Objectives

The primary objective is to provide comprehensive emission monitoring verification services for particulate matter (PM) and gas monitors installed on Smokestacks 1 and 2 at Majuba Power Station. This ensures regulatory compliance, accurate data collection, and optimal performance of Continuous Emission Monitoring Systems (CEMS) through standardized testing procedures over a five-year period.

Scope of Work

The service encompasses correlation, parallel, stratification, and spot-check testing conducted under a structured service agreement. Key deliverables include:

• Annual spot checks and gaseous correlation tests performed as required.
• Biennial full statutory correlation tests and QAL 2 parallel measurements.
• Stratification surveys to validate sampling representativeness across stack cross-sections.
• Submission of detailed technical reports within three weeks of test completion.
• Coordination with plant operations for unit light-ups, shut-downs, and load requirements, primarily scheduled over weekends.

The contract spans five years, with payments processed per completed task order upon report acceptance. Late delivery incurs financial penalties.

Technical Requirements

Contractors must demonstrate advanced metrological and operational capabilities:

• Maintain SANAS accreditation or Eskom approval as a certified Stack Tester.
• Conduct testing on large-diameter stacks ranging from 8.5 to 9 meters.
• Apply internationally recognized methodologies including ISO 12141 and EPA Methods 3A, 6C, 7E, and 10.
• Verify zero-calibration of existing monitors prior to correlation testing.
• Inspect Fabric Filter Plants (FFP) for bag leaks before testing commences.
• Comply with strict occupational health, safety, and environmental protocols, including asbestos exposure controls, ISO 14001 environmental management standards, and corporate safety rules.
• Provide all specialized testing equipment, consumables, and calibrated instruments unless otherwise specified.

Skills Requirements

Personnel must meet stringent qualification and authorization criteria:

• Specialist Engineers: Hold an engineering degree with a minimum of three years’ experience in mechanical or instrumentation fields, preferably with NEC contract administration knowledge.
• Artisans: Possess Grade 12, N4, or trade test certification alongside two years of relevant field experience.
• Authorised Supervisors: Complete employer-approved theoretical and practical training programs, obtaining biennial site-specific authorization.
• All staff must submit proof of qualifications, police clearance, and competency certificates for high-risk activities (confined spaces, working at heights, heat/cold stress) two weeks prior to mobilization.
• Recruitment mandates prioritize local economic development, requiring 100% of new general labor hires from the designated local municipality and utilizing local transport providers.

Key Contractual & Technical Terms

NEC3 TSC3: A proactive project management contract framework emphasizing early warning notifications, compensation events, and collaborative risk sharing rather than traditional punitive clauses.

QAL 2: Quality Assurance Level 2, an international benchmark requiring direct comparison of CEMS data against reference measurement methods to verify system accuracy.

Stratification Survey: A diagnostic procedure mapping gas velocity and concentration gradients across a stack’s cross-section to ensure probe placement yields representative samples.

SANAS Accreditation: National recognition of technical competence for testing laboratories and personnel under South African regulatory frameworks.