Overall Objectives, Scope, Technical Requirements, and Skills Summary

Objectives

The primary goal of this tender is to upgrade the Hillcrest Wastewater Treatment Works (WWTW) capacity from 1.25 million liters per day (ML/d) to 2 ML/d. This involves expanding infrastructure, installing new process, civil, electrical, and control systems, and ensuring continuous operation during construction. The project aims to enhance operational capacity, efficiency, reliability, and compliance with safety, environmental, and technical standards. It also seeks to incorporate modern automation, instrumentation, and safety features to meet current and future effluent load demands.

Scope

• Design, supply, construction, installation, testing, and commissioning of civil, mechanical, electrical, instrumentation, and control systems for plant upgrade and expansion.
• Construction of new infrastructure including tanks, clarifiers, reactors, pump stations, sludge handling facilities, stormwater systems, buildings, foundations, retaining walls, and civil modifications.
• Installation of process equipment such as screens, degritters, sludge pumps, mixers, aerators, screw presses, and associated piping and control systems.
• Upgrading existing systems, including electrical power supply, chlorination, sludge management, security fencing, and civil structures.
• Provision of new electrical and control systems, including MCCs, switchgear, control panels, SCADA, sensors, and instrumentation, with integration into existing systems.
• Removal of redundant equipment and civil structures, site preparation, and ensuring minimal disruption to plant operations during construction.
• Provision of training, manuals, testing, inspection, certification, and guarantee/maintenance services for installed systems and equipment.

Technical Requirements

• Compliance with relevant standards such as SANS, IEC, ISO, and international best practices for design, construction, and safety.
• Design of durable, corrosion-resistant infrastructure suitable for a sewage environment, including materials like stainless steel, galvanised steel, and epoxy coatings.
• Electrical systems must adhere to IEC 61439, SANS 10142, and other standards, incorporating proper earthing, safety, and protection features, including standby generators, UPS, and automatic transfer switches.
• Installation of process instrumentation (flow, level, pressure, temperature sensors) with calibration, testing, and documentation.
• Construction of civil structures with specified reinforcement, finishes, and corrosion protection, conforming to SANS standards.
• Implementation of control, automation, and SCADA systems with communication protocols such as Modbus TCP/IP and Ethernet/IP for process monitoring and control.
• Rigorous testing, inspection, and certification of all equipment and structures, including factory and site testing, with performance validation over a minimum operational period.
• Environmental and safety compliance, including noise control, fire safety, hazard management, lightning protection, and environmental management practices.

Skills and Competencies Required

• Expertise in civil, mechanical, electrical, and control system design, engineering, and manufacturing for wastewater treatment plants, with certifications such as ISO 9001 and ISO 14001.
• Proven experience in large-scale infrastructure projects, including process design, civil works, equipment installation, and system integration.
• Capability to produce and supply high-quality, durable equipment (pumps, mixers, screens, control panels) with comprehensive quality assurance documentation.
• Skilled installation teams for civil, mechanical, and electrical works, capable of executing complex plant upgrades safely and efficiently.
• Qualified personnel for factory and site testing, calibration, performance validation, and certification, especially in high-pressure and corrosive environments.
• Expertise in PLC programming, SCADA configuration, and network setup (MODBUS TCP/IP, Ethernet/IP) for automation and process control, ensuring reliable operation and fault diagnostics.
• Knowledge of environmental standards, safety regulations, noise control, fire detection, lightning protection, and corrosion prevention measures.
• Strong project management skills, including planning, scheduling, multidisciplinary coordination, procurement, and compliance with contractual and technical specifications.
• Ability to prepare detailed design calculations, shop drawings, method statements, quality plans, and operational manuals, along with staff training for plant operation and maintenance.