unstable
4. D Neutral
5. E Stable
6. F Very stable

The stability classes can be related to several driving forces: wind speed, solar radiation and cloud cover as

follows:

Table 2.15: Relating stability classes to wind speed, cloud cover and solar radiation

2.5.3.2 Stability Classes and Wind Speeds Used in this Assessment

To represent a range of weather conditions possible at the site, and in accordance with SANS 1461:2018, the

several stability classes and wind speeds were used in this assessment along with the corresponding time of

day.

Wind speed distribution per year was found to be as follows:

Table 2.16: Wind speed and fraction distribution at the site

Wind speed (km/h) Wind speed (m/s) Fraction per year

1 to 5 (>1) 0.83 0.31

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Wind speed (km/h) Wind speed (m/s) Fraction per year

5 to 12 (> 5) 2.36 0.46

12 to 19 (> 12) 4.31 0.17

19 to 28 (> 19) 6.53 0.05

28 to 38 (> 28) 9.17 0.00

38 to 50 (> 38) 12.22 0.00

50 to 61 (> 50) 15.42 0.00

61 16.94 0.00

From the table above and as per the methodology described SANS 1461:2018 Table C.3 the following weather

stabilities and corresponding wind speeds were used for the analysis:

Table 2.17: Pasquill stabilities and wind speeds used for the assessment

Day weathers Night weathers

B 1 f 1

C 2.36 E 2.36

2.6 Special Features Around Site

Close to the site is a Shell depot which is a confirmed MHI site and Bushveld Vanchem and Tam Alloys which

are also possible MHIs and may impact the site. This was described in more detail in Section 2.1: Site Location.

Furthermore, there is Witbank Airport located approximately 3 km north-east. The airport handles small aircrafts

and a sky-diving school. It is possible that the site is located underneath the flight path, and incidents onsite

could result in smoke dispersion which may affect flying into and out of the airport.

2.7 Relevant Topography of the Area

The area around the facility was noted to be generally flat (comprising mainly of industrial land) and geologically

featureless.

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{"briefingSession":"{"date":null,"time":null,"venue":"e: 29th August 2023","is_compulsory":false}"}

{"name":null,"email":"[email protected]","phone":null,"department":"of Employment and Labour: MHI-0001","address":"e Contact Details"}

9.3 Emergency Response Plan Evaluation .......................................................................................... 67

11 Recommendations / Risk Reduction Measures ...................................................................................... 70

MMRisk (Pty) Ltd were contracted by Transnet Pipelines (Pty) Ltd (‘TPL’), to conduct the Major Hazard

Installation (MHI) Risk Assessment of their Witbank Depot (‘Site’) in Emalahleni, Gauteng Province, South

Africa.

The risk assessment is an update of a previous risk assessment completed in August 2018.

The site is a depot receiving and distributing 50 ppm Diesel (D50), 95 Octane Unleaded Petrol (ULP 95) and

93 Octane Unleaded Petrol (ULP 93) to its external customers. The site receives diesel and petrol via pipeline

from the TPL Kendal Depot, which passes through a series of pipes and valves in the manifold before being

distributed to the nearby external clients, Shell and Engen depots. Any fuel that is intermixed when changing

the product in the pipeline is transferred to and stored in bulk intermix tanks. The site also has 5 bulk

aboveground clean petroleum products holding tanks.

As per the MHI Regulations of 2022 promulgated on 31st January 2023, the site is classified as a Medium

Hazard establishment. As such, the following requirements apply:

• An MHI Risk Assessment (this document);
• A Major Incident Prevention Policy (MIPP);
• A Process Safety Management System (PSM) (described in the MIPP but not submitted to the

authorities); and

• An Emergency Plan.

MMRisk are accredited by the South African National Accreditation System (SANAS, number MHI0037) and

approved by the Department of Employment and Labour to conduct Major Hazard Installation (MHI) Risk

Assessments (AIA approval Number CI MHI 0013, approval certificates attached in Appendix A).

Site activities

The Witbank TPL depot is a deport receiving and distributing petroleum products (Diesel and Unleaded Petrol).

The site receives diesel and petrol via 12-inch pipelines from the TPL Kendal Depot at a maximum operating

pressure of 8 bar and a flow rate of 11,300 litres/min. The duration of fuel receipt and distribution on site is

approximately 2 to 3 days per week.

The diesel and petrol received via pipeline are directed to the pipe manifolds and transferred to the external

clients while fuel that is intermixed when changing the product in the pipeline is transferred to and stored in 4

(four) bulk intermix tanks onsite. Any fuel that cannot be received by a client is transferred to and stored in 5

(five) bulk storage tanks.

The fuel that is stored in intermix tanks is then dispatched from site via road tanker and transported to the

Tarlton TPL depot for re-fractioning.

A simplified block flow diagram of the processes occurring onsite is shown in Figure 2.2.

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Figure 2.2: Process block flow diagram

Individual risk results

The individual risk contours illustrated in the figures below are of the type ‘Location Specific Individual Risk

(LSIR)’ contours. These show the chance of death of a theoretical person if they are positioned at a particular

location 24 hours per day, 365 days per year. LSIR is an overstatement of risk which is widely accepted as

sufficiently conservative. In reality, workers will spend the length of a shift per day and not the entire day.

However, when a worker is off, another worker may replace the worker in performing task(s), therefore, overall,

it can be considered that there is an individual at that particular point or area, all of the time.

The risk acceptability criteria are described in Section 3.5.1 and the individual risk profiles for the site are

illustrated in Figure 8.1.

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Individual risk for those located outdoors

Figure 8.1 illustrates individual risk of death for those located outdoors; being located outdoors implies a lack

of shielding for thermal radiation exposure, as would be the case for those located indoors. Only the estimated

consequences of a tank overfill event have been included in this report. The frequency of occurrence has been

excluded and as a result, the risks associated with this event have not been evaluated and are not included in

the figure below. The contours extend as follows:

Individual risk

Associated tolerability Observations

contour

1 x 10-3 / year Inside these contours risk is intolerable

This contour is not reached.

(blue contour) to workers.

The 1 x 10-4 contour envelopes the transfer tanks, the

pipe manifold, and the point where the incoming

pipeline from Kendal surfaces.

1 x 10-4 / year Inside this contour risk is intolerable to This contour appears over these areas due to the

(red contour) members of the public. relatively high frequency of small pump leaks leading to

flammable pools and associated pool fires restricted to

the contained areas. This contour does not extend

offsite.

The 1 x 10-5 contour envelopes the pipeline manifold, a 1 x 10-5 / year This contour indicates threshold of

portion of the road tanker gantry and the intermix tanks

(orange contour) tolerability for workers. pipework. This contour does not extend offsite.

The 1 x 10-6 contour extends over the abovementioned

1 x 10-6 / year This contour is the threshold for areas to a greater degree as well the bulk storage tanks

(yellow contour) tolerability for members of the public. onsite and the control room. This contour does not

extend offsite.

The 3 x 10-6 extends over the areas mentioned above to

a greater degree.

At this level, risk is broadly acceptable, 3 x 10-7 / year

but an indicator of appropriateness of The 1 x 10-8 and 1 x 10-9 / year contours also extend (green contour) land-use (see Section 8.5) over the areas mentioned above to a greater degree

than the 3 x 10-6. These contours extend slightly offsite

over the north and eastern site boundaries.

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Figure 8.1: Individual risk contours for personnel located outdoors

Conclusion:

Onsite, the risk contours extend such that the risk is considered tolerable if the site can prove that it is As Low

As Reasonably Practicable ‘ALARP’ for personnel especially at the pipe manifold. Offsite, the risk is considered

Broadly Acceptable.

Risk Judgement and Treatment are discussed in Section 8.4.

Societal risk results

Societal risk considers populations around the site to determine risk tolerability. In this study, this is presented

in the form of an FN-Curve, which illustrates scenarios with the potential to cause death, as well as considers

the frequency of each scenario. The frequencies of the scenarios are then summed to show a cumulative risk

of death, i.e., the frequency (F) of causing N or more fatalities against the number of fatalities, N.

As illustrated in Figure 8.2 there are tolerability limits as suggested by SANS 1461:2018 (see Section 3.5.2),

as illustrated by the red and blue sloped lines. Above the red line is the region where societal risk is intolerable;

below the blue line is the region where societal risk is broadly acceptable. Between these lines is the region

where risk can be tolerated if it is proven to be ALARP (see Section 3.5.2).

Description of the site’s FN curve (societal risk results)

Day time societal risk is based upon activities onsite which take place only during the day and upon day-time

population levels, and similarly night time risk is based upon activities taking place at night and also on

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populations of people during the night. The FN curve given below is a combination of day time and night time

risk.

Figure 8.2 shows that the maximum number of fatalities (on and off site) which can occur from a single event

occurring onsite is approximately 1 person; the associated frequency of this one large event is relatively low, at

approximately 1 x 10-4 / year. This corresponds to one of the high-impact, low-frequency events occurring at

the site.

Societal risk for the site lies predominantly below the blue line, indicating risk which is Broadly Acceptable.

Figure 8.2: FN Curve illustrating societal risk level of the site

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Top contributors to societal risk

Because Societal risk was assessed to Broadly Acceptable both to members of the public and personnel the

top contributors to societal risk were not analysed further.

Conclusion:

Societal risk was assessed to be Broadly Acceptable.