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SCOPE OF WORK PROCESS WATER TREATMENT

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Document No 140316-6290-45EW-5614 Revision 00 Date 16/08/2017 of 37

SNC-LAVALIN 140316-6290-45EW-5614_00 - Scope of Work - Process Water Treatment Package

REVISION CONTROL

Issued for Internal Review

Issued for Client Review

Issued for Study Use

REVISION HISTORY

Revision Date Pages Revised Remarks 00 16/08/2017 Multiple Comments incorporated


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TABLE OF CONTENTS 1 SCOPE DESCRIPTION 6

1.1 INTRODUCTION 6

1.2 WORK INCLUDED 6

1.2.1 Engineering and Services 6 1.2.2 Procurement and Supply 6

1.2.3 Tankage & Structural Steel 7

1.2.4 Civil & Concrete Works 7

1.2.5 Mechanical Equipment 7

1.2.6 Piping 7

1.2.7 Electrical Equipment 8 1.2.8 Instrumentation & Control Equipment 8

1.2.9 Fabrication 8

1.2.10 Shop Assembly 8

1.2.11 Spare Parts, Special Tools and Equipment 8

1.2.12 Lubricants 8

1.2.13 First Fills 8 1.2.14 Commissioning 9

1.2.15 Training 9

1.3 OPTIONAL WORK 10

1.3.1 Alternatives 10

1.4 RESPONSIBILITY MATRIX 10 2 WORK EXCLUDED 10

2.1 ENGINEERING AND SERVICES 10

2.2 FREE ISSUE ITEMS 10 3 TRANSPORT ENVELOPE 10

4 BATTERY LIMITS 11

5 REFERENCE DOCUMENTS AND STANDARDS 11

5.1 DRAWINGS AND SPECIFICATIONS 11

5.2 CODES, STANDARDS AND REGULATIONS 11

5.3 LANGUAGE AND MEASUREMENT SYSTEM 12 6 OPERATING ENVIRONMENT 13

7 DESIGN CRITERIA 13

7.1 PROCESS DESCRIPTION 13 7.2 OPERATING PHILOSOPHY 13

7.3 DUTY AND DESIGN CRITERIA 13

7.3.1 Plant Design Basis 13


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7.3.2 Rated Production Capacity 13

7.3.3 Design Process Water Analysis 13

7.3.4 Turndown 13 7.3.5 Plant Start-up Time 14

7.3.6 Occupational Health and Safety 14

7.4 EQUIPMENT DESIGN 14

7.4.1 Materials 14

7.4.2 Analysis and Monitors 14

7.5 PREFERRED EQUIPMENT 14 7.5.1 Preferred Mechanical Equipment 14

7.5.2 Preferred Piping & Valving Selection 14

7.5.3 Preferred Electrical & Instrumentation Equipment 15

7.6 UTILITIES AND SERVICES 15

7.7 OTHER 15

7.7.1 Lifting Lugs 15 7.7.2 Noise Level 15

7.7.3 Safety Guards 15 8 DETAILED TECHNICAL REQUIREMENTS 16

8.1 CIVIL WORKS, FOUNDATIONS AND BUILDINGS 16

8.2 STRUCTURAL 16 8.3 MECHANICAL 16

8.4 PIPING 16

8.5 ELECTRICAL 17

8.6 INSTRUMENTATION AND PLANT-WIDE CONTROL SYSTEM INTEGRATION 17

8.6.1 Instruments 17

8.6.2 Control Systems 18 8.6.3 Functional Safety 18

8.6.4 Documentation 18

8.7 SURFACE PROTECTION 19

8.8 EQUIPMENT IDENTIFICATION, MARKING AND LABELLING 19

8.9 PROVISION OF TECHNICAL DATA, DRAWINGS AND INSTRUCTION MANUALS 19

8.9.1 General 19 8.9.2 Technical Data 20

8.9.3 Drawings 20

8.9.4 Installation, Training, Operating and Maintenance Manuals 20 9 INSPECTION, TESTING AND ACCEPTANCE 21

9.1 QUALITY SYSTEM 21 9.2 VERIFICATION AND TESTING DURING FABRICATION 21


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9.3 FINAL ACCEPTANCE 21

9.4 PERFORMANCE CRITERIA AND TESTING 22

9.5 COMMISSIONING 22 9.5.1 Off Site Testing 22

9.5.2 On Site Testing 22

APPENDICES

Appendix A VENDOR’S QUALITY SYSTEM 23

Appendix B VENDOR DRAWING AND DATA REQUIREMENTS 26

Appendix C DRAWINGS AND SPECIFICATIONS 35

Appendix D RESPONSIBILITY MATRIX 36


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1 SCOPE DESCRIPTION

1.1 INTRODUCTION

This document sets out the scope of work and technical requirements for the design, supply, manufacture, delivery, testing, commissioning and performance testing of a complete Process Water Treatment Plant, herein referred to as the Process Water Treatment Plant.

The facilities shall all form part of the Syerston 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, commissioning, surface protection, quality assurance, inspection, testing, identification, packaging and transportation, together with the provision of all necessary installation and site acceptance testing relating to the following Process Water Treatment facilities for the Syerston processing plant.

The Process Water Treatment Plant will treat water supplied from the Process Water Tank in the tails thickening area which receives waste water streams from a number of sources from within the Syerston process plant, including, but not limited to, the following:

1) Decant Water

2) Cooling Water Blowdown

3) RO Plant Waste Water

4) Raw Water

5) Run-Off Water (intermittently)

6) Ore Prep Water (intermittently)

7) Cobalt Purification Filtrate

8) Tailings Thickener Overflow and

9) AMSUL Process Condensate

Collectively these streams combine to form the process water that must be treated by the water treatment plant comprising this package of works.

The anticipated scope associated with the Process Water Treatment Plant has been captured in the datasheet 140316-6290-45ED-PK0001The nominal battery limits for the Process Water Treatment Plant are defined in section 4 of this scope of work.

1.2.1 Engineering and Services

The Vendor shall design the Process Water Treatment Plant in accordance with this document, the applicable codes and standards, reference specifications, drawings, equipment data sheets and local government regulations, and shall ensure that the Process Water Treatment Plant is suitable for all of the specified duties.

1.2.2 Procurement and Supply

The Vendor shall supply and deliver the Process Water Treatment Plant and shall furnish all materials, accessories and services required for the complete testing, commissioning and site acceptance testing of the same.


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The Vendor shall supply duty only equipment – no installed standby equipment is required unless specifically mentioned within this scope of work or the Vendor believes it to be essential to achieve the required Plant availability.

The Vendor shall include in the scope of work, items, accessories and services that are usual or necessary to achieve the package outputs.

The Process Water Treatment Plant supplied shall be capable of achieving or exceeding the specifications, design criteria and technical requirements listed in Section 5, 7 & 8.

A Risk Analysis conforming to AS 61508, including a HAZOP (Hazard and Operability Study) and a CHAZOP (Control System HAZOP) shall be conducted by the Vendor’s nominated Safety Specialist with participation from the Vendor’s Engineers and the Client’s Representatives. The Vendor shall be solely responsible for implementing the solutions necessary to reduce or mitigate the consequences of identified hazards where they relate directly to the equipment supplied.

The Vendor shall employ an auditable Quality System for the execution of design engineering work. In particular, all calculations shall clearly show the basis and assumptions and these calculations should be checked. Calculations shall be stored in a systematic fashion and be available for scrutiny at short notice.

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

1.2.3 Tankage & Structural Steel

• Structural steel work, tanks, hoppers, plate work and all maintenance and operating access ways contained within the Plant

• Buildings to house control panel and any equipment requiring protection from the elements • Staircases, platforms and walkways on the storage tanks and all equipment, valves and

instrumentation requiring routine access for operation and maintenance • Pipe supports within the Process Water Treatment Plant boundaries • Suitable surface protection of structural steel, tanks and associated pipework and supports.

1.2.4 Civil & Concrete Works

Excluded. (Vendor to provide adequate foundation design loads and structural/equipment footprint dimensional information within 4 weeks of award to enable the civil and concrete detailed design to be completed by Others).

1.2.5 Mechanical Equipment

• Mechanical equipment including pumps, pressure vessels and ancillaries such as lubrication and cooling systems

• Insulation for process and personnel protection for equipment exceeding 60°C normal operating temperature, where required

• Fixed overhead hoists and monorail cranes to facilitate routine maintenance activities within the Process Water Treatment Plant, if required

• Treated and waste water pump sets as required • Suitable surface protection of all equipment external surfaces.

1.2.6 Piping

• Pipe work, valves, fittings, pipe supports including lining, painting and any necessary insulation for process and personnel protection within the Process Water Treatment Plant, (excluding reticulated firewater systems which will be provided by Others).


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1.2.7 Electrical Equipment

• Motors, heaters etc • Specific area lighting for 24-hour operation, compliant to AS1680 (Interior Lighting) and AS2293

(Emergency Lighting). General luminance guidelines for exterior lighting are 80 lux for General Access and Movement and 160 lux for areas requiring regular inspection and maintenance

1.2.8 Instrumentation & Control Equipment

• Equipment condition monitoring • Measurement and control field devices • Metering and totalising facilities for treated water production and flow • Emergency alarm facilities • Process Water Treatment Plant control system/s.

1.2.9 Fabrication

The Vendor shall be responsible for the fabrication and the shop assembly of the Process Water Treatment Plant equipment, inclusive of all piping systems, structures, electrical/instrumentation/control equipment and associated ancillaries that can be supplied and installed onto the plant modules prior to delivery to site.

In order to minimise site labour manhours and infrastructure requirements, off-site modular assembly of the Process Water Treatment Plant components shall be maximised.

1.2.10 Shop Assembly

The Process Water Treatment Plant shall be shop assembled to the greatest extent practical and prior to inspection and delivery.

Where practicable, the Vendor shall provide equipment in discrete sub-assemblies to minimise site assembly time. The sub-assemblies shall be capable of being transported as skid-mounted and/or containerised facilities that will fit within the dimensional envelope described in Section 2.2 of this scope of work. The Vendor shall nominate the extent of pre-assembly in the tender.

1.2.11 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 shall consist of specific long lead items which are critical to plant operation • One year’s operating spares • Special tools and equipment for the installation, commissioning, operation and maintenance.

1.2.12 Lubricants

The Vendor shall supply and install first fill lubricants required for shop testing of equipment, and provide a recommended lubricant schedule for the operation of the Process Water Treatment Plant equipment.

1.2.13 First Fills

The Vendor shall provide all first fill resins, membranes, cartridges and chlorine gas, lubricants and other materials and consumables for plant commissioning.


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1.2.14 Commissioning

The Contractor shall provide a team of suitably qualified personnel experienced in Process Water Treatment Plant operations to plan, document and direct the transition from mechanical completion through practical completion and satisfactory completion of performance guarantee tests.

The Contractor shall also provide all materials (e.g. spool pieces, blank flanges, and temporary strainers, hoses, and hose connectors), equipment (e.g. hydro testing equipment, pressure gauges) and services (e.g. supervision by equipment vendor representatives and condition monitoring services) necessary for the pre-commissioning and commissioning of the Cogeneration Plant. The minimum requirement for the staged testing and commissioning of the Process Water Treatment Plant is shown in Section 9.50.

During commissioning, the Contractor will assist the Client’s process and maintenance technicians on shift. This assistance will commence once piping, mechanical and electrical installation verification is complete to the punch listing stage. The Client’s process and maintenance technicians shall work at the direction of the Contractor during commissioning.

The Contractor shall submit a Commissioning Plan in the bid. This plan shall address issues such as:

• Safety • Integration into overall commissioning plan • Role of commissioning manager • Commissioning manning and schedule • Stages of commissioning • Designation of sub-systems • Control of construction/commissioning interface • Preparation of commissioning check sheets, instructions, manuals • Commissioning materials (e.g. temporary strainers, hoses, spool pieces, bunting, tags and signs) • Company supplied deliverables (e.g. utilities, consumables, spare parts, etc).

The Contractor shall advise the man hours required to fully commission the Process Water Treatment Plant and all associated equipment plus buildings.

1.2.15 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 and maintenance 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 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.


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1.3 OPTIONAL WORK

1.3.1 Alternatives

The Vendor’s tender shall conform to this document. 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 duties and throughput rates as indicated in this document.

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

1.4 RESPONSIBILITY MATRIX

Refer to Appendix D for the Responsibility Matrix applicable to this package of works.

2 WORK EXCLUDED

The following items are excluded from the Scope of Work:

2.1 ENGINEERING AND SERVICES

• Site preparation, levelling, access roads, perimeter drainage and underground services. • All support concrete foundations and plinths • All structural steelwork external to the plant modules. • Environmental impact assessment and environmental licensing • Mines Department, building approvals and site access permit • Site Risk Study • Site survey, soil testing and grading plan • Major perimeter piperacks including associated footings, structural steel, piping and cables and cable

supports. • Supply and installation of all pipework, valves and fittings for all service connections necessary for the

operation of the Process Water Treatment Plant, (including plant/instrument air, dilute sulphuric acid, slaked lime slurry and flocculant supply)

• Supply and installation of all pipework, valves and fittings up to the battery limit connections for discharge streams, (treated process water and waste water)

• Connection of 415V power supply to the Process Water Treatment Plant motor junction boxes and PLC control panel

• Fibre optic cable to integrate the Process Water Treatment Plant control system with the main plant control system.

• First fill sulphuric acid and slaked lime first fill, (provided by the Client).

2.2 FREE ISSUE ITEMS

None

3 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 7.5 meters out to out (width). A tyre loading limit of 2.25 tonnes shall further apply.


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The NSW transport authority has provided guidance that the longest standard truck allowed on their roads 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.

Larger 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.

4 BATTERY LIMITS

The Process Water Treatment Plant area have been designated as area 6290. The area is indicated in the Process Plant Area Key Plan Dwg No. 140316-0000-45D1-0004.

The available area for the Process water Treatment Plant amounts to about 1700m² represented by a 40m x 42m area of reserved space immediately south of the Raw Water Storage Pond.

All piping and electrical/instrumentation cables will be connected to the Process Water Treatment Plant from the East-West orientated pipe rack which will be located to the immediate south of the Process Water Treatment Plant.

5 REFERENCE DOCUMENTS AND STANDARDS

5.1 DRAWINGS AND SPECIFICATIONS

All work shall conform to this document and all relevant parts of the drawings and Specifications and drawings listed in Appendix C.

5.2 CODES, STANDARDS AND REGULATIONS

The equipment and materials supplied under this document shall comply in design, construction and performance with the current issue (including the latest addenda prior to the date of submission of bid), of the mandatory standards and the relevant Australian or approved US, ISO or British standards together with the requirements of the relevant Authorities having jurisdiction over all or part of their manufacture, installation and operation.

All work related to boilers and pressure vessels shall comply with the latest issue of the, SAA Boiler Code and SAA Pressure Vessel Code or ASME VIII Div 1.

The work shall conform to the latest edition of the Acts, Regulations, Standards and Codes included in the project Drawings and Specifications listed in Appendix C and those listed below.

Table 1 Standards

Standard Number Title ISO 9001: 2015 Quality Management Systems API 12F Shop Fabricated tanks AS 1023 Low Voltage Switchgear and Control gear – Protection of Electric Motors AS 1210 Pressure Vessels ASME VIII Div 1 Boiler and Pressure Vessel Code, Section VIII, Division 1: Rules for Construction

of Pressure Vessels AS 1271 Protective Devices AS 1359.5 General Requirements for Rotating Electrical Machines AS 1554 Structural Steel Welding AS 1680 Interior Lighting


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Standard Number Title AS 1768 Lightning Protection AS 2293 Emergency Lighting AS 2700 Colour Standards for General Purposes AS 2729 Rolling Bearings – Dynamic Load Ratings and Rating Life AS 2938 Gears – Spur and Helical – Guide to Specification and Rating AS/NZS 3000 Electrical Installations

AS/NZS 3007 Electrical equipment in mines and quarries - Surface installations and associated processing plant

AS 3008 Electrical Installations – Selection of Cables AS 3439 Low Voltage Switchgear Assemblies AS 3678 Structural Steel – Hot Rolled Plates, Floor Plates and Slabs AS 3679.1 Structural Steel – Hot Rolled Bars and Sections AS 3709 Vibration and Shock – Balance Quality of Rotating Rigid Bodies AS 3780 Storage and Handling of Corrosive Substances AS 3890 Rolling Bearings – System Life Reliability AS 3990 Mechanical Equipment – Steelwork AS 4020 Testing of Products for use in Contact with Drinking Water AS 4024.1 Safeguarding of Machinery – General Principles AS 4171 Rolling Bearings – Static Load Ratings AS 4766 Polyethylene Storage Tanks for Water AS 4991 Lifting Devices AS 5131 Fabrication & Erection of Structural Steelwork

AS 61508.0 Functional Safety of Electrical/Electronic/programmable Electronic Safety Related Systems

AS 61511.1 Functional safety – Safety Instrumented Systems for the Process Industry Sector Framework, Definitions, Systems, Hardware and Software Requirements

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

EN 13121.3 Above Ground GRP Tanks NOHSC :1007-2000 National Standard for Occupational Noise AS/ACIF S009:2006 Installation Requirements for Customer Cabling (Wiring Rules) Australian Dangerous Goods Code 6th Edition (1999) New Dangerous Goods Act & Regulations

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

5.3 LANGUAGE AND MEASUREMENT SYSTEM

All Vendor drawings, installation, maintenance and operating manuals, and equipment nameplates shall be in the English language for design and review purposes. All units of measurement used shall be based on the SI system.


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6 OPERATING ENVIRONMENT

The Process Water Treatment Plant shall be designed and supplied to provide continuous, long-term service under the ambient conditions that will prevail on the site as indicated in Project Specification 140316-0000-40EG-0001.

The Plant will be located outdoors and will be exposed to dusty conditions as well as hose down with process water.

7 DESIGN CRITERIA

7.1 PROCESS DESCRIPTION

The purpose of the Process Water Treatment Plant is to treat multiple waste water streams and supply that treated water to the Ore Prep Cold Water Tank.

The Ore Prep water will be used predominantly for the ore scrubbing process.

Waste streams from the Process Water Treatment Plant will be directed into a tank, (by others) and disposed of to ensure that it will not be returned to the Process Water Tank, (equipment tag 362-TK-0001).

7.2 OPERATING PHILOSOPHY

The Process Water Treatment Plant is required to operate continuously. Reliability of the Process Water Treatment Plant is important to ensure that water of a higher quality is not wasted to service the requirements of the Ore Preparation area of the processing plant and so the availability of the Water Treatment Plant shall be not less than 98%.

The Process Water Treatment Plant shall be designed to have a life of 20 years.

The Process Water Treatment Plant shall be designed to be suitable for frequent shutdowns and start-ups (up to 2 times per month) caused by upstream process plants in the first year of operation.

The Process Water Treatment plant shall have an adequate level of on stream analysis and control to maintain water quality and availability within a tight range.

7.3 DUTY AND DESIGN CRITERIA

7.3.1 Plant Design Basis

The Process Water Treatment Plant shall be designed on the basis of minimum capital cost with optimisation of operating and maintenance costs during the lifetime of the Plant.

7.3.2 Rated Production Capacity

The nominal and design (maximum) production rate for the treated water stream has been captured in the datasheet 140316-6290-45ED-PK0001

7.3.3 Design Process Water Analysis

An analysis of the untreated process water is provided in the datasheet 140316-6290-45ED-PK0001

7.3.4 Turndown

The Process Water Treatment Plant does not require a purpose built turndown of nameplate capacity.


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7.3.5 Plant Start-up Time

The Vendor shall nominate the expected time taken from idle or shutdown mode to full production (i.e. Water Treatment Plant restart times after a shutdown of variable duration 1 hour, 8 hours and 24 hours).

7.3.6 Occupational Health and Safety

The Vendor shall consult the Occupational Health and Safety Regulation 2010 as to Noise levels, machine guarding and the design aspects of workplace safety in general.

Noise levels of equipment under normal operation shall not exceed a sound pressure level of 82 dB (A) at 1 metre in all directions and peak sound pressure level Lpeak of 140 dB (lin).

7.4 EQUIPMENT DESIGN

7.4.1 Materials

The materials of construction for the Process Water Treatment Plant shall be suitable to meet the required plant availability and the shutdown requirements stated in Section 7.2.

7.4.2 Analysis and Monitors

The Vendor shall provide analysis and monitoring equipment and instrumentation for the on-line analysis of product water quality. The Vendor shall also provide manual sample points for all critical streams. The control hut should be equipped with a work bench and sink for collecting discarded samples. The sink discharge will be piped to the nearest Process Water Treatment Plant sump.

The Vendor shall provide all analysers, sampling systems and ancillary equipment with a maximum level of diagnostics. When analyser damage or analysis errors could occur as a consequence of other equipment failures, then the relevant analyser shall automatically shut down and isolated. The Vendor shall provide comprehensive calibration, maintenance and fault finding instruction manuals to the extent that the performance testing of analyser equipment shall be subject to proven application of these documents.

The analysis and monitoring data shall be processed in the PCS and suitably configured for reporting of emission levels to the Environmental Protection Authority.

7.5 PREFERRED EQUIPMENT

7.5.1 Preferred Mechanical 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 will provide guidance.

7.5.2 Preferred Piping & Valving Selection

The Vendor should select piping materials and valves in accordance with the project Piping Material Specification (Document No. 140316-0000-46EG-0001) and Manual Valves Specification (Document No. 140316-0000-46EG-0004) which have been included in Appendix C.


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7.5.3 Preferred Electrical & Instrumentation Equipment

The Vendor shall select and offer electrical and instrumentation equipment from within their standard range to meet the scope intent and comply with the following Specifications and Design Criteria:

140316-0000-40EG-0001 Project Specification 140316-0000-47EC-0002 Design Criteria for Electrical & Automation for Minor Packaged Plant 140316-0000-48EC-0001 Design Criteria Field Instrumentation & Control Valves

In the absence of clear direction, the Client’s Representative can provide some guidance. A list of electrical and instrumentation equipment adopted by the Vendor for the Process Water Treatment Plant shall be provided with their bid.

7.6 UTILITIES AND SERVICES

Refer to the Project Specification, (Document No. 140316-0000-40EG-0001 for design properties for the following utilities required at the Process Water Treatment Plant:

• Raw Water • Potable Water • Plant Air (same as Instrument Air) • Electric Power.

7.7 OTHER

7.7.1 Lifting Lugs

Where practical all components and assemblies for the Process Water Treatment Plant shall be provided with suitable 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 in accordance with AS 4991.

7.7.2 Noise Level

Noise levels from equipment within the Process Water Treatment Plant 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.

7.7.3 Safety Guards

All potentially hazardous moving items shall be guarded to AS 4024.1.

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


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8 DETAILED TECHNICAL REQUIREMENTS

8.1 CIVIL WORKS, FOUNDATIONS AND BUILDINGS

The design, supply and construction of all foundations, process slabs, bunds, sumps, sewers and drains within the Process Water Treatment Plant site shall be by others.

The Vendor shall review plant layout so as to ensure adequate access to major items of equipment by means of site mobile crane and shall specify what size mobile crane is required to meet the installation and ongoing maintenance requirements.

8.2 STRUCTURAL

The Vendor shall design, fabricate and supply all structural steel, walkways, platforms, stairways and ladders required to provide convenient access to plant and equipment.

Structural steel used for the construction of the Process Water Treatment Plant 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 shall maximise the use of mobile cranes and minimise fixed lifting devices. The Vendor shall provide suitably designed and certified monorails, davits or jib hoists to allow removal of machines and drives for maintenance where equipment items cannot be accessed by mobile crane.

The Structural Design Criteria for the project, document number 140316-0000-43EC-0001, is available upon request, however the Vendor shall use their own in-house standards and best practices that meet or exceed the guidelines and standards nominated elsewhere within this Scope of Work document.

8.3 MECHANICAL

The Vendor shall supply an equipment list for all vessels and rotating machines which shows the equipment weight and overall dimensions. This list should be accompanied by the Process Water Treatment Plant layout drawings on which these equipment items are clearly identifiable.

Allowance shall be made for condition monitoring of rotating equipment with consideration for ease of access and replacement of condition monitoring devices.

The Mechanical Design Criteria for the project, document number 140316-0000-45EG-0001, is available upon request, however the Vendor is encouraged to use in-house standards and best practices that meet or exceed the guidelines and standards nominated elsewhere within this Scope of Work document.

8.4 PIPING

The Vendor shall provide all piping and ducting, fittings, piping and ducting specials, pipe and ducting supports, lining, insulation, surface protection, temporary spools and strainers, gaskets and fasteners for all process and services piping and ducting systems interconnecting the modules of the Water Treatment Facility.


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The project specific Piping Design Criteria, document number 140316-0000-46EC-0001, Piping Material Specification, document number 140316-0000-46EG-0001 and the Manual Valves Specification, document number 140316-0000-46EG-0004 have been included for the reference and adherence by the Vendor for the relevant service streams.

8.5 ELECTRICAL

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

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

Motors shall be MEPS compliant in accordance with AS 1359.5.

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

Winding and Bearing RTDs are required for motors equal to or above 90 kW.

HV motors, if required, shall be provided with anti-condensation heaters.

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.

The Vendor will be responsible for the design, supply, testing and commissioning of all LV distribution, cabling (including power, control, analogue, digital and fibre optic), drives, drive switching and control devices, lighting, earthing (for power and instrumentation) for the Process Water Treatment Plant.

The Vendor shall nominate emergency power requirements for instances where the overall process plant power generation system trips out.

The Design Criteria for Electrical Engineering, document number 140316-0000-47EC-0001, is available upon request, however the Vendor shall only use their own in-house standards and best practices that meet or exceed the guidelines and standards nominated elsewhere within this Scope of Work document after receiving project approval.

8.6 INSTRUMENTATION AND PLANT-WIDE CONTROL SYSTEM INTEGRATION

The Vendor will be responsible for the design, supply, installation, testing and commissioning of all instrumentation, communication and control systems for the Water Treatment Plant.

The Design Criteria for Field Instrumentation and Control, document number 140316-0000-48EC-0004 is available upon request, however the Vendor shall only use in-house standards and best practices that meet or exceed the guidelines and standards nominated elsewhere within this Scope of Work document after receiving project approval.

8.6.1 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.


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

The supply and use of wireless instruments will be subject to the approval of the Client’s Representative.

8.6.2 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 9.5. The personnel nominated for this work shall be fully conversant with the Process Water Treatment 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.

8.6.3 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.

8.6.4 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


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• 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.

8.7 SURFACE PROTECTION

All external surfaces of the Process Water Treatment Plant equipment and structures, including base frames, guards and other ancillary equipment shall be provided with appropriate surface protection.

The Vendor may adopt their own painting and surface protection standards subject to approval by the Client’s Representative. The Client’s Specification for Corrosion Protection, 140316-0000-45EG-0002, is available for guidance on the preferred paint system and colours.

The Vendor shall specify, supply and apply protective coatings (consistent with the 20 year design life of the plant) for the following classes of materials and equipment:

• Structural Steel including structures, pipe supports, stairways, platforms and ladders • Mechanical, Electrical and Instrumentation equipment • Piping and cladding.

8.8 EQUIPMENT IDENTIFICATION, MARKING AND LABELLING

Equipment and component numbering shall be in accordance with the Client’s Equipment Numbering Standards. Spared equipment items shall be numbered from North to South and from East to West, (looking at a plan view of the Plant layout). Numbering and labelling should be clear and easily visible. Large vessel and equipment items should be labelled in 150mm high letters; where labelling is over cladding the labelling shall be by removable signage. The Vendor shall make a suitable allowance for the provision of the above equipment number labelling in their bid.

The Vendor shall provide all required signage including warning plant personnel of the hazards within the Process Water Treatment Plant areas.

8.9 PROVISION OF TECHNICAL DATA, DRAWINGS AND INSTRUCTION MANUALS

8.9.1 General

The Vendor shall submit information as identified in the Appendix B Vendor Data Requirements Schedule in this document.

The Vendor shall submit a list of current users of similar equipment with their tender, detailing duty, company, and name and telephone number of person responsible for operation.

The Vendor shall ensure that drawings, design calculations, training programmes and welding procedures submitted for review are signed by a professional engineer registered/licensed in the province, state or country where the equipment fabricator is located. That engineer shall be eligible for CPEng status with the Institute of Engineers in Australia.


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Certified vendor 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.

All data, drawings, calculations and any other technical document provided to, created by or otherwise assembled, are the property of the Client and as such shall be made available together with any technical, operating and instruction manuals, at the completion and acceptance of the works.

8.9.2 Technical Data

The Vendor shall allow for the provision of Manufacturer’s Data Reports (MDR) for all major equipment and piping systems of the Process Water Treatment Plant. The MDRs shall include but not be limited to:

• Design calculations • Inspection and test Plans (ITPs) • Weld traceability, mapping, Welding Procedure Specification (WPS) and Welding Procedure

Qualification Record (WPQR) • Materials records • Non-destructive testing (NDT) reports • Hydrostatic test reports • Paint application monitoring records • Rubber lining application monitoring records • Statutory approvals and registrations • As built drawings • PLC programming checks • Shop test run performance monitoring.

8.9.3 Drawings

The Vendor shall provide drawings as set forth in Appendix B Vendor Drawings and Data Requirements, which will form part of the Purchase Order.

The Vendor shall submit the company drawing standards for approval to the Client’s representative. The Vendor shall use a reputable design software package such as Autocad or Microstation. Electronic copies in native editable format of all drawings shall be handed over to the Client’s representative in accordance with the project schedule or at the time of practical completion.

8.9.4 Installation, Training, Operating and Maintenance Manuals

The Vendor shall allow for the provision of three sets in hard copy and one set in native file electronic format of Installation, Operating and Maintenance (IOM) manuals which will include all drawings, specifications, technical and safety data, vendor manuals, installation, start-up, commissioning, operating and maintenance instructions.

The IOM manuals shall be specifically written for the Process Water Treatment Plant and supplied by the Vendor. Their format and content shall be reviewed and approved by the Client’s representative prior to final submission.

The training documentation shall include a high level control and operating description.


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9 INSPECTION, TESTING AND ACCEPTANCE

9.1 QUALITY SYSTEM

The Vendor shall provide Quality System Requirements 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 document and all applicable codes, laws and regulations.

9.2 VERIFICATION AND TESTING DURING FABRICATION

The Vendor shall submit details of all tests to be carried out during manufacture of the equipment and structures for the Process Water Treatment Plant in the format of an Inspection and Test Plan 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 the commencement of manufacture.

Prior to shipment, the Vendor shall perform the tests specified and agreed 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 copies of mill analyses and test reports of materials in the Manufacturer’s Data Report (MDR).

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 Acceptance Tests shall not constitute a waiver of field commissioning requirements and the requirement to pass field tests under the specified operating conditions as per Sections 9.3 and 9.4.

Where possible, key equipment for the Water Treatment Plant shall be test run at the workshop witnessed by the Client’s Representative, in its fully assembled state, for a period of not less than 8 continuous hours.

Following the successful completion of the shop tests the Vendor will be assisted by the Client’s representative to perform a full function check using suitable controller hardware and simulation code. The purpose of the function checks is to confirm both the operation of the Process Water Treatment Plant equipment, and the control system code as a unit. The function checks shall include but not be limited to start-up and shutdown sequences, emergency shutdown sequence and control loop operation.

9.3 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 shall, 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’s Representative 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.


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Following completion of the work, the Vendor shall issue a Manufacturer’s Data Report (MDR) comprised of the 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 attached Vendor Data Requirements Schedule.

9.4 PERFORMANCE CRITERIA AND TESTING

The Process Water Treatment Plant shall be capable of meeting performance requirements against the following parameters, as detailed in the datasheet 140316-6290-45ED-PK0001.

• Continuous production rate of treated water • Quality of treated water • Amount of waste product generated • Power draw at design and maximum throughput rates for major equipment • Noise and Vendor specified vibration levels for the individual equipment and combined operating

plant.

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

9.5 COMMISSIONING

The Vendor shall provide a comprehensive staged testing and commissioning program which shall include but is not limited to:

9.5.1 Off Site Testing

• Single component equipment shall be individually factory tested and certified by the manufacturers • Multi component equipment shall be factory tested in the assembled or inter-connected state • Equipment which includes control equipment shall be fully factory tested. Tests shall be performed to

demonstrate all equipment functionality against an approved functional description or control diagram. In the case of all PLC or PCS hardware and software, a comprehensive Factory Acceptance Test shall be provided where all components are assembled/ connected and simulations of field inputs and outputs are used to verify functionality. This stage of testing will be witnessed by the Client’s Representative.

9.5.2 On Site Testing

The Vendor shall provide signed records approved test sheets for the following stages of Site Commissioning:

• Construction verification • Testing including electrical energisation • Function Testing • Process Commissioning.


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APPENDIX A VENDOR’S QUALITY SYSTEM

In the context of the quality system requirements detailed herein, the word ‘Vendor’ shall be taken to embrace Vendor, Subcontractor, Consultant, Sub consultant, Suppliers, Vendors or Sub suppliers supplying goods and/or services under the terms of the Contract and these requirements shall apply with equal force and effect to each of these parties.

The Vendor shall plan, establish, document and maintain a quality system which conforms to the requirements set out below and which is sufficiently comprehensive to ensure adequate control of the quality of the work to be performed or services to be provided.

The Vendor shall maintain throughout the life of the Contract a quality system that complies with the requirements of the particular Standard nominated in the table below or with a comparable alternative Standard.

Denotes Required Standard Rating Requirements A AS/NZS ISO 9001

X B AS/NZS ISO 9002 Plus AS/NZS ISO 9001 Clauses 4.4.6 to 4.4.9

C AS/NZS ISO 9002 D AS/NZS ISO 9003

QUALITY SYSTEM DOCUMENTATION

The Vendor shall comply with the following requirements as indicated:

Document Description To be submitted for review 28 days from award

To be available for review on request

QA Manual X Quality Plan X Inspection & Test Plan X X Quality Procedures X Design Validation Technical procedures X Quality Records X

ACCESS

The Vendor shall provide the Client’s Representative, and its agents, access to the Vendor's and each of its Suppliers and Subcontractor’s quality systems to enable monitoring and quality auditing.

NON-CONFORMANCE/CORRECTIVE ACTION

If the Vendor discovers material or work which is not in accordance with the specification or Contract, the Vendor shall promptly initiate the non-conformance procedure required by the Contract.


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If the Vendor proposes a disposition of any nonconforming materials or work which varies the requirements of the Specification or Contract, such a proposal shall be submitted in writing to the Client’s Representative whose decision on the proposal shall be obtained in writing before the nonconforming material or work is covered up or incorporated into the Works, or is the subject of any other disposition.

The disposition of non-conformances which do not vary the requirements of the Specification or the Contract may be approved by the Vendor.

QUALITY RECORDS

The Vendor shall maintain records of all documents necessary to provide objective evidence which demonstrates and verifies achievement of the Quality Assurance requirements specified in the Contract.

When the requirement for Design Validation is specified, the Vendor shall provide evidence of validation of the design that will satisfy the requirements of AS/NZS ISO 9001 and as defined in AS / ISO 8402.

The Vendor shall be responsible for ensuring the security -of such records for a period of retention, which as a minimum, meets statutory and/or contractual requirements, whichever is the greater.

The Vendor shall submit nominated Quality Records to Client’s Representative at the times and in the quantities specified in the Contract.

Unless otherwise agreed at the bid stage, original source material test certificates and NDE reports are required. Where it is not possible for the Vendor to provide the Client’s Representative with such originals, and the reasons for this are acceptable to the Client’s Representative, then copies of certificates/reports will be accepted only if they are individually certified as being a true copy of the original. These certified copies must be of sufficient clarity to permit microfilming or further copying.

PREPARATION AND SUBMISSION OF PROJECT QUALITY PLAN

A Project Quality Plan (PQP) shall be prepared by the Vendor where its quality system is required to comply with AS/NZS ISO 9001 or AS/NZS ISO 9002. The PQP shall supplement the Vendor's Quality Manual and shall define and document the specific quality practices, resources, activities and responsibilities relevant to the Contract.

The PQP shall include a Vendor Inspection and Test Plan (ITP) detailing in chronological order, the tasks, activities, and procedures serving to implement and record the Vendor's quality system. An ITP is required for all quality systems, including those to AS/NZS ISO 9003. The ITP shall conform to the requirements of AS/NZS 3905.2: ‘Quality System Guidelines, Part 2: Guide to Quality System Standards AS 3901/NZS 9001, AS 3902/NZS 9002 and AS 3903/NZS 9003 for construction’.

The Vendor shall list in the PQP, all procedures, work instructions and the like, which are applicable to the relevant Quality System elements. When requested for audit purposes, these documents shall be forwarded to the Client’s Representative at least two weeks prior to the scheduled date of such audit. The Client’s Representative undertakes not to make these documents available to any third party without the express permission of the Vendor and to return them to the Vendor at the conclusion of the audit.

The Vendor shall list in the PQP, all inspection and test procedures referred to in the ITP and shall submit these procedures to the Client’s Representative on request or when specified in the Contract.

The ITP shall be completed and signed off progressively by the Vendor's QC and the appropriate representative of the Client’s Representative and shall be submitted to the Client’s Representative with all progress claims and periodic progress reports, and prior to completion of the service or dispatch or the equipment.


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The Vendor may propose the use of its own standard forms, which must contain all information required by the Client’s Representative. Copies of any proposed Vendor ITP forms shall be submitted to the Client’s Representative for review and acceptance. The Client’s Representative reserves the right to request an ITP to be correctly completed on the Client’s Representative's format.

WITNESS AND HOLD POINTS

At least five days prior to reaching any Inspection and/or Test Point which has been designated by the Client’s Representative in the ITP as a Witness or Hold Point, the Vendor shall notify the Client’s Representative specifying the date, time and location at which the activity is to be carried out. Notification shall be by facsimile or other agreed procedure.

Refer to below for definitions of Witness and Hold Points.

TERMINOLOGY USED IN ITP

The following definitions shall apply to the preparation and use of Vendor Inspection and Test Plans.

Inspection & Test Point: A location or stage in the offsite or onsite work where inspection and/or testing are performed by personnel whose responsibility is to determine the acceptability of products or services and to record inspection and test data.

Witness and Hold Points: Refer to Clause above for details of Vendor obligations relating to Witness and Hold Points.

In the case of a Witness Point, if the Client’s Representative, or its representative, is not present at the designated time and place, the Vendor shall continue with the inspection and/or tests as defined.

In the case of a Hold Point, the Vendor shall not proceed with the work without the Client’s Representative or its representative being present, except where the Client’s Representative has notified the Vendor, in writing, that it may proceed.

Surveillance (SU): The continuing evaluation of the status of procedures, methods, etc, and analysis of records to assure that quality requirement will be met.

Review (R): The process of verifying by examination of documentary evidence that nominated inspections and/or tests have been satisfactorily conducted.

In-House (I): Applies to production at a facility under the direct control of the Vendor.

Subcontractor (S): Applies to production at a facility under the control of a Subcontractor to the Vendor.


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APPENDIX B VENDOR DRAWING AND DATA REQUIREMENTS

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 A1.0 GENERAL

A1.1 Overall Site Plan X X

A1.2 Process Block Flow Diagrams

X

A1.3 Process Flow Diagrams X X

A1.4 Mass / Energy Balance Diagrams

X X

A2.0 DISCIPLINE DRAWINGS

A2.10 CIVIL DRAWINGS

A2.11 Roads, Pads, Drainage & Earthworks

A2.12 Fencing

A2.13 Concrete Details

A2.14 Reinforcement Schedules

A2.20 STRUCTURAL STEEL DRAWINGS

A2.21 Structural Steel Arrangements & Details

X

A2.30 MECHANICAL DRAWINGS

General Arrangement, Plan and Elevation

X X

A2.40 PIPING DRAWINGS

A2.41 Piping and Instrument Diagrams

X

A2.42 In-Plant Piping Layout and GA Drawings, Details, etc

X

A2.50 ELECTRICAL DRAWINGS

A2.51 Equipment Layouts and Arrangements

X

A2.52 Cable and Cable Tray Layouts and Arrangement Drawings

X

A2.53 Single Line Diagrams X X

A2.54 Schematics X

A2.56 Electrical Standard Details


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VENDOR DRAWINGS AND DATA REQUIREMENTS PART A - DRAWINGS



Document Required

After Award

Issue Date (weeks after

award)


Remarks

A2.57 HV Power Reticulation and Transmission lines

A2.58 Termination Drawings X A2.60 INSTRUMENTATION

AND CONTROL DRAWINGS

A2.61 Control System Block Diagrams

X X

A2.70 INFRASTRUCTURE DRAWING

A2.71 Buried Services General Arrangement and Layouts

A2.72 Buildings Layouts and Arrangements

X

A2.73 Air-conditioning Services X

A2.74 Utilities and Services Layouts, Arrangements and Details

X

A2.75 HV Power Line and Pipe Line Easements

A2.76 Communications Systems

X

A2.77 Fire Protection Systems X A2.80 VENDOR DRAWINGS

A2.81 General Arrangement, Installation, Assembly, Parts Identification Drawings

X

A2.82 Foundation Loading Diagrams & Interface Drawings

X X

A2.90 OTHER

A2.91 Vendor to Nominate


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VENDOR DRAWINGS AND DATA REQUIREMENTS PART B – ENGINEERING DATA



Document Required

After Award

Issue Date

(weeks after

award)


Remarks

B ENGINEERING DATA

B1.0 GENERAL

B1.1 Process Design Criteria

X

B1.2 Engineering Design Basis

X

B1.3 Drawing Register X

B1.4 Water Treatment Plant Data Sheet

X X

B2.0 KEY DOCUMENTS

B2.1 Mechanical Equipment List

X X

B2.2 Electrical Equipment List

X X

B2.3 Cable Schedule X

B2.4 Instrument List X X

B2.5 Piping Line List X

B2.6 Valve Schedule X

B2.7 Electric Motor/Load List

X X

B2.8 Preliminary I/O Count X B3.0 ENGINEERING

CALCULATIONS

B3.1 Process X

B3.2 Concrete

B3.3 Structural Steel X

B3.4 Tankage and Platework

X

B3.5 Mechanical Equipment

X

B3.6 Vendor Equipment Sizing

X

B3.7 Pipework X

B3.8 Electrical Equipment and Cable Sizing

X

B3.9 Power Supply X

B3.10 Pump Performance Curves X X

B4.0 PLANT OPERATION

Control Logic and Operating Philosophy

X

Plant Installation, Operation, Training

X


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VENDOR DRAWINGS AND DATA REQUIREMENTS PART B – ENGINEERING DATA



Document Required

After Award

Issue Date

(weeks after

award)


Remarks

and Maintenance Manuals

Distribution Control System Programme

X

B.5.0 SPECIFICATIONS

Technical Specifications

X

Equipment Specifications

X

B.6.0 STATUTORY APPROVALS

Crane Certification X

Monorail Certification X

Pressure Vessels X

Power Supply System X B.7.0 OTHER

Vendor to nominate


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VENDOR DRAWINGS AND DATA REQUIREMENTS PART C – CONTRACT DOCUMENTATION



Document Required

After Award

Issue Date

(weeks after

award)


Remarks

C CONTRACT DOCUMENTATION

C1.0 GENERAL

C1.1 Commercial Non-Conformances

X X

C2.0 ESTIMATE DOCUMENTS

C2.1 Capital Cost Estimate X

C2.2 Operating Cost Estimate X

C2.3 Man-hours Estimate X C3.0 REGISTERS

C3.1 Scope Change Register X

C3.2 Purchase Order Register X

C3.3 Inspection/Expediting Register

X

C3.4 Contract Exposures Register, Variation Claims, EOT’s, Etc.

X

C4.0 SCHEDULES

C4.1 Overall Proj Schedule X X

C4.2 Engineering Schedule X X

C4.3 Construction Schedule X X

C4.4 4 Week Look-Ahead Schedule

X

C4.5 Shutdown & Tie-in Schedules

X

C4.6 Construction Manning Schedule X

C.5.0 REPORTS

C5.1 Monthly Project Reports X

C5.2 Manhour Reports – Home Office and Site

X

C5.3 Design Status Report X

C5.4 Drawing Status Report X

C5.5 Procurement Status Reports

X

C5.6 Inspection Status Reports X

C5.7 Expediting Status Reports

X

C5.8 Cost Reports X

C5.9 Site Construction Progress Reports – Summary Level

X


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Document Required

After Award

Issue Date

(weeks after

award)


Remarks

C5.10 Site Safety Reports X

C5.11 Site Goods Received Reports

X

C5.12 Commissioning Reports X

C5.13 Project Closeout Report X

C5.14 Manufacturer’s Data Reports (MDR)

X

C6.0 MEETINGS

C6.1 Project Meetings with SNC Lavalin

X

C6.2 Site Construction Meetings

C7.0 INSURANCE

C7.1 Workers Compensation X

C7.2 Public Liability X

C7.3 Motor Vehicle X

C7.4 Professional Indemnity X

C7.5 Marine Transit Cover X

C7.6 Other (Tenderer to Nominate)

C8.0. PROJECT IMPLEMENTATION

C8.1 Project Quality Plan X

C8.2 Project Procurement and Contracting Strategy

X

C8.3 Project Contracting Strategy

X

C8.4 Industrial Relations Strategy

X

C8.5 Project Risk Analysis X

C8.6 HAZAN/HAZOP Review and Recommendations

X

C8.7 Environmental Review and Recommendations

X

C8.8 Constructability Review and Recommendations

X

C8.9 Maintainability Review and Recommendations

X

C8.10 Occupational Health And Safety Review And Recommendations

X

C8.11 Statutory Regulations Review And Checklist

X


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Document Required

After Award

Issue Date

(weeks after

award)


Remarks

C8.12 Security Systems Review And Recommendations

X

C.9.0 INTERNAL AUDITS

C9.1 Process Audits X

C9.2 Design Audits X

C9.3 Cost Control/Forecast Audits

X

C9.4 Project Schedule Audits X

C9.5 Quality Assurance/Control Audits

X


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VENDOR DRAWINGS AND DATA REQUIREMENTS PART D – SITE RECORDS



Document Required

After Award

Issue Date

(weeks after

award)


Remarks

D SITE RECORDS D1.0 Daily Diaries X

D2.0 Inspection Records X

D3.0 Equipment Check Sheets, Mechanical, Electrical, Functionality, Etc.

X

D4.0 Installation Verification Records, Alignment Checks, Lubrication, Bolt Tensions, Belt Tensions, Etc

X

D5.0 Calibration Certificates X

D6.0 Lubrication Schedule including all equipment items rationalised for Client’s Representative preferred lubricant

X

D7.0 Site Testing Results Including, Geotechnical, Concrete, Paint Thickness, Electrical, Instrumentation, etc.

X

D8.0 Site Instruction Register X

D9.0 Site Instructions/Contract Variations

X

D10.0 Survey Data X


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VENDOR DRAWINGS AND DATA REQUIREMENTS PART E – COMMISSIONING RECORDS



Document Required

After Award

Issue Date

(weeks after

award)


Remarks

E COMMISSIONING PLAN, PROCEDURES & RECORDS

E1.0 Commissioning Plan (Integrated Commissioning Plan identifying logical and sequenced approach to overall plant commissioning)

X

E2.0 Commissioning Procedures

X

E3.0 Commissioning Records including Construction Verification Checksheets, Direction of Rotation Checks, Electrical and Safety Device Checks, Equipment No-Load Runs, Group Starts, PCS Configuration Verification, System Upset Condition Checks, Facility or System Operational Verification, and Process Commissioning respectively.

X

E4.0 Performance Trial/Test Procedures

X

E5.0 Performance Trial/Test Data

X


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APPENDIX C DRAWINGS AND SPECIFICATIONS

Drawing / Document No Description 140316-0000-40EG-0001 Project Specification 140316-0000-45EG-0002 Specification for Corrosion Protection 140316-0000-45D1-0004 Mechanical General Process Plant – Area Key Plan 140316-0000-46EC-0001 Piping Design Criteria 140316-0000-46EG-0001 Piping Material Specification 140316-0000-46EG-0004 Manual Valves Specification 140316-0000-47EC-0002 Design Criteria for Electrical & Automation for Minor Packaged Plant 140316-0000-48EC-0001 Design Criteria Field Instrumentation & Control Valves 140316-6290-45ED-PK0001 Datasheet: Process Water Treatment Plant


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APPENDIX D RESPONSIBILITY MATRIX

DESCRIPTION Vendor Client’s Rep

Comments

1.0 PROCESS DESIGN 1.1 Overall Plant Design Parameters X

1.2 Detailed Plant design X

1.3 Overall process Flow Diagram X

1.4 P & ID’s X 2.0 ENGINEERING DESIGN 2.1 Treatment Plant X

2.2 Treated Water Storage X

2.3 Utilities Design X

2.4 Waste Treatment Plant X

2.5 Civil & Structural Works

2.5.1 Design and specify all civil and structural works, excluding buildings/control rooms

X

2.5.2 Commission site survey X

2.5.3 Commission Geotechnical Survey X

2.5.4 Site preparation and Grading X

2.6 ELECTRICAL AND INSTRUMENTATION

2.6.1 Design: Switchgear & MCC’S; Substations; Switchrooms;

X

2.6.2 Site Installation Comprising Power/control, Cabling; Plant Lighting and GPO’s, PA systems; Instrumentation

X

2.6.3 Specify: 11kv Switchgear; 415V MCC’s Transformers; Substations; Switchrooms; Control Room

X

2.6.4 Instruments; Site Installation work X

2.6.5 Provide and programme distributed control system

X Client’s Rep to supply PCS Highway to Vendor

2.7 Drawing Approvals

2.7.1 Process Water Treatment Plant Design Drawing

X Client’s Rep to review and comment

2.7.2 Supplier Drawings X 3.0 SPECIFICATIONS 3.1 Provide specific Engineering Standards

where available X Client’s Rep to

provide

3.2 Prepare Equipment Specifications X

3.3 Prepare General Specifications X 4.0 OPERATING AND MAINTENANCE MANUALS 4.1 Specify and obtain Operating and

Maintenance Manuals from Sub Vendors X Client’s Rep to

provide site philosophy


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DESCRIPTION Vendor Client’s Rep

Comments

4.2 Prepare overall Operating and Maintenance Manuals

X

5.0 PERMITS AND APPROVALS 5.1 Obtain any permits and Approvals other

than for Mines Department. Approvals advise as required and Building Approvals

X Client’s Rep to assist and advise as required.

5.2 Mines Department Approvals and Building Approvals

X

5.3 Provide Plant Operating Permits X 6.0 PROJECT CONTROLS 6.1 Cost Control

6.1.1 Prepare Cost Schedule X

6.1.2 Maintain Cost Control X

6.1.3 Prepare Long Term and Monthly Cash Flow Forecasts

X

6.1.4 Prepare Variations X

6.2 Project Schedule

6.2.1 Prepare Project Schedule X

6.2.2 Prepare Summary Schedule with Critical Path

X

6.2.3 Update Schedules X

6.3 Progress Reports

6.3.1 Prepare progress Reports for SNC X One per month

6.4 Project Cost Reports

6.4.1 Prepare Cost Report for SNC X One per month

6.5 Project Meetings

6.5.1 Call and chair Project Meeting with SNC X One per month

6.5.2 Issue Minutes for Project Meetings X X ‘Host’ company to issue minutes

6.6 Project Procedures Manual

6.6.1 Prepare Project Procedures Manual X Client’s Rep to approve

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