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SCOPE OF WORK FILTER PACKAGE

Document No 140316-4000-45EW-5607 Revision 01 Date 20/03/2018 of 22

SNC-LAVALIN 140316-4000-45EW-5607_01 - Scope of Work - Filter Package.docx

REVISION CONTROL

Issued for Internal Review

Issued for Client Review

Issued for DFS

REVISION HISTORY

Revision Date Pages Revised Remarks 00 25/08/2017 All Incorporated review comments 01 20/03/2018 Section 6.1 Clarified filter type required




TABLE OF CONTENTS 1 SCOPE OF WORK 5

1.1 INTRODUCTION 5

1.2 WORK INCLUDED 5

1.2.1 Engineering and Services 5 1.2.2 Procurement and Supply 5

1.2.3 Fabrication and Shop Assembly 6

1.2.4 Quality System 6

1.2.5 Verification and Testing During Fabrication 6

1.2.6 Preparation, Packing and Shipment 7

1.2.7 Provision of Technical Data, Drawings and Instruction Manuals 7 1.2.8 Spare Parts, Special Tools and Equipment 7

1.2.9 Lubricants 7

1.2.10 Installation and Commissioning Assistance 7

1.2.11 Training 7

1.3 OPTIONAL WORK 8

1.3.1 Mn Precip Filter Package 8 1.4 SHIPPING, PACKING AND STORAGE 8

2 TRANSPORT ENVELOPE 8

3 WORK EXCLUDED 8

3.1 ENGINEERING AND SERVICES 8

3.2 FREE-ISSUE ITEMS 9 3.3 BATTERY LIMITS 9

4 REFERENCE DOCUMENTS AND STANDARDS 9

4.1 DRAWINGS AND SPECIFICATIONS 9

4.2 CODES, STANDARDS AND REGULATIONS 9

4.2.1 Government Acts, By-Laws and Regulations 9

4.2.2 Standards 9 4.3 LANGUAGE AND MEASUREMENT SYSTEM 10

5 OPERATING ENVIRONMENT 10

6 DESIGN CRITERIA 11

6.1 PROCESS DESCRIPTION 11

6.1.1 Eluate Neutralisation Filter Package, (421-PK-0001) 11

6.1.2 Eluate Polishing Filter Package, (423-PK-0001) 11 6.1.3 Co Purification Alkali Make Up Filter Package, (461-PK-0001) 11

6.1.4 Mn Precip Filter Package, (461-PK-0003) 12

6.1.5 Mn Precip Bag Filter, (461-FR-0003A/B) 12




6.1.6 Cu IX Feed Bag Filter, (461-FR-0002A/B) 12

6.2 OPERATING PHILOSOPHY 12

6.3 DUTY AND THROUGHPUT RATE 12 6.4 DESIGN REVERSE OSMOSIS (RO) WATER QUALITY 13

6.5 DESIGN LIFE AND AVAILABILITY 13

6.6 PREFERRED EQUIPMENT 13

6.7 OTHER 13

6.7.1 Lifting Lugs 13

6.7.2 Noise Level 13 6.7.3 Safety Guards 13

7 DETAILED TECHNICAL REQUIREMENTS 13

7.1 ENGINEERING AND SERVICES 13

7.2 MATERIALS OF CONSTRUCTION 14

7.3 MECHANICAL 14

7.4 AIR COMPRESSORS 14 7.5 PIPING 14

7.6 STRUCTURAL 14

7.7 ELECTRICAL 15

7.8 INSTRUMENTATION 15

7.8.1 Instruments 15 7.8.2 Control Systems 15

7.8.3 Functional Safety 16

7.8.4 Documentation 16

7.9 SURFACE PROTECTION 16

7.10 EQUIPMENT IDENTIFICATION, MARKING AND LABELING 17

7.11 TECHNICAL DATA, DRAWINGS AND MANUALS 17 7.11.1 General 17

7.11.2 Responsibility 18 8 INSPECTION, TESTING AND ACCEPTANCE 18

8.1 QUALITY SYSTEM 18

8.2 VERIFICATION AND TESTING DURING FABRICATION 18

8.3 FINAL ACCEPTANCE 19 8.4 PERFORMANCE CRITERIA AND TESTING 19

APPENDICES

Appendix A REFERENCE DOCUMENTS 20

Appendix B VENDOR DATA REQUIREMENTS 21




1 SCOPE OF WORK

1.1 INTRODUCTION

This document sets out the scope of work and technical requirements for the supply of a Filter Package for the Clean TeQ Sunrise Project in New South Wales, Australia.

1.2 WORK INCLUDED

The scope shall comprise the provision of all labour, materials, parts and services necessary to carry out the design, supply, manufacture, assembly, surface protection, quality assurance, inspection, testing, identification, packaging and transportation, together with the provision of all necessary services, relating to the following equipment:

Tag No. Description. Datasheet No. 421-PK-0001 Eluate Neutralisation Filter Package 140316-4210-45ED-PK0001 423-PK-0001 Eluate Polishing Filter Package 140316-4230-45ED-PK0001 461-FR-0002 Cu IX Feed Bag Filter 140316-4610-45ED-FR0002 461-FR-0003 Mn Precip Bag Filter 140316-4610-45ED-FR0003 461-PK-0001 Co Purification Alkali Make Up Filter Package 140316-4610-45ED-PK0001 461-PK-0003 Mn Precip Filter Package 140316-4610-45ED-PK0003

Each of the Filter Packages listed above shall be capable of meeting or exceeding the specifications, design criteria and technical requirements listed elsewhere within this document, as well as the requirements specified within the datasheets and the project specifications noted in Appendix A of this document.

The works shall include but not be limited to the following:

1.2.1 Engineering and Services

The Vendor shall design the overall Filter Package (which includes the six filters mentioned above) in accordance with this scope of work, the applicable codes and standards, reference specifications, drawings, equipment data sheets and local government regulations, and shall ensure that the Plants are suitable for the duties specified.

The Vendor shall detail all service requirements for the Filter Package.

1.2.2 Procurement and Supply

The Vendor shall supply and deliver the Filter Package and shall furnish all materials, accessories and services required for the complete testing and commissioning of the same.

The Vendor shall include in the scope of work items, accessories and services that are usual or necessary to complete the work, but which may not have been specifically mentioned herein.

The Vendor’s scope of work for the Filter Package shall include as a minimum:

• Design and supply of all mechanical equipment listed or implied in the datasheets listed in Appendix A, which includes air compressors, dryers & receivers, filter elements, filter frame, pumps and hydraulic systems

• Headers, piping manifolds and automated valves for introduction of filter feed, precoat, air and wash water

• Cloth washing system • Supply of electric motors for all equipment drives




• Design and supply of transfer chutes for filter cake, filter plant support framework, access platforms and ladders

• Shop testing (FAT) for mechanical equipment • All reaction loads to enable concrete footing design • Supply and application of protective coatings • Supply of all intrinsic instrumentation as required.

1.2.3 Fabrication and Shop Assembly

The Filter Package shall be fabricated in accordance with this scope of work, the applicable codes and standards, reference specifications, drawings, equipment data sheets and Australian local government regulations.

The Filter Package shall be shop assembled to the greatest extent practical prior to inspection and delivery, as dictated by road transport requirements and inherent limitations.

It is preferred that each Plant is modularised to the greatest extent possible to facilitate ease of transportation and to minimise onsite installation works.

Each Plant will be constructed to operate independently of any other and will be located in the vicinity of the tanks receiving the filter cake and filtrate discharge streams.

Where not practicable to provide fully assembled units for delivery, the Vendor shall supply equipment in discrete sub-assemblies to minimise site assembly time. The sub-assemblies shall be capable of being transported within the envelope described in section 2. The Vendor shall nominate the extent of pre-assembly in the tender and define the transport envelope.

1.2.4 Quality System

The Vendor shall provide a Quality Plan and systems detailing the handling of design, procurement, fabrication, installation and testing quality issues. The Quality Plan shall demonstrate how for each of these aspects an auditable trail can be established.

The Vendor shall arrange for sufficiently qualified personnel to provide auditing of the implementation of the Filter Package Quality Plan.

1.2.5 Verification and Testing During Fabrication

The Vendor shall submit details of all tests to be carried out during manufacture in the format of an Inspection and Test Plan (ITP), with detailed Vendor/sub-Vendor inspection points shown and test procedures clearly defined.

Prior to dispatch from the Vendor’s premises, basic workshop testing Filter Plant equipment shall be performed which include:

• Hydrostatic testing of shop fabricated and assembled filter frames • No-load operating tests on all motor driven equipment.

No-load operating tests shall be performed for a period of at least one hour, to verify the operation, bearing temperatures and levels of vibration of all rotating equipment are acceptable.

Prior to shipment, the Vendor shall perform the tests as defined by the Quality Assurance requirements of this scope of work and as per the established and agreed ITPs.




1.2.6 Preparation, Packing and Shipment

The Vendor shall shop assemble components to the maximum extent practical, such that field assembly is both minimised and simplified, and matching of components is assured. The Vendor shall shop fit, drill, identify and match mark parts that cannot be shop assembled prior to shipment. The Vendor shall individually tag equipment items shipped ‘knock down’ with the assigned tag number and suffix -A, -B, -C, etc.

The Vendor shall identify individual pieces in accordance with the identification schedule used on the shop drawings and bill of materials to clearly indicate their location in the work for installation.

The Vendor shall prepare the equipment for shipment, preserve, pack and transport the equipment.

1.2.7 Provision of Technical Data, Drawings and Instruction Manuals

The Vendor shall provide design data, operating manuals, specifications, shop drawings, catalogue data sheets, installation and maintenance information, etc. in accordance with the attached Vendor Data Requirements Schedule which forms part of this document.

1.2.8 Spare Parts, Special Tools and Equipment

The Vendor shall provide the following recommended lists of spare parts, consumables and special tools and their costs:

• Commissioning spares • Capital spares consisting of specific long lead items which are critical to equipment operation • One year’s operating spares • Special tools and equipment for the installation, commissioning, operation and maintenance. • Equipment to test strength of mixer flocculant product.

1.2.9 Lubricants

The Vendor shall supply and install the first fill lubricants for the purpose of workshop testing of equipment.

The Vendor shall provide a recommended schedule of lubricants for the operation of the equipment within the Filter Package.

1.2.10 Installation and Commissioning Assistance

The Vendor shall include an estimate of costs and associated scope, based on their experience, for the provision of assistance during the installation and commissioning stages of the Filter Package. The daily charge out rates for the supervision of installation and commissioning of the Filter Package shall be provided and an anticipated visit schedule allowed for in that pricing. Accommodation and messing in a nearby construction camp will be provided by the Project.

1.2.11 Training

The Vendor shall be responsible for the supply of all training documentation as well as the training of the Client’s process, operations and maintenance technicians in the appropriate methods of plant operation, maintenance and safety under normal and emergency operating conditions. The training shall be carried out with reference to the Installation, Operating & Maintenance (IOM) manuals.

The Vendor shall submit a training program which will be reviewed and approved by the Client’s representative and the Client. The Vendor shall include all costs and resources to provide for an agreed minimum number of contact hours of classroom and field training for the Client’s process and maintenance technicians to ensure an adequate level of competency for the trained personnel has been achieved.




Training documentation shall include a high level control and operating description and all detailed operating and maintenance manuals.

1.3 OPTIONAL WORK

The Vendor’s tender shall conform to this scope of work. The Vendor may supplement their base tender with alternatives provided that they offer significant advantages with respect to capital cost, operating cost, delivery date, safety, quality, reliability or suitability for a specific service. However, it is mandatory that the equipment be capable of meeting the duty and throughput rate(s) as indicated in this scope of work.

The Vendor shall submit a list of all exceptions to, and/or deviations from, this scope of work with the tender package, and shall describe each in detail.

1.3.1 Mn Precip Filter Package

The filtrate stream from the Mn Precip Filter, (part of Vendor Package 461-PK-0003), will be delivered directly into the Mn Precip Bag Filter (equipment No. 461-FR-0003). In order to achieve the necessary delivery pressure into the bag filter to achieve the required filtration, it is anticipated that a break tank and pump will be required between the two filters.

The Vendor is encouraged to provide a fully priced proposal to incorporate the necessary equipment between the two filters in order to supply the Filter Package 461-PK-0003 and bag Filter 461-FR-0003 as one complete combined package.

The same generic battery limits will apply in relation to the additional equipment.

1.4 SHIPPING, PACKING AND STORAGE

All packaging shall comply with the document: Documentation, Packaging, Marking and Shipping Instructions, document number GP-5500-FO-01-E provided as part of the suite of package documentation.

2 TRANSPORT ENVELOPE

For preliminary design purposes the Contractor may assume an extreme road transport envelope consisting of an air draft of 9m from road surface to top of load and 7.5m out to out (width). A tyre loading limit of 2.25 tonnes shall further apply.

The NSW transport authority has provided guidance that the longest standard truck allowed on their roads without escort or special permitting shall be a B-Double with a total length not exceeding 25m. Other requirements have been summarised in the NHVR, (National Heavy Vehicle Regulator), July 2016 Bulletin.

Wider and longer loads can be proposed by the Contractor for consideration by the Client if the Contractor believes that significant cost and schedule savings could be achieved.

3 WORK EXCLUDED

3.1 ENGINEERING AND SERVICES

The following is excluded from the scope of supply:

• Equipment foundations will be designed, supplied and installed by others in accordance with data provided by the Vendor

• Equipment anchor bolts will be supplied and installed by others • Equipment will be off-loaded, handled and stored on site by others




• Equipment will be installed on site by others • Instrument/plant air (external to filter cycle operation), and water will be supplied to the Filter Package

battery limits by others.

3.2 FREE-ISSUE ITEMS

There are no free-issue items associated with this scope of work.

3.3 BATTERY LIMITS

The Vendor’s battery limits for the supply of Filter Package Plants

• Top of concrete footings, including cast in HD bolts • Outer face of inlet flange for filter slurry feed • Outer face of flange for filter filtrate discharge • Service connections to equipment for plant/instrument air and reverse osmosis (RO) water supply • Motor power, thermistor and RTD terminals • Terminal connections of field instruments and instrument terminal strip in local terminal boxes.

4 REFERENCE DOCUMENTS AND STANDARDS

4.1 DRAWINGS AND SPECIFICATIONS

All work shall conform to this specification and all relevant parts of the drawings and specifications appended to it as indicated in Appendix A.

4.2 CODES, STANDARDS AND REGULATIONS

4.2.1 Government Acts, By-Laws and Regulations

The design and manufacture of all equipment shall comply with all relevant Australian government acts, by-laws and regulations, both state and federal.

All design, procedures, materials, inspection, testing and analysis shall conform to the latest editions of the following codes, standards, (or approved International equivalents), regulations and specifications, including all amendments and revisions at the time of tender.

4.2.2 Standards

All design, procedures, materials, inspection, testing and analysis shall conform to the latest editions of the following codes, standards, regulations and specifications, including all amendments and revisions at the time of tender:

Standard No. Standard Title AS 1170 Structural Design Actions AS 1210 Pressure Vessels AS 1554 Structural Steel Welding – Welding of Steel Structures AS 1657 Fixed platforms, walkways, stairways and ladders AS 2700 Colour Standards for General Purposes AS 2729 Rolling Bearings – Dynamic Load Ratings and Rating Life AS 3000 Australia/New Zealand Wiring Rules AS 3678 Structural Steel – Hot Rolled Plates, Floorplates and Slabs




Standard No. Standard Title AS 3990 Mechanical Equipment – Steelwork AS 4024.1 Safeguarding of Machinery – General Principles AS 4343 Pressure Equipment – Hazard Levels AS 4458 Pressure Equipment-Manufacture AS 4991 Lifting Devices AS 5131 Fabrication and Erection of Structural Steelwork

AS 61508 Functional Safety of Electrical/Electronic/programmable Electronic Safety Related Systems

AS 61511 Functional safety – Safety Instrumented Systems for the Process Industry Sector

AS 62061 Safety of Machinery – Functional Safety of Safety-related Electrical, Electronic and Programmable Electronic Control Systems

ASME B16.20 Metallic Gaskets for Pipe Flanges ASME B16.5 Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24 ASME B31.3 Process Piping ASME VIII Div 1 Boiler and Pressure Vessel Code NOHSC:1007-2000 National Standard for Occupational Noise AS/ACIF S009:2006 Installation Requirements for Customer Cabling (Wiring Rules)

The Vendor shall comply with all codes and regulations applicable in Australia.

In the event of conflict between the reference codes and standards, drawings, specifications, and/or the Purchase Order, the Vendor shall obtain clarification before proceeding with the work.

4.3 LANGUAGE AND MEASUREMENT SYSTEM

All Vendor drawings, installation, maintenance and operating manuals, other documents and equipment nameplates shall be in the English language.

All units of measurement used shall be based on the SI system.

5 OPERATING ENVIRONMENT

The Filter Package shall be designed and supplied to provide continuous, long-term service under the ambient and environmental conditions that will prevail on the site as indicated in the Project Specification, document No. 140316-0000-40EG-0001.

The Filter Packages will be located outdoors. They will be exposed to dusty, wet and humid conditions as well as occasional hose down with process water.

The Filter Packages will be located in Areas 4200 and 4600 of the Process Plant.

The respective Plant areas are shown in the Process Plant Area Key Plan, Dwg No. 140316-0000-45D1-0004.

The areas are all classified as non-hazardous.




6 DESIGN CRITERIA

6.1 PROCESS DESCRIPTION

6.1.1 Eluate Neutralisation Filter Package, (421-PK-0001)

Underflow slurry from the Eluate Neutralisation Clarifier, (421-TH-0001) is pumped into the agitated Eluate Neutralisation Filter Feed Tank, (421-TK-0007). From there it is pumped directly into the Eluate Neutralisation Filter, (421-PK-0001).

The Eluate Neutralisation Filter will separate the solids from the slurry stream to achieve a filter cake with a nominal moisture content as stated in the datasheet 140316-4210-45ED-PK0001. The cake is directed by gravity flow through a chute or dumped to conveyor / feeder into the agitated Repulp Tank, (421-TK-0009).

The Eluate Neutralisation Filter shall be of a Pressure Membrane type.

The aqueous sulphate filtrate stream is directed into the Eluate Neutralisation Filtrate Tank, (421-TK-0008).

It is anticipated that the Eluate Neutralisation Filter Package will operate on a continuous high rate cyclical basis.

6.1.2 Eluate Polishing Filter Package, (423-PK-0001)

Overflow liquor from the Eluate Neutralisation Clarifier is directed into the Eluate Neutralisation Clarifier Overflow Tank, (421-TK-0006) from which it is pumped directly into the Eluate Polishing Filter (423-PK-0001).

This Filter Package is a duty standby arrangement.

The performance requirements for the Eluate Polishing Filter package are provided in datasheet 140316-4230-PK-0001.

The Eluate Polishing Filter shall be of a Pressure Leaf Polishing type.

Filtrate from the Eluate Polishing Filter is directed into the SX Feed Heat Exchanger Feed Tank, (423-TK-0003).

It is anticipated that the Eluate Polishing Filter Package will operate on a continuous high rate cyclical basis.

6.1.3 Co Purification Alkali Make Up Filter Package, (461-PK-0001)

The cobalt sulphate purge stream from the Cobalt Crystalliser Package, (462-PK-0001) is directed into the agitated Co Purification Alkali Make Up Tank, (461-TK-0001) along with sodium carbonate solution. The resulting mixture is pumped directly into the Co Purification Alkali Make Up Filter, (461-PK-0001).

The Cobalt Purification Alkali Make Up Filter will separate the solids from the slurry stream to achieve a filter cake with a nominal moisture content as stated in the datasheet 140316-4610-45ED-PK0001. The cake is directed by gravity flow through a chute into the agitated Co Purification Alkali Storage Tank, (461-TK-0002).

The Co Purification Alkali Make Up Filter shall be of a Pressure Membrane type.

The aqueous Co sulphate filtrate stream is directed into the Co Purification Filtrate Tank, (461-TK-0005).

It is anticipated that the Co Purification Alkali Make Up Filter Package will complete a cycle nominally every six hours on a continuous basis.




6.1.4 Mn Precip Filter Package, (461-PK-0003)

The acidic Manganese di-oxide (MnO2) slurry is pumped directly into the Mn Precip Filter, (461-PK-0003).

The Mn Precip Filter will separate the solids from the slurry stream to achieve a filter cake with a nominal moisture content as stated in the datasheet 140316-4610-45ED-PK0003. The cake is directed by gravity flow through a chute into the agitated Waste Recycle Tank, (461-TK-0012).

The Mn Precip Filter shall be of a Pressure Membrane type.

The aqueous cobalt sulphate filtrate stream is directed into the Mn Precip Bag Filter, (461-FR-0003).

It is anticipated that the Mn Precip Filter Package will complete a cycle nominally every twenty four hours on a continuous basis.

6.1.5 Mn Precip Bag Filter, (461-FR-0003A/B)

The intention is that the aqueous cobalt sulphate filtrate stream is directed into the Mn Precip Bag Filter, (461-FR-0003).

The Mn Precip Bag Filter will operate in a Polishing duty.

The output stream of purified cobalt sulphate from the bag filter will be delivered directly into the Cobalt Crystalliser Feed Tank, (462-TK-0001).

The Mn Precip Bag Filter will operate on a duty/standby basis to enable routine filter bag cleaning and replacement.

As there is a concern that there will be insufficient pressure available at the discharge of the Mn Precip Filter Package to ensure adequate performance of the Mn Precip Bag Filter, the Vendor is requested to consider the additional scope described in section 1.3.1 with consideration of the Mn Precip Bag Filter duty requirements provided in datasheet 140316-4610-FR-0003.

6.1.6 Cu IX Feed Bag Filter, (461-FR-0002A/B)

Mixture from the Cu IX Feed Tank is pumped into the Cu IX Bag Filter, (461-FR-0002).

The Cu IX Feed Bag Filter will operate in a Polishing duty.

The filtered output stream will be delivered directly into the Cu Impurity IX package, (461-PK-0002).

The Cu IX Feed Bag Filter will operate on a duty/standby basis to enable routine filter bag cleaning and replacement.

6.2 OPERATING PHILOSOPHY

The Filter Package shall be designed for operating on a continuous batch basis, 24 hours per day. The requirement for planned and breakdown maintenance activities must be defined and filter output must not be interrupted without the ability to catch-up to steady state operating conditions.

6.3 DUTY AND THROUGHPUT RATE

The duty requirements for all of the Filter Plants within the Filter Package are captured in the datasheets listed in Appendix A.




6.4 DESIGN REVERSE OSMOSIS (RO) WATER QUALITY

Anticipated analysis of the RO water to be supplied for the Filter Package operation is provided below:

Constituent Units Amount Conductivity µS/cm <50 Total Hardness as CaCO3 mg/L <1.0 Chloride, Cl mg/L <10

6.5 DESIGN LIFE AND AVAILABILITY

The required equipment service life is 20 years.

The Vendor shall specify the estimated equipment availability for each of the Filter Plants within the Filter Package, with examples provided of other similar installations with stated actual availabilities achieved.

6.6 PREFERRED EQUIPMENT

The Vendor is encouraged to select and offer equipment from within their standard range to meet the scope intent. In the absence of clear direction, the Client’s Representative can provide guidance.

Piping and valving selection shall be in accordance with section 7.5

6.7 OTHER

6.7.1 Lifting Lugs

Where practical all components and assemblies within the Filter Package shall be provided with suitable rated lifting lugs or eye bolts to allow for easy off-loading and installation. Lifting lugs shall be tested, certified and stamped with the Working Load Limit (WLL), and calculations provided to confirm the lug capacity based upon its location on the equipment.

6.7.2 Noise Level

Noise levels of the equipment under normal operation shall be in accordance with National Standard for Occupational Noise (NOHSC:1007-2000) and shall not exceed an eight-hour equivalent continuous A-weighted sound pressure level, LAeq,8h, of 82 dB(A) at 1 metre in all directions and peak noise level, Lpeak, of 140 dB (lin).

If the required noise levels cannot be achieved without external acoustic dampening measures being applied, the Vendor shall clearly state this in their bid and identify the associated scope and cost to achieve noise level compliance, if possible.

6.7.3 Safety Guards

Guards shall be designed to allow manual installation and removal by a single person, wherever possible. Rated and certified lifting lugs shall be provided on heavier guards for easy installation and maintenance. Guards shall be painted Golden Yellow, Y14 to AS2700.

7 DETAILED TECHNICAL REQUIREMENTS

7.1 ENGINEERING AND SERVICES

The Vendor shall supply all specified equipment, materials, special tools, spare parts and services as outlined in this scope of work.




7.2 MATERIALS OF CONSTRUCTION

Materials shall be provided in accordance with this specification and the manufacturer’s recommendation for the conditions specified.

Materials of construction shall be selected to resist corrosion from the use of RO water for filter cloth washing and equipment rinsing processes over the specified design life of the equipment.

The Vendor shall fabricate equipment in the Filter Package using only new materials free from defects impairing strength, durability and appearance.

7.3 MECHANICAL

The Vendor shall design each Filter Plant with slotted supports to allow for expansion of the unit under maximum press load.

With the exception of the bag filters, each Filter Plant shall be installed on an elevated structure of sufficient height to allow for gravity flow of discharged filter cake. The design of each Filter Plant shall allow for gravity discharge of the solids into an agitated tank or conveyor located at a suitable distance below the discharge opening.

The Contractor is encouraged to use in-house mechanical standards and best practices that meet or exceed the guidelines and standards nominated elsewhere within this Scope of Work document.

7.4 AIR COMPRESSORS

The compressed air requirements for each Filter Plant shall be provided by the Vendor as part of the scope of supply.

The Vendor shall assume that each Filter Plant requires a completely independent compressed air system.

7.5 PIPING

Piping shall be in accordance with the Piping Material Specification, 140316-0000-46EG-0001.

Valving shall be in accordance with the Manual Valve Specification, 140316-0000-46EG-0004.

Flanges and bolting shall be of standard sizes and according to ASME B16.5, unless otherwise specified within the Piping Material Specification for the selected service.

7.6 STRUCTURAL

The Vendor shall design, supply and fabricate all structural steel, walkways, platforms, stairways and ladders required to provide convenient access to critical components of each Filter Package for operation and maintenance activities as far as practically possible.

Structural steel used for the construction of the Filter Package shall be minimum Grade 250 in accordance with Australian standards or approved international equivalents. High yield strength steel shall not be used unless approved in writing by the Client’s Representative.

All welding shall comply with AS 5131, AS 1554 Category SP, or an approved international equivalent.

The Vendor is encouraged to use in-house structural design standards and best practices that meet or exceed the guidelines and standards nominated elsewhere within this Scope of Work document.




7.7 ELECTRICAL

The Vendor shall design, select materials and construct the electrical equipment for the Filter Package in accordance with the requirements specified in 140316-0000-47EC-0002, Design Criteria for Electrical & Automation for Minor Packaged Plant, subject to the additional requirements stated below.

Rated voltage and frequency of electrical motors shall be as per the Project Specification (140316-0000-40EG-0001).

Thermistors shall be provided for motors above 22 kW and below 90 kW.

MEPS approved electric motors shall be supplied in accordance with AS 1359.5.

Motor terminal boxes shall be readily accessible for cable installation and maintenance. Terminal boxes shall be sized large enough to permit the termination of the cables one size larger than the maximum size of cable permitted by the motor terminals

Switchgear Protection IEDs (Intelligent Electronic Device) for Incomers, Feeders, Transformer Protection Relays to support IEC61850 digital communications.

The Vendor shall only use in-house standards and best practices that meet or exceed the relevant guidelines and standards nominated elsewhere within this document.

7.8 INSTRUMENTATION

The Vendor will be responsible for the design and supply of all instrumentation within the Filter Package.

The Vendor shall only use in-house standards and best practices that meet or exceed the relevant instrumentation guidelines and standards nominated elsewhere within this Scope of Work document.

7.8.1 Instruments

Instrument power supply shall be 24 VDC with instrument signals to be 24 VDC for digital signals and 24 VDC / 4-20 mA for analogue signals, with HART capability.

Instruments shall be installed in locations that are readily accessible for maintenance.

Tubing for air supply and process impulse lines shall be stainless steel with run lengths as short as is practicable.

The supply of wireless instruments will be subject to the approval of the Client.

7.8.2 Control Systems

Where the equipment is supplied with a programmable control system (e.g. PLC), the control system shall be capable of being integrated into the Plant-Wide Control System using a digital communications protocol such as PROFIBUS-DP, MODBUS TCP, PROFINET or Ethernet/IP

Where the equipment is not supplied with a programmable control system, the equipment shall be able to be integrated into the Plant Control System using hard wired connections to instruments and signals. The instruments and signals shall in wired to terminals in a Vendor supplied junction boxes. To ensure compatibility with the Plant Control System, the signals and instruments shall be:

• voltage free contacts, minimum rating of 1A / 240 VAC • 3 wire PNP solid state switches • 0.5A / 24 VDC solenoid coils • Isolated 4-20mA analog input or output signals.




It is envisaged that there will be a single PCS system across the plant. The Vendor’s control system design shall allow for the installation of a fully functional autonomous system which will merge into the plant wide system in a seamless manner. It is also essential that the system selection and configuration conform to the site wide practice from a maintenance perspective.

The Vendor shall ensure that sufficient resources are allowed to perform the PCS Factory Acceptance Test and the PLC or PCS Site Acceptance Test in accordance with section 8. The personnel nominated for this work shall be fully conversant with the Filter Package Plant Functional Description. Where PLC control is chosen then the Vendor must allow for acceptance testing of the PLC-PCS interface both at FAT and SAT stages.

7.8.3 Functional Safety

Functional Safety, including Emergency Shutdown systems, shall be assessed and implemented according to the framework standards AS61508 and AS4024 and the sector specific standards AS61511 (Process Industry) and AS62061 (Machine Guarding).

The supply of any Safety Instrumented Functions or Safety Related Control Functions shall have followed a traceable lifecycle covering risk assessment, required risk reduction, function design, realisation, verification, installation, commissioning, validation, operation and maintenance.

All Functional Safety lifecycle documentation shall be supplied by the vendor to support the lifecycle traceability.

7.8.4 Documentation

The electrical and instrumentation documentation to be provided by the Vendor beyond the placement of a Purchase Order shall include, as a minimum, a control function specification including:

• Process Control Functional Descriptions • Boolean Block Logic/SAMA Control Drawings (containing all start-up and shutdown sequences, alarm

requirements, set points) • P&IDs • Cause and Effect Matrix • Interlock Schedule • Alarm and Trip points schedule • Instrument Data Sheets • Cable Block Diagrams • Instrument list • I/O list • Electrical load list • Equipment layout drawings • Interconnection and field device termination diagrams • Junction box termination details.

7.9 SURFACE PROTECTION

All external surfaces of the Filter Package including support frames, guards and other ancillary equipment shall be provided with appropriate surface protection.

The Vendor may adopt their own internal painting and surface protection standards subject to approval by the Client’s Representative.




7.10 EQUIPMENT IDENTIFICATION, MARKING AND LABELING

The Vendor shall provide a stainless steel tag complete with instrument tag number for each instrument supplied with the equipment.

The Vendor shall provide each item of equipment in the Filter Package with nameplates including the following:

• Purchaser’s equipment number • Manufacturer’s name • Model no./Size • Serial number • Year of construction • Capacity • Speed • Motor size(s) • Recommended Lubricant.

The driven equipment in the Filter Package shall also have a direction of rotation arrow indicated on a plate mounted close to the drive units.

All labels and name plates shall be made from 1mm thick stainless steel plate, with machine engraved lettering in-filled with indelible black paint and incorporate the following:

Item Description Mechanical Equipment Main Titles Lettering 5mm high Spacing 3.5mm between the lines Sub Titles Lettering 3mm high print Spacing 1.5mm spacing between the lines Electrical Equipment Control Panels, Marshalling Boxes, Junction Boxes, Motors 5mm high Instruments/Valves 3mm high

Labels shall be firmly fastened to the equipment with a minimum of four stainless steel screws (which are not self-tapping) or rivets. If the label on 316SS junction boxes and the like is spot welded, the welds shall be passivated.

7.11 TECHNICAL DATA, DRAWINGS AND MANUALS

7.11.1 General

The Vendor shall submit information as identified in the Vendor Data Requirements Schedule in Appendix B of this specification at the appropriate stage of the bidding and order placement process.

The Vendor should submit a list of current users of similar equipment with their tender, detailing duty, company, and preferably contact details for the person responsible for operation.

The Vendor shall complete and return the attached Technical Questionnaire and/or Equipment Data Sheets with their tender otherwise the tender will not be considered.




The Vendor shall ensure that drawings, design calculations and welding procedures submitted for review after order placement are signed by a professional engineer registered/licensed in the province, state or country where the equipment fabricator is located.

Shop drawings shall include, but not necessarily be limited to, design data such as size, dimensions, material thickness, materials, spacing and location of attachments, anchor bolt size, location and projection, reinforcement, welding, points of connection, nozzle orientation, temporary supports and bracing, motors, couplings or belt drives, etc., as applicable.

The Vendor shall provide detailed installation drawings showing requirements for all field welds and all other necessary details of installation after order placement.

The Vendor shall provide drawings and/or reports showing the necessary data for the design of the supporting steel structure or foundation. This should include, but is not necessarily limited to, the following:

• Magnitude and location of all equipment dead loads including loads from fixed equipment, piping, platforms and tankage

• Magnitude and location of all operating live loads with contents at maximum design density • Magnitude and location of any out-of-balance forces • Magnitude and location of upset operating loads due to equipment being filled to maximum capacity,

scale accumulation, ‘sanded’ vessels, plugged chutes, etc. • Equipment operating frequencies • Acceptable amplitudes of vibration of the supporting steel structure or foundation • Harmonic vibration analysis over the full range of operating speeds • Any requirement to accommodate operating movements at support locations • Impact factors to be applied to support reactions.

Installation, Operation and Maintenance Manuals (IOM) shall be supplied by the Vendor. Refer instructions to Tenderers for minimum requirements for IOM manuals.

7.11.2 Responsibility

Review by the Client’s Representative of Vendor’s drawings or other documents, or release of equipment for shipment by the Client Representative’s inspector shall not relieve the Vendor of his responsibility for compliance with the Purchase Order nor alter the conditions of the performance guarantee.

8 INSPECTION, TESTING AND ACCEPTANCE

8.1 QUALITY SYSTEM

The Vendor shall provide a Quality Plan in accordance with ISO 9001 or approved equivalent.

The Vendor is responsible for the testing and inspection of all materials and work in accordance with this specification and all applicable codes, laws and regulations.

8.2 VERIFICATION AND TESTING DURING FABRICATION

The Vendor shall submit details of all tests to be carried out during manufacture in the format of an Inspection and Test Plan (ITP) with detailed vendor/sub-vendor inspection points shown and test procedures clearly defined. Test results shall be collated and supplied for Client review.

The ITP index shall be submitted for Client approval prior to commencement of manufacture.

Prior to shipment, the Vendor shall perform the tests specified within this document and as listed in the Client approved ITP and Quality Plan.




The Vendor shall inspect all shop welds prior to assembly and provide copies of the reports to the Client. The inspection of welds shall comply with AS 1554, category SP.

The Vendor shall submit a written statement that materials conform to the drawings and specifications with documents establishing traceability and conformance.

The Vendor shall provide the Client and/or the Client’s Representative with all reasonable access to the work whether it is in preparation or progress. The Vendor shall provide proper facilities for such access and for inspection.

Factory tests shall not constitute a waiver of field commissioning and site acceptance testing requirements and the requirement to pass field tests under the specified operating conditions.

8.3 FINAL ACCEPTANCE

On completion of the entire installation, the Vendor will be required to assist the Client’s Representative in carrying out all tests deemed necessary in order to determine the proper functioning and general performance of the equipment. The Vendor will, at their own cost, make any adjustments and changes required, to such end that an efficient and fully operational installation will result. Final acceptance by the Client’s Representative will be conditional upon fulfilment of this requirement.

For equipment subject to inspection by a regulatory authority, department, or agency, the Vendor shall submit to the Client Representative’s original copies of the test data reports and all other documentation required for the final field inspection of the equipment by the regulatory authority, department or agency.

Following completion of the work, the Vendor shall issue a MDR comprising quality certificates, inspection and test records, and any other relevant documents related to manufacture and testing for the Client Representative’s record files. This shall include all documents listed in the Vendor Data Requirements Schedule included in Appendix B.

8.4 PERFORMANCE CRITERIA AND TESTING

The Vendor shall demonstrate the full range of controls, operating functions and compliance with the performance criteria.

The Filter Package shall be capable of meeting performance guarantees against the following parameters, as detailed in the Equipment Data Sheets included in Appendix A.

• Filtration Rate • Filter cake moisture content, (where applicable) • Filtrate Clarity • Power draw at design, (where applicable) and maximum throughput rates • Noise levels of running equipment.

The Vendor shall demonstrate the full range of controls, operating functions and compliance with the performance criteria.




APPENDIX A REFERENCE DOCUMENTS

The following reference documents form part of this Scope of Work.

Document No. Document Title 140316-0000-40EG-0001 Project Specification 140316-0000-46EG-0001 Piping Material Specification 140316-0000-46EG-0004 Manual Valves Specification 140316-0000-47EC-0002 Design Criteria for Electrical and Automation for Minor Packaged Plant 140316-4210-45ED-PK0001 Datasheet – Eluate Neutralisation Filter Package 140316-4230-45ED-PK0001 Datasheet – Eluate Polishing Filter Package 140316-4610-45ED-FR0002 Datasheet – Cu IX Feed Bag Filter 140316-4610-45ED-FR0003 Datasheet – Mn Precip Bag Filter 140316-4610-45ED-PK0001 Datasheet – Co Purification Alkali Make Up Filter Package 140316-4610-45ED-PK0003 Datasheet – Mn Precip Filter Package 140316-0000-45D1-0004 Mechanical – General - Process Plant – Area Key Plan 140316-4210-49D1-0002 Process Flow Diagram: Refinery – Eluate Neutralisation

140316-4230-49D1-0001 Process Flow Diagram: Refinery – Eluate Neutralisation – SX Feed Preparation

140316-4610-49D1-0001 Process Flow Diagram: Refinery – Co Crystallisation And Packaging – Co Purification

140316-4610-49D1-0003 Process Flow Diagram: Refinery – Co Crystallisation And Packaging – Co Purification




APPENDIX B VENDOR DATA REQUIREMENTS

The following vendor data shall be provided electronically by the Vendor at the relevant stage of the bid and award process:

VENDOR DRAWINGS AND DATA REQUIREMENTS PART A – DRAWINGS

No. Description Document

Required with Feasibility Study Bid

Document Required

After Award

Issue Date (weeks

after award)

Qty. /Version of Issue

Remarks

A. DRAWINGS A1 Vendor Drawings and Document

List X 1

A2 General Arrangement Drawings X X 1

A3 Foundation Load Plan and Anchor Bolt Location

X X 1

A4 Assembly Drawings X X 1

A5 Installation Drawings X X 1

A6 Structural Steel Shop Details

A7 Detail Drawings Mechanical Electrical

X

1

A8 Hydraulic Schematic Diagrams

A9 Hydraulic Assembly Details

A10 Electric Motor Details X X 1

A11 Electrical Wiring Diagrams and Schematics

X 1

A12 Cable Block Diagrams

A13 Piping and Instrumentation Diagrams (P&IDs)

X X 4

A14 Electrical/Instrument Location and Layout Drawings

X 4

A15 Electrical / Instrument Termination Drawings

X 4

A16 Single Line Diagrams X

B. DOCUMENTATION B1 Code and Material Specifications

B2 General Description of Equipment, Operation & Duties

X

B3 Catalogue and Technical Brochures of Components

X

B4 Itemised List of all Auxiliary Equipment

X 1

B5 Approvals of Relevant Authorities

B6 Design Calculations for bearing life

X 4

B7 Performance Curves and Data




VENDOR DRAWINGS AND DATA REQUIREMENTS PART A – DRAWINGS

No. Description Document

Required with Feasibility Study Bid

Document Required

After Award

Issue Date (weeks

after award)

Qty. /Version of Issue

Remarks

B8 Completed Equipment Data Sheets

X X 2

B9 Bills of Material

B10 Welding Procedures and Qualification Tests Reports

B11 Inspection and Test Plan (ITP) X 2

B14 Calibration Procedures X 4

B15 Hydro test Procedures

B18 Commissioning Procedures X 6

B19 Label Schedule X 4

B20 Nameplate Details X 4

B22 Instrument List X X 4

B23 Control & Instrument Equipment Specifications Sheets (Instrument Data Sheets)

X X 4

B24 I/O Schedules X X 4

B25 Intrinsic Safety Dossiers

B26 Software Documentation

B27 Sequence & Logic Diagrams/ Flowcharts/Cause and effect matrix/Interlock schedule

B28 Vendor/ Sub Vendor’s standard surface treatment and painting procedures

X 4

B29 Vendor/Sub Vendor’s standard rubber lining procedures

X 4

B30 Electric Motor Data Sheet X 4

B31 Electrical Load List X X 4

B32 Control System I/O Mapping X 6 C. MANUALS C1 Installation and Commissioning

Instructions X 4 4P*

C2 Operating Manual X 4 4P*

C3 Maintenance Manual including Lubrication Instructions and Complete Parts List

X 4 4P*

C4 Manufacturer’s Data Report

C5 Training Manuals X 4 4P

C6 Training 2 weeks before PC

Note: * P = hard copy required in quantity indicated

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