ANNUAL PERFORMANCE EVALUATION REPORT FOR THE
KATHU WASTE WATER TREATMENT WORKS
NORTHERN CAPE
CHIEF DIRECTORATE: BULK INFRASTRUCTURE PROGRAMME
PERIOD: 01 APRIL 2013 – 31 MARCH 2014
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REGIONAL BULK INFRASTRUCTURE GRANT PROGRAMME
APRIL 2014
Table of Contents
1.
INTRODUCTION ............................................................................................................................ 3
2.
BACKGROUND TO THE PROJECT .............................................................................................. 3
2.1.
Project description ................................................................................................................... 3
2.2.
Project History .......................................................................... Error! Bookmark not defined.
2.3.
Project concept, design and plan ............................................................................................. 4
2.4.
Start date – duration of the programme ................................................................................... 4
2.5.
Funds previously allocated to the project ................................................................................. 5
3.
PROGRESS TO DATE ................................................................................................................... 5
3.1.
Implementation of the approved business plan ........................................................................ 6
3.2.
Schedules of work and phasing of the activities ....................................................................... 6
3.3.
Risks taken and management thereof ...................................................................................... 6
3.4.
Capacities dedicated to the programme ................................................................................... 6
3.5.
Key challenges within the project ............................................................................................. 7
4.
3.5.1.
Water Conditions .............................................................................................................. 7
3.5.2.
Tie-in to existing services .................................................................................................. 7
3.5.3.
Delays .............................................................................................................................. 7
PROJECT RESULTS AND BENEFICIARIES ................................................................................ 7
4.1.
Outcomes and Outputs ............................................................................................................ 7
4.2.
Beneficiaries and project results .............................................................................................. 8
5.
CONCLUSION / LESSONS LEARNED .......................................................................................... 9
5.1.
Main successes and failures of the project to date ................................................................... 9
5.2.
Ownership and sustainability of infrastructure works ................................................................ 9
6.
RECOMMENDATIONS................................................................................................................... 9
Annexure A:
Project Implementation Photo’s
Annexure B:
Contract details
Annexure C: Job opportunities
Annexure D: Commissioning Protocol
Annexure E:
EPWP sheet
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REGIONAL BULK INFRASTRUCTURE GRANT PROGRAMME
1.
APRIL 2014
INTRODUCTION
In terms of Section 10(7)(b) of the Division of Revenue Act No 2 of 2013 (DORA) as
promulgated in Government Gazette No 36555 dated 10 June 2013, the transferring national
officer must submit an annual performance report for Schedule 6 within four months in
respect of a province and six months in respect of a municipality after the end of the financial
year to the National Treasury.
The Regional Bulk Infrastructure Grant (RBIG) is a Schedule 6 indirect conditional grant for
the benefit in kind of municipalities.
The objective of this Report is to provide an annual performance evaluation report covering
the 4th quarter of RBIG funded projects, in compliance with the DORA. The objective of this
evaluation was to determine whether the progress on the project is commensurate with the
expenditure to date as well as to determine whether the project is still on course in terms of
the original planning.
This performance evaluation report, covering quarter 4 and the annual report of the 2013/14
fiscal year, is for the Kathu Waste Water Treatment Works, a Regional Bulk Infrastructure
Grant project being implemented by the Gamagara Local Municipality in the Northern Cape
Province, with Department of Water Affairs (DWA) as funder.
2.
BACKGROUND TO THE PROJECT
2.1. Project description
The project entails the construction of a new 5700 m3 reactor, two 24 m diameter clarifiers,
new RAS\WAS pump station, new supernatant pump station and tanker discharge area, new
sludge drying beds, renovation of the existing chlorination building, interconnecting pipework
and general site works for the Upgrade of the Kathu Waste Water Treatment Works.
The existing Kathu WWTW with a capacity of 3.5 Mℓ/day is the only WWTW serving Kathu.
The current measured inflow is in the order of 4.5 Mℓ/day, which exceeds the aeration
capacity of the existing Works resulting in poor effluent quality. The poor condition of the
existing equipment further necessitates the upgrading of the Works
Gamagara Local Municipality comprises of an area of 2619 square kilometres, and is located
in the North Eastern sector of the Northern Cape, on the N14 National Road between
Upington and Vryburg. It is approximately 200 km North East of Upington and 280 km North
West of Kimberley.
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REGIONAL BULK INFRASTRUCTURE GRANT PROGRAMME
APRIL 2014
Figure 1: Locality Map
2.2. Project concept, design and plan
The intention of the project is to upgrade the WWTW to improve the quality and increase the
capacity of the existing works and as such the key drivers of the project are:



Provision of basic services to the community
Compliance with the requirements of the National Water Act
Supporting economic growth and developments
The present wastewater flow to the works varies between 4 and 4.5 Mℓ/day while the works
have a capacity of approximately 4 Mℓ/day and an aeration capacity of 3.5 Mℓ/day. The works
is thus hydraulically as well as organically overloaded. The new 6.5 Mℓ/day activated sludge
module will
accommodate the flow for approximately 10 years after which the existing pasveer ditches
will be re-commissioned to allow the works to accommodate the estimated 2030 population
of approximately 50 000 people. Provision was also made on site for a second and third
phase upgrade (each 6.5 Mℓ) once the treatment capacity requirements exceed the projected
2030 population figures.
The Gamagara Local Municipality lies within the John Gaetsewe District Municipality’s area
of jurisdiction and includes the towns of Kathu, Sesheng, Dibeng, Dingleton and Olifantshoek
with a population of ± 40 000 people.
2.3. Start date – duration of the programme
The contract details are mentioned below:
Contract Number
Contract name
Contractor
Contract start date
Contract completion date
Revised completion date
GM2012/10
Upgrading of Kathu WWTW: Civil Engineering Works
Civils 2000
6 September 2012
16 October 2013
28 July 2014
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REGIONAL BULK INFRASTRUCTURE GRANT PROGRAMME
APRIL 2014
Contract value
Percentage
complete
(overall)
R34 485 000.00 (VAT included)
95%
Contract Number
Contract name
GM2012/11
Upgrading of Kathu WWTW: Mechanical & Electrical
Engineering Works
Lektratek Water Technology
06 September 2012
06 November 2013
30 May 2014
R13 281 939.21 (VAT included)
98%
Contractor
Contract start date
Contract completion date
Revised completion date
Contract value
Percentage
complete
(overall)
(See annexure B)
2.4. Funds previously allocated to the project
The project is managed by the Department of Water Affairs, jointly through the Regional Bulk
Infrastructure Programme and coordinated by the DWA Regional Office in the Region.
The total project cost is R61 486 000.00 (VAT included) and the revised completion date of
the civil works is 28 July 2014.
Table 1: RBIG funding that was made available to the project to date.
2011/12
2012/13
2013/2014
Approved RBIG allocation
amount
Spent amount RBIG
Spent amount Counter
Funding
N.A
N.A
N.A
Total (vat
included)
R17 283 672.00
R628 000.00
R17 911 672.00
R16 655 915.34
R628 000.00
R17 283 915.34
R19 941 311.98
R19 941 311.98
R
0.00
EXPENDITURE UNTIL END MARCH 2014 ON BUDGET
Total (RBIG & Counter Funding) expenditure to end March 2014 = R37 225 227.32 (Vat
included).
3.
PROGRESS TO DATE
The performance evaluation was conducted on 14 May 2014 by a team consisting out of the
following people:






L Mditshane
MF Hanyane
L Guqa
P Kekana
K More
B de Waal
: DWA RBIG – National office
: DWA RBIG
: DWA – Regional office NC
: Gamagara Municipality
: Gamagara Municipality
: Worley Parsons RSA
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REGIONAL BULK INFRASTRUCTURE GRANT PROGRAMME
APRIL 2014
3.1. Implementation of the approved business plan
Product
Feasibility Study
Start date
Name of Organization compiling/
developing
Completion date
Gamagara Local Municipality in
conjunction with WorleyParsons
Jan 2011
March 2011
Implementation
Readiness Study
Gamagara Local Municipality in
conjunction with WorleyParsons
Feb 2011
June 2011
Preliminary Design
WorleyParsons
Aug 2011
Jan 2012
EIA
MDA
N/A
WUL
Gamagara LM
WorleyParsons
N/A
In place
ROD issued on
9/9/2012
13/3/2014
In place
WorleyParsons
Funding secured
Funding secured
Operation
and
Maintenance Plan
Financial Funding
Plan
3.2. Schedules of work and phasing of the activities
Please see Annexure D: Commissioning protocol
3.3. Risks taken and management thereof
The most significant risk associated with this project is the volume of hard rock that is
encountered just below the ground level. As such all excavation quantities were measured as
100% rock and priced accordingly by the contractor.
A further risk was the level of operator skill required to operate and maintain the new works.
This risk was addressed by making allowance for an accredited service provider to operate
and maintain the works during the defects liability period. This period would then be used
transfer knowledge and skills to the staff currently operating the works.
3.4. Capacities dedicated to the programme
The project is managed by the Department of Water Affairs, jointly through the Regional Bulk
Infrastructure Programme and the Construction Unit of the Department and coordinated by
the DWA Regional Office in Kimberley.
The capacities dedicated to the project are as follows:






Funder: DWA Regional Infrastructure Grant
Co-funded by Gamagara Municipality
Implementing agent: Gamagara Municipality
Operation & Maintenance: Gamagara Municipality
Consulting Engineer: WorleyParsons RSA
Contractor (current): Civil contractor: Civils 2000 & Mechanical Contractor: Lektratek
Water Technology
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REGIONAL BULK INFRASTRUCTURE GRANT PROGRAMME
APRIL 2014
3.5. Key challenges within the project
3.5.1. Water Conditions
Water is found at about 2m below ground level across the site. As such, backfilling of over
break has to be done with a soil cement mixture instead of normal fill material. Pipes laid in
pipe trenches has to be bedded in 19mm aggregate, acting as a sacrificial layer, to overcome
water conditions. All of this adds to slower work rates and has a negative impact on the
programme.
3.5.2. Tie-in to existing services
a)
With the current inflow of water to the Kathu WWTW, the plant has to be in operation
full time and this makes it very difficult to connect to existing services. The most
significant challenge so far was to move the pipes at the inlet works division box while
the plant was still in operation. This was done by closing one sluice at a time inside the
box and moving the pipes one by one. Water inside the reactor basins was controlled
by pumping water from one to the other.
b)
To accommodate the tie-in of the new works to the existing chlorination sump, the
chlorination lay-out was revised to ensure that the time needed to do the actual tie-in is
minimal.
A new inlet and outlet chamber was designed to let effluent water from the new works
and the existing works flow together over a newly created sharp-crested weir.
By doing this, optimal chlorine dosing is applied to the effluent water.
New sluices were added to the Inlet and Outlet chambers so that water can either be
directed to the chlorination sump or the retention pond. The pipe connecting the outlet
chamber to the retention pond also has a dual purpose, in that in periods of low flow,
water can be returned from the retention pond to the chlorination sump.
Provision was also made for a suction point for water to be used as irrigation water
across the site after installation of an irrigation system.
The actual tie-in is planned for the week of 5 May 2014 and 12 May 2014.
3.5.3. Delays
Due to the fact that Kathu is situated in a rich mining area, suppliers of material and plant
often gives preference to the mines instead of commercial or private entities, which results in
delays with delivery and availability.
4.
PROJECT RESULTS AND BENEFICIARIES
4.1. Outcomes and Outputs
Civil work include the following:



Site clearance and excavations, including the demolition & removal of existing civil
structures;
Alteration to the existing inlet works including the relocation of the existing wash water
tank to the chlorination building;
Constructon of a new biological reactor;
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REGIONAL BULK INFRASTRUCTURE GRANT PROGRAMME







APRIL 2014
Construction of two new settling tanks;
Construction of new return activated sludge (RAS) and waste activated sludge (WAS)
pump station (including ablution facilities, office & laboratory on the second floor;
Laying & bedding of interconnecting pipework;
General site- & road works, including paving around selected structures & buildings;
Construction of new sludge drying beds;
Construction of new supernatant pump station & tanker discharge area;
Renovation of the existing chlorination building.
Mechanical and Electrical work include the following:

5 off 4 kW vertical shaft mixers;

5 off 55 kW vertical shaft aerator;

2 off axial flow pumps;

Tilting weir at the reactor outlet;

1 off 150 mm diameter knife gate valve complete with electric actuator at the
Secondary.
Settling Tank feed box:

Three self-priming centrifugal Return Activated Sludge (RAS) pumps (2 duty, 1
standby), complete with pipe work and valves;

Two self-priming centrifugal Waste Activated Sludge (WAS) pumps (1 duty,1 standby)
complete with pipe work and valves;

Two self-priming centrifugal Supernatant Return (SRP) pumps (1 duty, 1 standby)
complete with pipe work, valves, screenings basket and gantry;

Two rotating bridges with scraper mechanisms for the new 24 meter diameter
secondary.
Settling tanks complete with ancillary equipment:

Sluice gates and hand stops;

A gas chlorination system with a gas leakage detection system and safety equipment
for disinfecting the treated effluent including makeup water filtration system;

Two magnetic flow meters and ancillary equipment at the RAS/WAS pump station for
measuring RAS and WAS;

Monitoring and metering equipment and instrumentation

Decommissioning of existing mechanical and electrical equipment

Alterations to the mechanical and electrical equipment at the Inlet Works

Electrical switchboards, switchgear and cables, including electrical cable reticulation on
site;

Grouting in of pipes through walls will be executed by the civil contractor. The
mechanical contractor shall however grout base plates of pumps and other mechanical
equipment to concrete plinths.

Area lighting;
4.2. Beneficiaries and project results
The upgrading of the works aims to improve the capacity of the existing works and also to
ensure that the final effluent quality complies with General Limit Values as determined by the
Department of Water Affairs.
Once the Works have been upgraded the Works will be able to serve a population of 40 000
and all the households in Kathu and Sesheng will benefit from this project. This will
enhance economic development towards achieving the national services target by 2014.
The eradication of the housing backlog and future development cannot proceed without the
additional treatment capacity that will be provided by the Works
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REGIONAL BULK INFRASTRUCTURE GRANT PROGRAMME
APRIL 2014
The Gamagara Local Municipality lies within the John Gaetsewe District Municipality’s area
of jurisdiction and includes the towns of Kathu, Sesheng, Dibeng, Dingleton and Olifantshoek
with a population of ± 40 000 people
Jobs created
Job creation details are summarized in Annexure C
EPWP Sheets (see Annexure E)
5.
CONCLUSION / LESSONS LEARNED
5.1. Main successes and failures of the project to date
Successes:
a)
Accurate pricing or rock: Hard calcrete material is found across the site at a depth of
±200mm below NGL. As such rock quantities were priced at 100%.
b)
The quality of concrete work is of outstanding quality. The standard as set right in the
beginning of the project was maintained throughout the project and quality was not
sacrificed because of a delay in program as is normally the case on a delayed
construction project.
c)
Aesthetics: The design team incorporated an irrigation system and a lot of paving in
their design of the site, so that it would not resemble a typical waste water treatment
plant. The final shaping will be done once all water testing has been completed.
Failures
a)
The time estimated for excavation: The contractor allowed too little time for the
excavation of structures and this has directly led to the delay in the project.
b)
Volume of overbreak: the nature of the excavated material and an incompetent
blasting contractor that had no previous experience of material in the area resulted in
the large amount of material that had to be imported for filling overbreak. This in turn
resulted in a further delay of the project because the estimated time for filling of
overbreak at the Bioreactor was not enough and at the SST’s there was no provision
made.
5.2. Ownership and sustainability of infrastructure works
The Gamagara Municipality will take ownership and will sustain the infrastructure works.
(Refer to paragraph 3.3).
6.
RECOMMENDATIONS
None
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REGIONAL BULK INFRASTRUCTURE GRANT PROGRAMME
Annexure 1: PHOTOGRAPHS ON THE IMPLEMENTATION OF THE PROJECT
Figure 1: Sludge drying beds
Figure 2: Turning circle
APRIL 2014
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REGIONAL BULK INFRASTRUCTURE GRANT PROGRAMME
Figure 3: Clarifier 2
Figure 4: Clarifier 1
APRIL 2014
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REGIONAL BULK INFRASTRUCTURE GRANT PROGRAMME
Figure 5: Pumps inside the RAS|WAS pump station
Figure 6: Electrical panels inside the RAS|WAS pump station
APRIL 2014
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REGIONAL BULK INFRASTRUCTURE GRANT PROGRAMME
Figure 7: Bioreactor
Figure 8: Joint sealing around the aerator base
APRIL 2014
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REGIONAL BULK INFRASTRUCTURE GRANT PROGRAMME
Figure 9: Axial flow pumps at the Bioreactor
APRIL 2014
Annexure B: Contract details
Contractor
Contract No
Civils 2000
GM2012/10
Lekratek
GM2012/11
Contract amount (VAT
included)
Construction start
date
Revised
completion date
R 34 485 000.00
6-Sep-13
28 July 2014
R 13 281 939.21
6-Nov-13
30 May 2014
Amount spent to
date
(VAT Included)
R
R
22 765 428.33
9 094 798.27
Annexure C: Job opportunities
Project Name and
Number
Kathu WWTW - April 2013 - March 2014
Summary of Decent Job Opportunities
Decent job opportunities Decent job opportunities for the financial year 2013/14
for people employed at
Adult Men
various occupational
Person Days Actual cost No
No
levels: Decent = Full time
on job
for at least 5 months or
opportunities
more
Clerical Ongoing
Clerical New
Labourers Ongoing
Labourers New
Managerial Ongoing
Managerial New
Semi-Skilled Ongoing
Semi-Skilled New
Skilled Ongoing
Skilled New
Supervisor Ongoing
Supervisor New
Other Ongoing
Other New
TOTAL Ongoing
TOTAL New
46,801
1
236
2
258
7
236
564,682
11
237
921,798
3
236
1
74
25
0
1,277
0
1,533,281
0
2
1
29
18
2
1
29
18
0
0
27
236
1,402,409
2
236
119,891
1
236
5
249
35
0
957
0
1,522,300
0
1
212
1
0
34
15
2
0
246
15
47,189
47,189
0
TOTAL
Person Actual cost
on job
Days
opportunities
Disabled
Person Actual cost No
on job
Days
opportunities
Youth Women
Person Days Actual cost No
on job
opportunities
Youth Men
Person Days Actual cost No
on job
opportunities
Adult Women
Person Days Actual cost No
on job
opportunities
0
0
0
0
0
0
0
0
29
0
2
0
7
0
13
0
4
0
10
1
64
1
0
0
684
0
258
0
236
0
473
0
472
0
385
33
2,508
33
0
0
1,496,399
0
0
0
564,682
0
1,041,689
0
0
0
0
0
3,102,770
0
Annexure D: Commissioning Protocol
KATHU WWTW Commissioning Protocol
Completion of mechanical/electrical installation
Completion of adjustments and rotational testing (DRY commisioning)
Completion of commisioning and training (WET commisioning)
Completion of testing of equipment for acceptance by Engineer
Acceptance by Engineer
Commencement of 12 month defects liability period
Completion of all civil work by Civils 2000
17-Apr-14
4 days
2 days
5 days
2 days
25-Apr-14
2&3 June 2014
4,5&6 June 2014
9&10 June 2014
Lektratek Operating manuals
3 Manuals should be supplied prior to handover acceptance therefore before the 9 June 2014
Operation of Works for 12 months by Service
Provider
Service provider should commence as of 10 June 2014 until 9 June 2015
10 June 2014 to 9 June 2015
28-Jul-14
Annexure E: EPWP Sheet