Objectives

The primary objective is to conduct a comprehensive condition assessment of the existing fire protection system at the Port of East London’s Tanker Berth. The assessment aims to verify system integrity, operational readiness, and regulatory compliance, while identifying deterioration, corrosion, and functional deficiencies. The outcome will be an engineering documentation package to guide targeted repairs, system upgrades, and long-term maintenance planning.

Scope of Services

The consultant will execute detailed field inspections, laboratory-grade testing, and engineering analysis across all firewater and foam system components. Key deliverables include:

• As-Built Drawings: Updated P&IDs, general arrangements, piping isometrics, equipment layouts, and electrical schematics in PDF and DWG formats, incorporating field mark-ups and version control.
• Condition Assessment Report: Executive summary, inspection methodology, component-level findings, NDT results, condition grading (Good/Repair/Replace), compliance evaluation, risk register, and remaining service life estimates.
• Repair & Coating Specifications: Step-by-step repair sequences, material/weld specifications, pipe coating/surface protection requirements, and a CESMM-aligned Bill of Quantities (BOQ).
• Maintenance Plan: A five-year forward schedule aligned with NFPA 25 and SANS codes, including inspection intervals, checklists, resource requirements, and record-keeping templates.
• Electrical & Control Redesign: Root cause analysis and engineering solutions for the deluge valve system to enable independent monitor operation, eliminate extended pre-priming delays, and mitigate water hammer risks.
• Foam System Testing: Procurement of fluorine-free foam concentrate, followed by functional testing of pumps, proportioners, fixed monitors, and portable pourers to verify flow, pressure, coverage, and induction accuracy.

Technical Requirements

All works must comply with a comprehensive matrix of international and South African standards, including NFPA, EN, IMO, ASME, ISO, SANS, and API specifications. Key technical mandates include:

• Inspection & Testing Protocols: External/internal visual inspections, ultrasonic thickness testing (minimum three readings per metre), certified non-destructive testing (NDT), and functional/hydraulic performance trials.
• Performance Benchmarks: Monitors must achieve ≥90% of rated flow/pressure/throw; foam induction accuracy within ±1% of 3%; expansion ratio and drainage time compliant with EN 1568/NFPA 11; deluge valves must operate independently with full flow within 60 seconds and pre-priming under 5 minutes.
• Project Planning: Submission of a Level 3 Microsoft Project schedule spanning five months, with no activities exceeding two weeks, clearly defined critical path, and full resource dependency mapping.
• Site & Safety Constraints: Access restricted to periods when the berth is unoccupied; strict hazardous area electrical certifications required; mandatory work permits for heights, berths, and hazardous operations; comprehensive SHE file maintenance on-site.

Skills & Personnel Requirements

• Professional engineering expertise in mechanical piping, fire protection systems, corrosion engineering, hydraulic modelling, and electrical/control logic redesign.
• Certified NDT personnel meeting ISO 9712 Level II standards.
• Competence in developing CAD drawings, BOQs, risk registers, and maintenance schedules aligned with industry standards.
• Strict adherence to TNPA health, safety, and environmental policies, including mandatory site inductions, daily personnel records, and provision of appropriate PPE (fire-resistant overalls, reflective gear, chemical goggles).
• Ability to manage subcontractors transparently and maintain rigorous document control through the Employer’s filing system.

Explanation of Unusual/Complex Terms

• NEC3 Contract: A collaborative project management contract framework emphasizing early risk identification, shared responsibility, and formal processes for managing changes (compensation events).
• Fluorine-Free Foam (FFF): An environmentally sustainable firefighting agent that replaces traditional PFAS-based foams. It requires specific viscosity and performance validation to ensure compatibility with existing pumps and monitors while meeting hydrocarbon fire suppression standards.
• Deluge Valve System Redesign: The current setup activates all monitors simultaneously, suffers from prolonged pre-priming delays (~35 minutes), and experiences repeated solenoid failures. The redesign must enable selective monitor control, implement rapid automatic priming, and incorporate surge/water hammer mitigation.
• CESMM: Civil Engineering Standard Method of Measurement, a standardized framework for preparing Bills of Quantities to ensure consistent pricing and measurement of civil/mechanical works.
• Class 3 Cost Estimate: A preliminary budgetary estimate with typical accuracy ranges of ±10% to ±30%, developed during the conceptual assessment phase using available design data and historical benchmarks.