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ENGINEERING SPECIFICATION

DOCUMENTATION

SPEC 00-G-02

REV DATE DESCRIPTION OF REVIEW BY APPROVED

A 28/02/92 Issued for comment BL

0 23/11/92 Issued for use JB A Popp

1 18/02/03 Section 2.3 revised. JB


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Specification No. 00-G-02Revision 1

Page No. 1

1.0 SCOPE OF SPECIFICATION

This specification covers the requirements for the documentation of engineering workswithin KCGM. The standard and quantity of drawings and data is given in thespecification.

2.0 TECHNICAL REQUIREMENTS

2.1 All drawings and data shall be submitted to the address nominated by KCGM.

2.2 All drawings shall be submitted with a covering numbered transmittal notewhich shall show the Contract number and list all documents included in thesubmission, the revision numbers of the issue where appropriate, and thenumber of copies submitted.

2.3 All drawings shall be prepared as per Specifications 00-G-06 & 00-G-07.

2.4 General arrangement drawings shall be in sufficient detail to show layout ofequipment, access for maintenance and operation and for necessary design byothers of foundations, supports and other interfaces.

2.5 The Contractor shall submit marking plans and elevations at the same time asor before any detailed shop drawings are submitted.

2.6 Drawings submitted for approval shall be signed by the Contractor; drawn,checked, designed, design checked.

2.7 As Built drawings shall be submitted and to show all changes made duringmanufacture, erection and commissioning. As built drawings shall be providedfor at least the following:

Arrangement Drawings

Cabling wiring and termination diagrams

Drawing list

Electrical drawings

Loop diagrams

P&ID drawings

Underground services

2.8 The Contractor shall provide at least the following design calculations:

Conveyor calculations

Detailed building structure design

Motor support pedestal

Process calculations/equipment sizing

Pump/piping calculations

Structural calculations

Structural steel design

2.9 Detailed engineering documentation shall be provided to detail the following

(but not limited to):

Electrical/instrumentation specifications


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Page No. 2

Electrical/instrumentation data sheets

Equipment data

Equipment specifications

Lubricants/chemical requirements

Motor lists

Painting/insulation specifications

PLC logic flow charts

PLC logic printouts and associated

Process data sheets

Process operations manuals

Program manuals

Protection co-ordination calculations and graphs

Screen graphics

Utilities requirements

2.10 Detailed drawings shall be prepared for (but not limited to) the following:

All as-built drawings and records

All construction drawings

Cable schedules

2.11 Welding Procedure Requirements

The Contractor shall submit to KCGM detailed procedures for all weldingincluding:

The name of sub-contractor, if any

The names and experience of the welders The proposed joint preparation

Full details of the welding procedure and weld consumables

Details of grinding

2.12 Test Reports and Certificates

The Contractor shall submit test reports and test certificates in respect ofmotors, couplings, exciter units in accordance with the requirements defined inthe relevant specification.

2.13 Operating Manuals

Manual format shall be A4 size on the filing side which shall be vertical with a20mm margin for filing. Pages shall be punched with holes, centrally, innerholes 48mm centres, outer holes 89mm centres.

The operating manuals shall include but not necessarily be limited to thefollowing:

Full description and details of design capacity and design criteria for eachitem of equipment and each product.

Detailed description and function of all operator controls.

Detailed description of all alarms, indications and protective devices.

Operating instructions, these must also cover the different modes ofoperating including start up, normal operation, shut-down and abnormal


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Page No. 3

operation, procedures to set up for operations and sequence of machineoperation.

Relevant reduced drawings general arrangements, assemblies, electricalschematics, etc.

Procedures in case of faults.

Operating manuals shall be submitted in three stages:

Preliminary for KCGMs approval reflecting the theoretical, designoperation.

Final approved, including all requirements.

As commissioned incorporating all changes made during thecommissioning phase and the as built condition.

2.14 Maintenance Manuals

Manual format shall be A4 size on the filing side which shall be vertical with a20mm margin for filing. Pages shall be punched with holes, centrally, innerholes 48mm centres, outer holes 89mm centres.

The manuals shall include but not necessarily be limited to at least thefollowing:

Technical description of all components, both mechanical and electrical.

Maintenance instructions (including proprietary items).

Repair, overhaul and installation procedures. These must be specific andnominate all necessary tolerances, fits, tensions, etc. Change outprocedures must also be included.

Recommended inspection and frequencies. Schedules for running maintenance, shut-down maintenance and

lubrication.

Electrical data and drawings.

Spare parts lists detailing the item, the number of units installed and therecommended quantity of spares to be held.

Ladder listings of all PLC programs, with mnemonic labels, crossreferences for all contracts, descriptions of all less than obvious instructionsand comments.

Input and Output Allocation tables with PLC I/O address mnemonic label foreach Input and Output.

Maintenance manuals shall be submitted in three stages:

Preliminary for KCGMs approval reflecting the theoretical, designedoperation.

Final approved, including all requirements.

As commissioned incorporating all changes made during thecommissioning phase and the as built condition.

2.15 Parts Lists and Recommended Spares

Parts lists and a list of priced spares recommended for one years operation

and as insurance spares shall be submitted to KCGM. Information regardingmajor spares shall be provided in sufficient time for manufacture to be carried


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Page No. 4

out concurrent with the items required to be supplied under the scope of theContract.

The information for all spares shall be submitted by the Contractor in sufficienttime for selection, order, manufacture, and delivery to be completed before

commissioning and start-up.

2.16 All drawings must be legible, suitable for microfilming and be prepared inaccordance with the following Australian Standards:

AS1100 All Parts

AS1101 All Parts

AS1102 All Parts

AS1103 All Parts

AS1104

2.17 All calculations and documentation shall conform to all applicable KCGMspecifications.

All calculations and documentation shall conform to the requirements of thecurrent applicable Australian Standard and relevant Statutory Authoritieshaving jurisdiction in Western Australia. Alternatively where no AustralianStandard exists, work shall conform to the most current and applicable BritishStandard.

All calculations shall show sufficient explanatory detail to enable independentchecking.

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