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SCOPE OF WORK SULPHURIC ACID PLANT

Document No 140316-5130-45EW-5601 Revision 01 Date 13/10/2017 of 81

SNC-LAVALIN 140316-5130-45EW-5601_01 - Scope of Work - Sulphuric Acid Plant

REVISION CONTROL

Issued for Internal Review

Issued for Client Review

Issued for Study Use

Issued for Tender

REVISION HISTORY

Revision Date Pages Revised Remarks

00 18/08/2017 Multiple Owner comments incorporated. Document number revised from previous document: 140316-5130-45EW-5901

0A 08/09/2017 Multiple Various throughout relating to Battery Limits 01 13/10/2017 Multiple Various throughout




TABLE OF CONTENTS 1 SCOPE OF WORK 7

1.1 INTRODUCTION 7 2 DEFINITIONS 8

3 WORK INCLUDED 10

3.1 ENGINEERING AND SERVICES 10 3.2 PROCUREMENT AND SUPPLY 11

3.2.1 Civil and Building Works 11

3.2.2 Concrete Works 11

3.2.3 Tankage and Structural Steel 12

3.2.4 Mechanical Equipment 12

3.2.5 Piping 12 3.2.6 Electrical Equipment 13

3.2.7 Instrumentation and Control Equipment 14

3.2.8 Materials and Consumables 14

3.3 FABRICATION AND SHOP ASSEMBLY 15

3.4 TRANSPORT TO SITE 15

3.5 SAFETY, HEALTH AND ENVIRONMENT 16 3.6 QUALITY SYSTEM 16

3.7 VERIFICATION AND TESTING DURING FABRICATION AND SITE INSTALLATION 16

3.8 PROVISION OF MDR 17

3.8.1 Technical Data 17

3.8.2 Drawings 18 3.8.3 Installation, Operating and Maintenance Manuals 18

3.9 PERMITS, LICENCES, REGISTRATIONS AND APPROVALS 18

3.9.1 Pressure Equipment, Fixed Cranes & Hoists 19

3.10 SITE OFFICE 19

3.11 SITE PREPARATION 20

3.12 CONSTRUCTION 20 3.13 VERIFICATION AND TESTING SITE INSTALLATION 22

3.14 COMMISSIONING 22

3.14.1 Off Site Testing 23

3.14.2 On Site Testing 23

3.14.3 Commissioning Plan 23

3.15 SPARE PARTS, SPECIAL TOOLS AND EQUIPMENT 24 3.15.1 Spare Parts 24

3.15.2 Special Tools and Equipment 25




3.16 SITE ASSISTANCE 25 3.16.1 Inclusion 25

3.16.2 Exclusion 25

3.17 TRAINING 25

3.18 PERFORMANCE GUARANTEES 26

3.18.1 Absolute Guarantees 26 3.18.2 Primary guarantees 26

3.18.3 Secondary Guarantees 27

3.18.4 Performance Assessment against Guarantees 28

3.19 RESPONSIBILITY MATRIX 28

3.20 WARRANTY 28 4 OPTIONAL WORK 28 5 Owner Supplied Matters 29

5.1 ENGINEERING AND SERVICES 29

5.2 FREE ISSUE ITEMS 29

5.3 OTHER EXCLUSIONS 30 6 BATTERY LIMITS 30

7 REFERENCE DOCUMENTS AND STANDARDS 32

7.1 DRAWINGS AND SPECIFICATIONS 32

7.2 CODES, STANDARDS AND REGULATIONS 32

7.3 LANGUAGE AND MEASUREMENT SYSTEM 36 8 OPERATING ENVIRONMENT 36

9 DESIGN CRITERIA 36

9.1 PROCESS DESCRIPTION 36 9.2 OPERATING PHILOSOPHY 37

9.2.1 Sulphur Melting, Filtration, Burner, Conversion and Acid Production 37

9.3 DUTY AND DESIGN CRITERIA 37

9.3.1 Sulphur Melting, Filtration and Storage 37

9.3.2 Rated Production Capacity 37 9.3.3 Sulphuric Acid Product 37

9.3.4 Steam Production 37

9.3.5 Cooling 38

9.3.6 Turndown 39

9.3.7 Emissions 39

9.3.8 Occupational Health and Safety 40 9.4 EQUIPMENT DESIGN 40

9.4.1 Sulphur Melting and Storage Plant 40




9.4.2 Sulphur & Hydrated Lime Addition 42 9.4.3 Sulphur Combustion 42

9.4.4 Catalytic Converter 43

9.4.5 Materials 43

9.4.6 Analysis and Monitors 43

9.4.7 Plant Hygiene System 44 9.4.8 Equipment Design Life 44

9.4.9 Vessels in Bunded Areas 44

9.5 PREFERRED EQUIPMENT 44

9.6 UTILITIES AND SERVICES (PERMANENT WORKS) 44

9.6.1 Boiler Feed Water (Demineralised Water) 44

9.6.2 Reverse Osmosis Water 45 9.6.3 Potable Water 45

9.6.4 Raw Water 45

9.6.5 Incoming Electric Power 45

9.6.6 Diesel Fuel 45

9.6.7 Sulphur 45

9.6.8 Hydrated Lime 45 9.6.9 Instrument Air 46

10 DETAILED TECHNICAL REQUIREMENTS 46

10.1 SITE 46

10.2 CIVIL WORKS, FOUNDATIONS AND BUILDINGS 46

10.3 STRUCTURAL 47

10.4 MECHANICAL 48 10.5 PIPING 48

10.6 ELECTRICAL 48

10.7 CONTROL AND INSTRUMENTATION 49

10.8 SURFACE PROTECTION 49

10.9 EQUIPMENT IDENTIFICATION, MARKING AND LABELLING 50




LIST OF TABLES

Table 1 Absolute Guarantees 26 Table 2 Primary Guarantees 26 Table 3 Secondary guarantees 27 Table 4 Input services and process lines terminal points for the Permanent Works 31 Table 5 Output services and process lines terminal points for the Permanent Works 31 Table 6 Frequently used standards 34 Table 7 Steam Production 38 Table 8 Distribution of maximum wet and dry bulb temperatures 39 Table 9 Emissions 39 Table 10 Sulphur (Indicative) 45 Table 11 Hydrated Lime (indicative) 46 Table 12 Quality Rating Requirements 51 Table 13 Quality System Documentation Requirements 51

APPENDICES

Appendix A CONTRACTOR’S QUALITY SYSTEM 51

Appendix B CONTRACTOR DRAWING AND DATA REQUIREMENTS 54

Appendix C DRAWINGS AND SPECIFICATIONS 69 Appendix D SULPHURIC ACID PLANT DESIGN DATA 71

Appendix E RESPONSIBILITY MATRIX 80




1 SCOPE OF WORK

1.1 INTRODUCTION

This Scope of Work (SOW) describes the minimum requirements for the ‘turnkey package’ design, supply, manufacture, installation, erection, testing, commissioning and performance testing of a Sulphuric Acid Plant, which includes a sulphur melting plant and a Sulphuric Acid Production Plant. These Works shall all form part of the Syerston Project at Syerston near Parkes in New South Wales, Australia.

SNC-Lavalin Australia Pty Ltd (the Owner’s Representative) is managing the project on behalf of Scandium21 Pty Ltd, a member of the Clean TeQ Group of Companies, hereafter referred to as Clean TeQ (the Owner).

Clean TeQ is developing its world-class Syerston Nickel Cobalt Scandium Project, utilising its Clean-iX® technology. The Syerston deposit is one of the largest and highest grade undeveloped nickel and cobalt resources outside Africa and contains the world’s largest and highest grade scandium resource.

The Syerston deposit is situated in central New South Wales, approximately 350 km WNW of Sydney. The project is well supported by major centres, with the mining communities of Parkes, Dubbo and Condobolin, all located within 100 km of the project area.

The Contractor shall supply all labour, supervision, process equipment, construction equipment, project documentation, services and materials other than the free issue items listed in section 5.2 and include all Works necessary for the design, supply, fabrication, assembly, inspection and testing, delivery to site, mobilisation to and demobilisation from site, construction, installation, training, testing, commissioning and performance (site acceptance) testing up to the issue of the Performance Certificate for the Sulphuric Acid Plant.




The Contractor shall also supply a sulphur melting plant inclusive of a sulphur dosing system. A feed stream of prilled sulphur will be supplied to the Contractor at the feed point of the sulphur dosing system. Hydrated lime will be supplied by the Owner in 1 - 2 t bulk bags to be fed to the Contractor supplied storage and addition system.

The rated capacity of the Sulphuric Acid Plant shall be 2 700 tonnes per day (100 % H2SO4 basis). The sulphuric acid shall be delivered at 98.5 % concentration.

The Sulphuric Acid Plant shall produce high pressure superheated steam, high pressure saturated steam (optional) and medium pressure saturated steam for use in the cogeneration plant and throughout the process plant.

The Contractor shall offer a solution which utilises its most efficient proven technology. The Owner desires a Sulphuric Acid Plant that has the highest economical thermal efficiency and proven design available, which can ultimately produce the best quality steam possible for maximum power generation.

The design, construction, installation and commissioning of the sulphuric acid storage and truck unloading facilities downstream of the Sulphuric Acid Plant will be by the Owner under a separate turnkey package. The design, construction, installation and commissioning of the co-generation plant will be by the Owner under a separate turnkey package Scope of Work document no: 140316-6120-45EW-5701. The Contractor may offer these as optional items complete with fixed and firm pricing for these separate turnkey packages.

2 DEFINITIONS

In addition to the definitions as per the General Conditions of Contract and Particular Conditions of Contract, the following definitions shall apply:

• Approved by Owner: shall mean prior written approval by the Owner’s Representative. The words such as Approval(s) and Approve shall also mean Approved by the Owner.

• Chartered Professional Engineer: shall mean a professional engineer who has a current and valid chartered status conferred upon them by Engineers Australia which certifies that this professional engineer practices in a competent, independent and ethical manner.

• Commencement Date shall have the meaning as set out in the Contract • Contract: shall have the meaning as set out in the document entitled ‘Sulphuric Acid Plant’ Contract

Number 140316-T-5601 • Construction Area means the part of the Site on which the Contractor will carry out and complete the

Works, including the lay down area • Contractor: shall have the meaning as set out in the Contract • Country: shall mean the State of New South Wales, Australia, as defined in the Contract • DDP: shall mean Delivered Duty Paid as defined by Incoterms www.incotermsexplained.com/ • Defects list: shall mean the punch listing, punchlist, defect(s) list and defects • Defect: shall mean any non-conformance, deficiency, rejection, defect, action, inaction, error, mistake,

deviation from the SOW, or non-compliance/non-conformance as deemed a deficiency, by either the Contractor, the Owner or the Owner’s Representative, as Approved by the Owner’s Representative. These will be added to the Punchlist.

• Document: shall mean documents, Drawings, manuals, MTO’s, calculations and lists, in hardcopy, pdf and native format

• Drawing(s): shall mean all sketches, drawings, vendor drawings, vendor data, engineering and construction data, redline mark-ups, as-built, unconnected models, connected 3D models, marking plans, assembly plans, fabrication drawings, and numerical control files. Drawings shall be in both native and pdf format.

• Owner’s Representative (also Owner’s Rep): shall have the meaning as set out in the Contract.

http://www.incotermsexplained.com/




• E&I: Electrical and Instrumentation • Fasteners: shall mean fastener(s) including but not limited to all bolts, nuts, washers, huck bolts,

spacers, rivets, chemical anchors, gaskets, shims, bespoke and special fasteners, floor anchor systems, cladding and roofing hold-down systems. Fasteners shall also include fasteners to effect structural steel, mechanical, concrete and electrical & instrumentation works.

• FAT: shall mean Factory Acceptance Testing • H2SO4: shall mean sulphuric acid at 100% strength • HAZOP: shall mean Hazard And Operability Study as well as Risk assessment, CHAZOP (Control,

Instrument and Electrical HAZOP), SIL study, Hazardous Area classification and alike. • ITP: shall mean Inspection and Test Plan. • kPa(g): shall mean kilopascal gauge pressure. • LOPA: Layer of Protection Analysis as defined in AS IEC 61511 • MDR: shall mean Manufacturer’s Data Report. It shall include but is not limited to all contractor quality

assurance systems, contractor quality assurance inspection and test records, contractor drawing and data requirements, drawing and specifications, design data, responsibility matrix, technical data, manuals, procedures, weld procedures, material certification, ITP’s, etc.

• Mechanical Completion (or MC): shall mean the completion of the design, fabrication, and installation of the geotechnical, civil works, mechanical, electrical, instrumentation, PCS, construction documentation and rectification of construction Deficiencies. This point could also be referred to as MC.

• MTO: Material take off • OH&S: shall mean Occupational Health and Safety • PCS: shall mean Plant Control System, SIS system, PLC, Scada, DCS, Burner Management System

(BMS), field monitoring devices, LCD/LED type screens, networks, cables, fibre, panels, programming tools, programming source coding, compiled code, firmware, control philosophy and manuals.

• PFD: shall mean Process Flow Diagram • P&ID: shall mean Piping and Instrumentation Diagram • PLC: shall mean Programmable Logic Controller and shall form part of the PCS • Project Area: shall mean complete Site on and near the Syerston project, including all references to

Site • Punchlist: shall mean the Defect list • Performance Certificate: shall have the meaning as set out in the Contract • Review: shall have the meaning as set out in the Contract • SAT: shall mean Site Acceptance Testing • Site: shall mean the places where the Permanent Works and Temporary Works are to be executed and

to which Plant and Materials are to be delivered, and any other places as may be specified in the Contract as forming part of the Site.

• SIF: shall mean Safety Instrumented Function as defined in AS IEC 61511 • SIL: shall mean Safety Integrity Level as defined in AS IEC 61511 • SIS: shall mean Safety Instrumented System as defined in AS IEC 61511 • SOW: shall mean Scope of Work • Syerston Project: shall mean the Syerston Nickel Cobalt Scandium Project • Taking-Over Certificate: shall have the meaning as set out in the Contract • Works: shall have the meaning as set out in the Contract.




3 WORK INCLUDED

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

3.1 ENGINEERING AND SERVICES

The Contractor shall design the Sulphuric Acid Plant in accordance with this document, the applicable codes and standards, reference specifications, drawings, and government regulations. The Contractor shall ensure that the Sulphuric Acid Plant is in every way robust, efficient, safe, fit for purpose and suitable for the duties specified.

The following engineering deliverables and services shall be included:

• All process and engineering design, comprising of drawings, detailed design, calculations, equipment specifications, bills of materials, mass and energy balances, PFDs, P&IDs, plant layouts, civil, structural, mechanical, piping, electrical and instrumentation design and detail drawings, equipment lists and all other design documents necessary for the complete design, specification, documentation and construction and commissioning of the Sulphuric Acid Plant. Contractor Drawing and Data Requirements are set-out in Appendix B

• Maintenance schedule for the first five years of operation of the Sulphuric Acid Plant, providing a high-level task list and estimated duration for planned maintenance activities that will impact overall availability during the period. All Works nominated in this document shall be included and undertaken by the Contractor unless clearly and specifically excluded

• A Risk Analysis including a HAZOP and a CHAZOP shall be conducted by the Contractor’s nominated Safety Specialist with participation by the Contractor. The Contractor shall be solely responsible for implementing the solutions necessary to reduce or mitigate the consequences of identified hazards. The Owner’s Representatives shall also participate in the HAZOP and CHAZOP.

• The Contractor shall conduct all Hazardous Area Classification, design, equipment installation and inspection services in order for the Sulphuric Acid Plant to achieve compliance with the requirements of AS60079. These activities shall include, but is not limited to: hazardous area classification, equipment inspections, conformity assessment documentation of imported (i.e. non Australian) equipment, design and installation compliance reviews, Hazardous Area verification dossier compilation and Hazardous Area installation project management.

• The Sulphuric Acid Plant shall have an inherently safe process design. The Contractor’s scope shall include the design, supply, installation, implementation, testing and independent verification of all safety instrumented systems (SIS) which will carry out all safety instrumented functions (SIF) as described in AS IEC 61511.

• The Contractor shall perform all Works associated with all SIS safety life cycle phases and functional safety lifecycle activities as outlined in AS IEC 61511 but excludes the functional safety assessment stages associated with post commissioning modifications and decommissioning of the Sulphuric Acid Plant. The Contractor’s scope shall include but is not limited to: - Management of functional safety and functional safety assessment plus auditing - Preparation of a functional safety management plan - All functional safety related activities plus deliverables - Hazard and Risk Assessment (e.g. HAZOP as described above) - SIL determination - LOPAs - Preparation and obtain any permissions needed as required - design and engineering of safety instrumented systems in accordance with the SIL rating as

determined from Functional Safety assessments - installation, commissioning and all third party verification activities.




• The Contractor shall obtain all Approvals and regulatory authorities in the Country. The Owner’s obligation in relation to functional safety will be solely limited to the provision of a risk profile or tolerable risk levels. The Owner reserves the right to check, change, audit and Approve all outcomes associated with functional safety.

• The Contractor shall use an auditable quality system for the execution of design engineering work. In particular, all calculations shall clearly show their basis and assumptions. All calculations shall be checked and stored in a systematic and traceable fashion and be available for scrutiny by the Owner and/or the Owner’s Representative at short notice.

• The Contractor shall design an Emergency Shut Down system in accordance with the relevant codes, standards, regulations and established practice and shall identify any Hazardous Areas. The Emergency Shut Down system design along with details on the codes, standards, regulations and established practices shall be formally submitted to the Owner’s Representative for Approval.

3.2 PROCUREMENT AND SUPPLY

The Contractor shall include in the provision for all items, accessories and services that are usual or necessary to complete the Works, but which may not have been specifically mentioned herein. Procurement and supply shall include, but not be limited to the following:

3.2.1 Civil and Building Works

• Excavations as required to allow for equipment and tankage support foundations • All underground services within the battery limits, including buried conduits, pipes and ducts • Competent or engineered backfill as required (Note: hardstanding to be provided by the Owner) • Paving and/or crushed stone surface finishing between concrete Works • All buildings c/w HVAC and building services inclusive but not limited to:

- Substation - Switchroom and motor control centres - Main air blower(s) room (if required)

• Laying of earthing grid.

3.2.2 Concrete Works

Subject to the Terms & Conditions of the Contract, uncured concrete shall be available to the Contractor for the Works via the on-site batching plant, subject to the Contract and according to concrete supply schedule Approved by the Owner’s concrete supply schedule. Refer to free issue items in section 5.2.

The Contractor shall design, supply, construct and commission all foundations, process slabs, bunds, sumps, sewers and drains within the Sulphuric Acid Plant site. These include:

• Concrete foundations, footings, fasteners and slabs • Slabs around the acid handling and acid distribution areas • Floor sumps • Acid proofing (inclusive of acid resistant tiling) and protection of slabs, floor sumps and drains.

The supply of uncured (wet) concrete will be back charged as per the schedule to the Contractor. For the avoidance of any confusion, concrete, pouring, vibrating, shuttering, formwork, quality control, rebar and alike is by the Contractor. The Contractor shall be responsible for scheduling with the batching plant operator in regards to delivery quantity, time, quality and anything else as deemed necessary.




The Contractor shall review the Syerston Project plant layout and design to ensure sufficient access to major equipment items within the Contract by means of a site mobile crane. The Contractor shall specify the mobile crane size required to meet installation and ongoing maintenance requirements.

3.2.3 Tankage and Structural Steel

• Structural steel work, tanks, plate work, buildings, plant control room, maintenance and operating access ways

• Personnel protection insulation for all tankage with normal operating temperature exceeding 60°C as well as thermal insulation required by the process

• Seal pots on tank overflow pipes • Staircases, platforms and walkways on the storage tanks and all equipment requiring maintenance

access for operation and maintenance • Roof, sheeting, flashing and cladding • Pipe supports • Cable supports • Brackets for CCTV, lighting, poles, lightning equipment and instruments. This will also include earthing

lugs and/or holes. • As a minimum, suitable surface protection of structural steel, tanks and pipework as per the Contractor’s

design for modern sulphuric acid plants • Acid proofing.

In areas of concern, the Contractor shall propose additional features or alternative solutions for Approval by the Owner’s Representative.

3.2.4 Mechanical Equipment

• All mechanical equipment including ancillaries such as lubrication and cooling systems. The Contractor shall meet or exceed the guidelines and standards nominated elsewhere in this Scope of Work and subject to Owner’s Approval, may utilise its own in-house standards for modern Sulphuric Acid Plants.

• All distribution pumps which is inclusive of those required for sulphur, oleum and sulphuric acid service • Lining, painting, weather-proofing and insulation for process and personnel • Personnel protection for equipment with normal operating temperature exceeding 60°C • Fixed overhead hoists, and monorails complete with trolleys and cranes to facilitate routine maintenance

activities • Sump pumps complete with strainer mesh and support frames • Noise mitigation • Neutralisation equipment to cater for acid spills. The Contractor shall provide an appropriate system to

allow operational personnel to neutralise acid spills in an emergency situation. • Wash down equipment to allow personnel to wash acid, sulphur and the like into sumps • Flue gas treatment systems for emissions controls • Fire extinguishers, fire prevention, fire detection and firefighting systems • Heat tracing of equipment (as applicable).

3.2.5 Piping

• Piping and duct work, valves, fittings, supports and anchors including lining, painting and insulation for process and personnel protection for equipment exceeding 60°C normal operating temperature




• Pipe flange covers complete with leakage detection on all critical sulphuric acid lines, according to industry standards. The Contractor shall provide details of its proposed leakage detection system. The Contractor shall propose an automated system for the leakage detection system.

• Underground piping, valves, fittings, supports and anchors where specified • Pipe stress analysis of stress critical lines using established software such as Caesar • Heat tracing of piping (as applicable).

3.2.6 Electrical Equipment

• 11 kV, 2 500A, 50 kA switchboards/motor control centres and the like • 24 V DC battery chargers for 11 kV switchgear trip and close • All transformers • 11 kV incoming circuit breakers, the incoming 11 kV cable rack and all cable terminations • Local motor control stations • 415 V motor control centres and the like with at least 30% equipped spare capacity • All Motor starters shall be in the motor control centre and shall be of the intelligent kind including a motor

protection relay and remote I/O modules, and suitable for the connection of external emergency stop signals

• For all the motor starters, an UPS shall be used to maintain control voltages, communications and other essential loads for a loss of power event of 2 hours

• Electrical switchroom with air-conditioning and air lock with no less than 20% room for expansion • 11 kV switchboard shall allow for 2 additional breakers; one feeding the Sulphur unloading and one

equipped spare • Cable ladder, conduit and any other cable containment equipment • Power cable, control cable, earth cable and optical fibre • Variable speed drive(s) required for the main air blower(s), inlet guide vanes and any other mechanical

equipment (Note: The Contractor shall advise the quantity of blowers in its bid) • Area welding outlets and small power outlets throughout the Sulphuric Acid Plant • Electrical earthing grid • Lightning protection system • Specific area lighting for 24-hour operation • Building lighting, area and road lights • Small 240 V power distribution boards • Uninterruptible power supply system(s) • All electric motors shall be Minimum Energy Performance Standard (MEPS) compliant in accordance

with AS1359.5 as well as fully compliant with all requirements set out in the Greenhouse and Energy Minimum Standards (GEMS) Act of Australia. Orientation and size of the terminal box is subject to Approval by the Owner’s Representative

• Thermistors shall be provided for motors above 22 kW and below 90 kW • Winding and bearing resistance temperature detectors are required for motors of 90 kW and above • HV motors shall be provided with anti-condensation heaters.




3.2.7 Instrumentation and Control Equipment

Field Instruments and Control valves and shall be nominated and supplied by the Contractor in order to allow for the safe operation of the Sulphuric Acid Plant. The Equipment shall exceed or be in accordance with 140316-0000-48EC-0001 and shall include:

• Monitoring and leak detection equipment • Measurement and control field devices • Metering and totalising facilities for acid production, steam production and sulphur metering • Emergency alarm facilities • Air actuated valves and dampers • Instrumentation and control cabling • Instrument earthing • Instrument field junction and marshalling boxes • All network equipment, fibre and cables • Connection equipment to the fibre communication with the main control room • Plant control system (PCS) for the Sulphuric Acid Plant.

In addition to the normal instrumentation, all fans and blowers driven by a motor larger than 250 kW shall be fitted with no less than five vibration accelerometers (including both monitoring and axial vibration trip) with 4-20 mA output on the mechanical components as well as no less than two bearing temperature transmitters on blowers and motor bearings.

Where the equipment is supplied with a programmable logic control system (e.g. PLC):

• the supplied control system shall be capable of being integrated into the Plant-Wide Control System using a Ethernet digital communications protocol such as MODBUS TCP, PROFINET or Ethernet/IP.

• the supplied control system shall be configured to exchange data with the site wide PCS. The configuration shall monitor the health of the communications link and take any necessary action to safely react to a failure of the communications link. The data exchange configuration shall also provide a watching signal in the form of a continuously changing value to allow the site wide PCS to monitor the health of the communications link at the application level.

• the Contractor shall supply a datamap which shall list the following details for all the produced and consumed signals - tag (and address if required) - function (covering all values and states of the signal) - engineering range - engineering units - data type - scaling factor.

The Contractor shall state with the tender bid any additional instrumentation and controls required for the safe operation of all equipment.

3.2.8 Materials and Consumables

The Owner will supply the following materials for hot commissioning purposes:

• First fill sulphuric acid • Hydrated lime




• Sulphur • Diesel fuel, LP steam and 11kV power • Utility services at Battery Limits.

The Contractor shall specify the required supply quantities in its bid.

Prior to the Taking-Over Certificate being issued, the Contractor shall provide all material and consumables, not provided by the Owner. Material and Consumables shall include, but are not limited to:

• First fill catalyst • Cooling system chemicals and dosing system • Chemicals including for waste heat boiler boil-out and passivation • Lubricants and other materials • Consumables for commissioning (operational, defects, punchlists and maintenance) • Fuel required prior to cold commissioning for curing of refractory and alike. If during hot commissioning,

fuel by Owner.

After the Taking-Over Certificate been issued, the Contractor shall supply all material and consumables (except the Owner supplied consumables provided at the battery limits) needed for Performance tests to achieve the Performance Certificate and alike.

3.3 FABRICATION AND SHOP ASSEMBLY

The Contractor shall be responsible for the fabrication and the shop assembly of the Sulphuric Acid Plant equipment, piping and ducting systems, structures and buildings, electrical, instrumentation, control equipment and associated ancillaries.

To minimise site labour man-hours and infrastructure requirements, it is preferred that off-site modular assembly of the Sulphuric Acid Plant components be maximised subject to transportation constraints.

3.4 TRANSPORT TO SITE

For preliminary design purposes the Contractor shall assume road transport envelopes as below. A tyre loading limit of 2.25 tonnes shall further apply. In addition to the above constraints, the NSW Transport Authority specifies that the longest truck allowed on NSW roads shall be a B-Double with a total length not exceeding 25 m.

Route A. The route from Port Pirie to site has an indicative transport envelope of 9 m high and 7.5 m wide. The approximate distance of this route is 1250 km.

Route B The route from the port in Newcastle to site has an indicative transport envelope of 5.5 m high and 7.5 m wide. The approximate distance of this route is 550 km.

Larger loads can be proposed by the Contractor for Approval by the Owner’s Representative if the Contractor believes that significant cost and schedule savings could be achieved.

While a route survey has been included in the document ‘MMG-P17-016-015 - MMG Preliminary Construction Materials Transport Report Rev. A’, the Contractor shall verify the suitability of the transport route and loads prior Contract commencement date.




3.5 SAFETY, HEALTH AND ENVIRONMENT

The Contractor shall also design, supply, install and commission the Sulphuric Acid Plant so that it will meet or exceed all safety, health and environmental protection requirements as outlined in all Acts, Regulations, standards, SOW, design criteria, specifications and any other documentation referenced/stated in this SOW and the Contract. These measures shall typically include:

• Emergency stop stations shall be positioned away from any possible acid spray • Double block and bleed valves for isolation before and after all pumps and equipment when

maintenance is needed on a pipeline containing dangerous goods such as acid • Avoiding manual valves operation, placing operators in close proximity of dangerous goods such as acid • All safety signage for the temporary and permanent Works • Temporary and permanent Works noise attenuation • Dust suppression, other than main roads • Fire extinguishers, fire prevention, fire detection and firefighting systems • Fire protection reticulation network c/w hydrants (fire water available at the battery limits). • Safety showers, baths (if needed) and eyewash stations complete with monitoring, valving and ring

main. The Contractor shall determine if additional cooling is needed using the data as per 140316-0000-40EG-0001- Project Specification. Note: water in this system must not exceed 38 °C

• All stacks shall be provided will sampling ports for permanent instruments which shall be compliant to AS4323. In addition, for isokinetic sampling, 2 off sampling ports at 90°, no less than Ø100 mm c/w ball valve and flange. Access to the platform and a platform around the stack for more than 120°. This platform shall be equipment with air and power outlets.

3.6 QUALITY SYSTEM

The Contractor shall provide a Quality Plan and systems which shall show how design, procurement, fabrication, installation and testing quality issues shall be addressed. The Quality Plan shall demonstrate the establishment of an auditable trail for each of these aspects.

The Contractor shall arrange for appropriately qualified personnel to provide auditing of the implementation of the Sulphuric Acid Plant Quality Plan.

Quality System detailed requirements are listed in Appendix A.

3.7 VERIFICATION AND TESTING DURING FABRICATION AND SITE INSTALLATION

The Contractor shall allow for the provision of appropriately experienced staff to expedite and inspect shop fabricated items. It shall be demonstrated that items are inspected for satisfactory construction prior to leaving the fabricator’s shop or yard. This applies in particular to pipe spooling, ducting sections, prefabricated steelwork, pipe supports, vessels, heat exchangers, pumps, fans, switchboards and PCS’s.

Heat numbers of all flanges and fittings shall be traceable on demand.

The Contractor shall supply a Critical Equipment list and shall be able to demonstrate, during the implementation of the project, that up-to-date expediting reports from direct shop visits are being received and corrective action is being taken as required.

The Contractor shall allow inspection, monitoring and control by the Owner’s Representative’s own inspectors as per Inspection and Test Plan (ITP), Approved by the Owner’s Representative.




3.8 PROVISION OF MDR

The MDR shall include but not be limited to all technical data, drawings, manuals, weld procedures, materials certificates, verifications, ITP, etc.

All documentation shall be handed over to the Owner’s Representative in both native format and as PDF renditions.

The Contractor shall allow for the provision of technical data, drawings and installation, operating and maintenance manuals in accordance with Contractor drawings and data requirements listed in Appendix B.

Where required by statute, the Contractor shall ensure that drawings, design calculations and welding procedures submitted for review are signed by a Chartered Professional Engineer registered or licensed in the Country, regardless of the fabrication country, suitable for use in the Country.

Shop drawings shall include, but not necessarily be limited to, design data such as size, dimensions, tolerances, material thickness, materials, spacing and location of attachments, fastener sizes, 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 documents provided to, created by or otherwise assembled, shall be made available to the Owner together with any technical, operating and instruction manuals, all prior to the application for the Taking-Over Certificate.

All registration and associated verification documentation for fixed/mobile cranes and pressure vessels shall be included in the MDR.

For equipment subject to inspection as per regulatory requirements by a Government Department, or Agency in the Country, the Contractor shall submit to the Owner original copies of the test data reports and all other documentation required for the final field inspection of the equipment by the Government Department or Agency in the Country. Refer to Section 3.9.

3.8.1 Technical Data

The Contractor shall allow for the provision of technical data to the Owner for all significant and major equipment and piping systems of the Sulphuric Acid Plant. The technical data shall include, but not be limited to:

• Design calculations • ITPs • Weld traceability, mapping, WPS and WPQR • Materials records • NDT reports • Hydrostatic test reports • Paint application monitoring records • Corrosion barrier application monitoring records • Statutory Approvals and registrations • All Hazard Level Classifications for all pressure equipment • As built drawings • PCS programming checks including PLCs • PCS source code with comments • Shop test run performance monitoring.




3.8.2 Drawings

The Contractor shall provide drawings as set forth in the Contractor drawings and data requirements listed in Appendix B.

The Contractor shall submit the drawings as per the Owner drawing standards for Approval to the Owner’s Representative. The Contractor shall use a reputable CAD software package. Native format copies of all electronic files such as drawings (e.g. DWG and DGN) and connected 3D models shall be handed over to the Owner before Taking-Over Certificate.

The 3D model shall include clash detection. The model shall include concrete, structures, pipes ≥ 50mm, mechanical equipment, significant electrical rooms, instrument placement and cable racks ≥ 300mm. A constructability review session with the Owner’s Representative at the Owner’s premises shall be carried out by the Contractor.

The Contractor shall comply with the following requirements:

• Open, read-only access to all technology and modelling environments during project execution • All engineering information and data (inclusive of 3D models) shall be formally handed over in ISO15926

connected and iModel formats with attribute data specified in the Owner’s class libraries (available upon request). The submission of the engineering information and data will be a progressive transition, and the Owner’s operational personnel and Owner Representative will evaluate and approve the quality and readiness of this information.

• All engineering models shall be handed over in native format, with at least one working licence in each of the design tools used to generate the integrated model.

3.8.3 Installation, Operating and Maintenance Manuals

The Contractor shall allow for the provision to the Owner of one set in electronic format of Installation, Operating and Maintenance (IOM) manuals which will include all drawings, specifications, technical and safety data, Contractor manuals, installation, operating and maintenance instructions.

The IOM manuals shall be specifically written for the Sulphuric Acid Plant supplied by the Contractor and their format and content shall be reviewed and Approved by the Owner’s Representative prior to final submission.

3.9 PERMITS, LICENCES, REGISTRATIONS AND APPROVALS

Further to the General Conditions, the Owner’s Representative shall arrange, obtain and pay for the following permits, licences, registrations and approvals as may be applicable to Work under the Contract.

• Environmental protection authority approval • Planning permits • Access permit.

All other permits, licences, registrations, Approvals and notifications required in respect of the Contract shall be obtained or given and paid for by the Contractor. These shall include all Approvals to carry out any Works in the Country. The Contractor shall provide copies of such documents to the Owner’s Representative upon request. These licences shall include, but not be limited to:

• Licences associated with the Dangerous Goods Act • Licences and registrations for construction cranes in the Country




• Approvals for all Certified Goods including but not limited to: - pressure vessels - boilers - combustion systems - combustion appliances - Hazardous area classification - HV electrical systems and electrical submission - cranes and hoists - radiation sources, both active and passive.

3.9.1 Pressure Equipment, Fixed Cranes & Hoists

The Contractor shall design the pressure vessels in strict accordance with AS 1210, ASME VIII Division 1/2, ASME IX or internationally accepted relevant boiler codes (subject to Approval). The design shall meet the requirements of AS 3920 and AS 4343. It is mandatory for the Contractor to perform all AS4343 hazard level calculations for submission to the Owner’s Representative. The Contractor shall specify the design hazard level of the pressure vessels to AS 3920.

This Specification (Section 7.2 Codes, Standards and Regulation) references AS 1210 as the design code for pressure vessels. Submissions will be accepted using the ASME boiler and pressure vessel code, with the qualification that third party verification of the pressure vessel and boiler designs for compliance with AS 1210 and/or AS 1228 will be required. All fixed cranes and hoists shall be compliant with AS1418. Verification must be done by a Certified Professional Engineer in the Country.

All Works shall be carried out by the Contractor to ensure that all pressure vessels, cranes and hoists are registered as mandated with the New South Wales Department of Planning and Environment – Resources & Energy. This includes, but is not limited to, production of design drawings, calculations, designer statement of conformance, third party design verification by an Australian independent service provider, on site equipment inspection by an independent Australian service provider, and completion of all relevant registration forms and documentation.

The Contractor shall ensure that all requirements of this document, reference specifications, drawings and government regulations are met or exceeded and shall ensure that the pressure vessels are suitable for the duties specified.

3.10 SITE OFFICE

The Contractor shall provide a suitably equipped site office (including telecommunications and information technology, office space for Owner’s Representatives, and meeting rooms) to accommodate all the Contractor’s requirements. The Contractor will be allocated an area of approximately 5 000 m² for offices, workshops, ablutions, stores and lay down of materials and equipment. This will be referred to as the Contractor’s Yard.

The Contractor will be provided with construction water from an allocated area, within 500 m from the site office.

Supply of potable drinking water shall be the responsibility of the Contractor.

The Contractor shall supply electrical power for its general office amenities as well as the construction power for the Works.

The Contractor shall be responsible for safety, housekeeping and clean-up of both the Sulphuric Acid Plant site and the Contractor’s yard. This applies both during and on Issue of the Performance Certificate of the Works.




The Contractor shall be responsible for the disposal of waste (noxious or otherwise) in a manner satisfactory to the Owner’s Representative and the local authorities. The Contractor shall also be responsible for the disposal of any excess excavated materials to a suitable location which shall be approved by the Owner’s Representative.

3.11 SITE PREPARATION

The site will be levelled by the Owner. The Contractor shall be responsible for all other civil works required for the Sulphuric Acid Plant. The Contractor shall provide hardstand for cranes as required. See Section 10.2.

3.12 CONSTRUCTION

The Contractor shall be responsible for all construction within the Sulphuric Acid Plant battery limits:

• Detailed earthworks including localised excavations to provide clearance for footings construction, roads within the battery limit plot area, final levelling and grading of earthworks, drainage and finishing of unpaved areas with crushed rock

• Hardstanding pads for mobile cranes and alike • Concrete Works including all piling, equipment foundations, concrete pads, footings, paving, kerbing

and bunds (Contractor to advise nominal concrete volumes required) • Structures including column, floors, kickboard, handrail, roof, cladding, sheeting, bracing and alike • All equipment preservation measures throughout the entirety of the Works • All isolation and equipment lockout procedures for use during construction and commissioning • All lagging, insulation, cladding, roofing, flashing • Tanks, bins, chutes transfer systems and vessels • Concrete acid proofing including acid resistant tiling • Refractory installation including curing • Mechanical Works including supply and installation of all equipment items • Piping Works including ductwork, supports, flexibles, transition pieces, valves, and heat tracing (as

applicable) • All fasteners • Electrical Works including cabling and terminations, conduit, cable ladder, cable tray, supports and

protection as well as heat tracing as applicable. • Instrumentation, networks and control works • Fire detection and suppression systems inclusive of fire hydrant systems • Temporary and permanent Works noise attenuation • Dust suppression, other than main roads • Removal of rubbish and construction debris from the Sulphuric Acid Plant site including regular clean-

ups • Any other Works required for the construction of the Sulphuric Acid Plant.

The Contractor shall also provide:

• Mobilisation and demobilisation to and from the site • OH&S requirements including R&R (Roster Rotation on-site/offsite) and welfare for all personnel under

their care • A Safety Management Plan to address all safety issues during construction and commissioning phases.

The Safety Management Plan shall comply with the Owner’s requirements which are available from the Owner upon request.




• Safety management including, but not limited to toolbox meetings, safety committees, safety audits, job safety analysis, incident reporting, emergency response plan, work permit procedures, and provision of safety training

• Environmental management plan to address all related issues and comply with the Owner’s requirements (note: these requirements are available upon request) during construction and commissioning phases. This shall include but not be limited to the following: - general waste disposal - oily waste disposal - control of weeds and seeds - control of chemical spillage - control of dust - control of noise - access and egress during construction and commissioning - fencing, guarding or any other means of ensuring security for materials, systems and

documentation on site.

• Facilitate and provide information for the Owner’s Environmental Impact Assessment (EIA), environmental licensing and any other statutory Approvals that may be required

• General construction power • Construction ablutions • Rainwater control at the site offices and Sulphuric Acid Plant site throughout the duration of the Contract • All cranage, spreader beams, lifting, rigging and scaffolding as required to complete the construction

works • Lifting studies • Suitable storage area for catalyst and other equipment and materials requiring weather protection • All surveying services as required to ensure Works including foundations are correctly placed and that

required final grades are established. The spatial reference system is Geocentric Datum of Australia GDA 94 / Map Grid of Australia MGA zone 55.

• Construction schedule, manning histogram levelled for resources, which clearly displays the construction critical path. This schedule shall be updated at least weekly and be submitted to the Owner’s Representative for Approval.

• The Contractor shall generate and distribute its own electrical power where required during the entire period including construction and commissioning stages (except where indicated in section 3.2.8)

• The Contractor shall distribute construction water (within 250 m) from the allocated area to where it is required during all construction and commissioning stages

• Experienced construction management and supervision • Skilled and experienced personnel to manage the following disciplines:

- Project management - Project administration - Personnel and industrial relations - Project scheduling and cost control - Civil/structural construction - Welding - Piping - Mechanical - Electrical - Instrumentation (including PCS) - Testing and pre-commissioning - Commissioning.




On site messing and accommodation for the Contractor’s personnel will be provided by the Owner, subject to the site manning histogram, as Approved by the Owner Representative.

All flights and travel arrangements shall be provided by the Contractor, including all vehicles for travel around the site.

All and any costs associated with the Owner’s inductions and miscellaneous activities e.g. toolbox meetings at any stage of the on-site Works shall be borne by Contractor.

3.13 VERIFICATION AND TESTING SITE INSTALLATION

The Contractor shall allow for the provision of appropriately experienced and competent staff to expedite and inspect shop-fabricated items. It shall be demonstrated by the Contractor, that items are inspected for satisfactory construction, prior to leaving the fabricator’s shop or yard. This applies in particular to pipe spooling, ducting sections, prefabricated steelwork, pipe supports, vessels, heat exchangers, pumps, fans, switchboards and PCS.

Heat numbers of all piping, flanges and fittings shall be traceable on demand.

The Contractor shall supply equipment lists and shall be able to demonstrate, during the implementation of the project, that up-to-date expediting reports from direct shop visits are being received and corrective action is being taken as required.

The Contractor shall allow inspection, monitoring and control by the Owner’s Representative’s inspectors.

3.14 COMMISSIONING

The Contractor shall provide a team of suitably competent personnel experienced in Sulphuric Acid Plant operations and perform all Plant commissioning activities inclusive of planning, documentation preparation and directing the transition from Mechanical Completion through to the issue of the Taking-Over Certificate and issue of the Performance Certificate.

The Contractor shall provide all labour personnel inclusive of process and maintenance technicians and carry out all commissioning activities. The Contractor shall develop and submit an operational involvement plan during the design phase of the Works to the Owner for Approval. This plan shall detail all phases and requirements necessary to prepare and involve the Owner’s personnel throughout the Works so that they are competent to operate and maintain the Sulphuric Acid Plant after the issue of the Taking-Over Certificate. The operational involvement plan shall also outline when the Owner’s operational personnel should become involved and what their responsibilities should be. These aforementioned requirements are subject to Approval by the Owner. The Owner reserves the right to supply competent operational personnel for the purposes of commissioning. Competent personnel are defined in the Work Health and Safety (Mines and Petroleum Sites) Regulation 2014.

The Contractor shall also provide all materials (e.g. spool pieces, blank flanges, temporary strainers, hoses, and hose connectors), equipment (e.g. hydro testing equipment, pressure gauges) and services (e.g. supervision by equipment Contractor representatives and condition monitoring services) necessary for the pre-commissioning and commissioning of the Sulphuric Acid Plant.

The commissioning Works shall commence once piping, mechanical and electrical installation verification is complete as well as the completion of the work as listed on the construction Punchlist.

The Contractor shall advise the manning histogram and time schedule required to fully commission the Sulphuric Acid Plant, all associated equipment and buildings.

The Contractor shall provide all laboratory instruments and equipment required for commissioning and operation of the Sulphuric Acid Plant.




The Contractor is required to appoint a commissioning manager independent of the Contractor’s construction manager.

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

3.14.1 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 and Approved by Owner Representative 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 and Approved by the Owner’s Representative. The Contractor shall submit all details of the Factory Acceptance Tests for the Owner’s Approval.

3.14.2 On Site Testing

The Contractor shall provide signed records and Approved by the Owner’s representative, test sheets for the following stages of site commissioning:

• Construction verification • Testing including electrical energisation • Function testing • Process commissioning.

3.14.3 Commissioning Plan

The Contractor shall provide a commissioning plan for review and Approval by the Owner’s Representative, no later than 25 weeks after Commencement Date.

As a minimum the commissioning management plan shall contain details regarding:

a. Off-site Testing b. FAT (E&I) – Very comprehensive, until all coding, sequences, I/O, tags and connectivity have been

proven c. Pre-commissioning d. SAT (E&I) e. Cold commissioning f. Hot commissioning

i. Water and simulation material ii. Hot commission with product and normal feed inclusive of steam export iii. Acceptance of material and production iv. Ramp-up

g. Taking-Over Certificate h. Performance tests i. Emission compliance test j. Ramp-up




k. Performance test certificate

For each step in the sequence, a Punchlist shall be compiled by both the Contractor and Owner. Depending on the rating per item, the Contractor and the Owner may proceed to the next step in the sequence.

The commissioning plan shall address items including but not limited to:

• Safety • Integration into overall process plant commissioning plan • Role of commissioning manager • Commissioning manning histogram and schedule • Stages of commissioning • Punchlist after each commissioning stage • 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) • Commissioning procedures • Owner supplied deliverables (e.g. utilities, consumables, spare parts, etc).

3.15 SPARE PARTS, SPECIAL TOOLS AND EQUIPMENT

3.15.1 Spare Parts

The Contractor shall supply:

• Commissioning spares • Six months acid lining, catalyst top-up (if needed) and ceramic replacement • Materials and consumables as per Section 3.2.8 • Full set of refractory material • Full set of wear liners c/w drawings • All two year spares excluding items nominated above.

The Contractor shall hand over all of the remaining/unused abovementioned equipment, materials and consumables to the Owner after the issue of the Taking-Over Certificate.

The Contractor shall provide a priced spare parts schedule which nominates categories of spare parts and specific details for each spare part.

Spare Parts categories are:

• Commissioning spares including catalyst first fill (including excess) • Two year spares • Operation and maintenance consumables • Insurance spares (critical to the operation or long lead items).

The Contractor shall provide a Spares Price List for shortfall purchases by the Owner prior to the issue of the Taking–Over Certificate. The spares prices shall be DDP (as defined by Incoterms 2010) and valid until the date of issue of Taking-Over Certificate.




3.15.2 Special Tools and Equipment

The Contractor shall provide all special tools which may be necessary for the Works, including commissioning, on-going operation and maintenance of the Sulphuric Acid Plant. The Contractor shall hand over all of the remaining/unused special tools to the Owner after the issue of the Taking-Over Certificate.

3.16 SITE ASSISTANCE

3.16.1 Inclusion

The Contractor shall provide a schedule of engineering man-hour rates for ongoing site assistance for a period of up to six months after the issue of the Taking-Over Certificate. It shall exclude Works in section 3.16.2. The schedule shall include as a minimum an engineer, control system programmer, a process engineer and an operational support person.

3.16.2 Exclusion

Site assistance does not relieve the Contractor from completion of Works as set out in the Contract. The work referenced in the paragraph will typically be after rectification of Defects on the Punchlist, achievement of the Performance Certificate and obligations under the warranty.

3.17 TRAINING

The Contractor shall provide training for the Owner’s process and maintenance technicians in the appropriate methods of plant operation and maintenance under normal and emergency operating conditions. The IOM manuals shall be issued (Note; ‘Issued for Owner Approval’) prior to commencement of training, to provide the Owner’s personnel an in-depth understanding of the Sulphuric Acid Plant inclusive of the location and function of each piece of equipment. The Contractor shall submit draft versions of the IOM to the Owner for comment and Approval. The Contractor shall incorporate all comments and revise the content of the IOM as required to meet the satisfaction and final Approval of the Owner. Final versions of the IOM shall be provided by the Contractor after Owner comments, post training, are incorporated and Approved by the Owner.

The purpose of the training is to instruct the Owner’s personnel in the safe and efficient operation and maintenance of the Sulphuric Acid Plant facilities under normal and emergency operating conditions.

The Contractor shall submit a thorough, competency based training program for Approval by the Owner’s Representative. This training programme shall be inclusive of an extensive set of training materials such as presentations, educational manuals, and written competency tests/examinations. The competency tests shall be designed so that upon passing the tests, the Owner’s personnel shall be deemed by the Contractor and the Owner as being fully competent to operate and maintain the Sulphuric Acid Plant under normal and emergency conditions. The Contractor shall ensure that the competency based training program shall enable operational personnel to be deemed competent as per the requirements in the Work Health and Safety (Mines and Petroleum Sites) Regulation 2014, upon successful completion of the aforementioned tests.

As part of the Works, the Contractor shall carry out a minimum of 200 hours for site classroom and in-Plant training in accordance with the Approved by the Owner’s Representative, competency based training program for the Owner’s process and maintenance technicians. The Installation, Operating and Maintenance (IOM) manuals shall only be used as supplementary reference material for the training program.




3.18 PERFORMANCE GUARANTEES

3.18.1 Absolute Guarantees

The Absolute guarantees that the Sulphuric Acid Plant shall achieve are summarised in Table 1.

Table 1 Absolute Guarantees

Absolute guarantees Unit rates Guaranteed values Duration Rated sulphuric acid production capacity (nameplate capacity) tonnes per day

2 700 (on 100% H2SO4 basis)

48 hours continuous test period

Achievement of emissions certification at nameplate capacity


3.18.2 Primary guarantees

The Primary guarantees that the Sulphuric Acid Plant shall achieve are summarised in Table 2. Table 2 Primary Guarantees

Table 2 Primary Guarantees

Primary guarantee Unit rates Guaranteed values Duration

Sulphur Melt Rate tonnes per day 130 % of design capacity

(Vendor to confirm sulphur melt rate value)


Rated Sulphuric Acid Production Capacity (Nameplate Capacity) tonnes per day

2 700 (on 100% H2SO4 basis)


Minimum Sulphuric Acid Strength % Instantaneous

Never less than 98.3% 100 hours continuous test

period

Sulphuric Acid Strength % Average of ≥ 98.5 % 100 hours continuous test period

Minimum High Pressure Superheated Steam Production Rate

tonnes per hour @ 100%

production

As per quoted generation from Contractor’s

technology


Minimum Medium Pressure Saturated Steam Production Rate

tonnes per hour @ 100%

production


technology


Minimum High Pressure Superheated Steam Conditions kPa(g) at X ºC


technology


Minimum Medium Pressure Saturated Steam Conditions kPa(g) at X ºC


technology


Environmental emissions compliance As per Table in Section 9.3.7

Minimum catalyst conversion performance (SO2 → SO3) % SO2 > 99.8%

3 years before catalyst screening is required

(Refer to Primary Guarantee)




Primary guarantee Unit rates Guaranteed values Duration Availability This includes breakdowns, planned shutdown, refractory and catalyst replacement. Thus, total plant online time, regardless.

Hours based >95% of total hours in one year.

One year spanning over a shutdown event

Plant downtime (Excluding planned inspections, refractory and catalyst screening as well as occasions when there is a shortage of prilled sulphur or when the acid product storage tanks are full)

hours <20 hours per year One year

Turndown ratio % of Nameplate Capacity

As per Contractor’s capability


Primary Guarantee Notes:

The sulphur melting plant shall be capable of melting sulphur at the rate specified in Section 9.3.1 for a continuous period of 100 hours based on a lime dosed sulphur feed.

The Sulphuric Acid Plant shall be capable of producing sulphuric acid at the rate specified in Section 9.

The product acid quality shall be as specified in Section 9.

SO2, acid mist (as 100% H2SO4 basis) and NOx emissions from the Sulphuric Acid Plant tail gas stack shall be as specified in Section 9.

Steam production rates, pressures and temperatures for HP superheated steam and MP saturated steam as specified in Section 9.

Emission volume, temperature and exit velocity shall conform to third party environmental study recommendations. Air dispersion modelling will be provided by the Owner for detailed design.

The catalyst life shall be guaranteed such that the minimum SO2 to SO3 conversion performance shall be met at any time during normal operation for a period of three years before any catalyst maintenance is required.

The Contractor shall advise suitable catalyst life to meet the SO3 conversion criteria before screening is required, given the catalyst technology being offered.

3.18.3 Secondary Guarantees

The following secondary guarantees shall be provided for:

The Secondary Guarantees that the Sulphuric Acid Plant shall achieve are summarised in Table 3.

Table 3 Secondary guarantees

Secondary guarantee Guaranteed values Duration Acid mist concentrations at the exit of the Drying Tower and Intermediate Absorption Tower

Moisture content in the gas leaving the Drying Tower NOX concentration in the tail gas stack




Secondary guarantee Guaranteed values Duration Utilities and services consumption at the battery limits Maximum acid temperatures to the product acid storage tanks

Minimal increase in pressure drop across the plant during two years of continuous operation

Heating up of the sulphur furnace and converter from cold conditions to operating temperature in no more than 48 hours

The maximum hydrocarbon content allowable in the feed sulphur entering the furnace.

Sulphur melter stack H2S emissions Sulphur melter stack NOx emissions Sulphur melter stack SO2 /SO3 emissions Sulphur melter stack particles emissions

The Contractor shall submit with its tender bid the Secondary Guarantee values that it will offer. The Contractor shall review the Secondary Guarantee parameters for Approval by the Owner’s Representative.

3.18.4 Performance Assessment against Guarantees

Following successful commissioning, performance acceptance testing shall be conducted to measure the performance of the plant against the absolute, primary and secondary guarantees detailed above. The Contractor shall submit procedures for these guarantee runs to be reviewed and approved by the Owner.

3.19 RESPONSIBILITY MATRIX

Refer to Appendix E for the responsibility matrix.

3.20 WARRANTY

Regardless of delivery date, all equipment shall be covered by a warranty of not less than twelve months from the issue of the Taking-Over Certificate. Under the Terms and Conditions, the twelve months may be extended.

4 OPTIONAL WORK

The Contractor’s tender shall conform to the requirements of this document. The Contractor may supplement the base tender package with alternatives provided that they offer significant advantages with respect to capital cost, operating cost, delivery schedule, safety, quality, reliability or suitability for a specific service. However, it is mandatory that the equipment shall be capable of meeting the duty and throughput rates outlined in this document.

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

The Contractor may offer the following as optional items complete with fixed and firm pricing:

• An intelligent 3D Building Information Model (i.e. BIM) • The specification, supply and installation of the laboratory instruments and equipment typically used for

sulphuric acid plant laboratories.




• Should the Contractor be of the opinion that the dilution and emergency air damper prior to the catalyst is not needed, a take-out price may be offered for consideration by the Owner. The default option shall be the dilution and emergency system being included as part of the SOW.

• Sulphuric acid storage and loading facility. The draft SOW for this turnkey package is available upon request from the Owner’s Representative.

• Cogeneration plant. The draft SOW and datasheet is available upon request from the Owner’s Representative.

• Contractor to nominate a separable portion complete with a take-out price for Site assistance after issue of the Taking-Over Certificate as per section 3.16.1. The Contractor shall provide a schedule of engineering man-hour rates for ongoing site assistance for a period of up to six months after the issue of the Taking-Over Certificate. It shall exclude Works in section 3.16.2. The schedule shall include an engineer, programmer, a process engineer and an operational support person.

• Turndown ratio: It is mandatory for the Sulphuric Acid Plant to achieve a turndown ratio of 40% of Nameplate Capacity. The Owner’s preference is for a Plant turndown ratio of 30%. The Contractor shall provide a technical proposal complete with a price to achieve a turndown ratio of 30%

• Contractor to nominate a separable portion complete with take-out price for the control system, to allow the Owner to consider the integration of the control of the supplied equipment into the Site wide plant control system

• Contractor to provide a separable portion c/w take-out price for the stack to allow the Owner to adjust the height to meet environmental requirements

• Direct acid cooling system inclusive of all associated requirements as per section 9.3.5

5 OWNER SUPPLIED MATTERS

The following items are excluded from the Scope of Work:

5.1 ENGINEERING AND SERVICES

• Environmental impact assessment (EIA) and environmental licensing (Contractor to provide information) • General site risk study outside this plant’s geographical area • Soil testing and grading plan, subject to section 10.2 • East-West and North-South perimeter piperacks and associated footings, structural steel, piping and

cables and cable supports. For clarity, piperacks, footing, structural steel, piping, cables and cable rack inside the Plant shall be provided by the Contractor.

• Dust suppression of the main roads at the perimeter of the Sulphuric Acid Plant • Site survey datum points • Air dispersion model (plume study).

5.2 FREE ISSUE ITEMS

• Fibre optic cable between the Sulphuric Acid Plant control system and the main plant control system. The Contractor shall supply and install the fibre transceivers and its panel. The Owner will terminate the fibre to the Contractor’s fibre transceivers or ports inside the acid plant. Commencement of communication flow during cold commissioning

• First fill concentrated sulphuric acid at the Sulphuric Acid Plant storage tank • 11kV power during hot commissioning. The Contractor shall provide 11kV power during all Works

before hot commissioning. • Demineralised water required for waste heat boiler flushing, boil out and passivation. The Contractor

shall provide details of the quantities, water specification and schedule of usage. • Area for the Plant construction complete with earthwork backfilled to grade




• Site accommodation and messing as per the schedule Approved by the Owner’s Representative • Area of laydown 50m x 50m • Area for site offices10m x 5m • The use of an on-site batching plant.

5.3 OTHER EXCLUSIONS

• Site access and clearing prior to mobilisation • External roads, external perimeter drainage and external underground services • Sulphur handling including receiving, stockpiling and reclaiming systems prior to the feed into the

sulphur dosing system • Acid storage, truck unloading and distribution downstream of the Sulphuric Acid Plant other than the

PCS interface • Road access to the construction site • CCTV’s. Note: CCTV support brackets shall be designed, supplied and installed by the Contractor. • Dual 11 kV power incomer cables • Provision of all service streams feeding the Sulphuric Acid Plant up to the battery limit connection points

discussed in section 6 of this Scope of Work • Provision of all pipework for discharge streams beyond the battery limit connection points discussed in

section 6 of this Scope of Work • Front-end-loader for the sulphur filter cake disposal during commissioning. Thus, all other vehicles,

other than this front-end-loader shall be provided by the Contractor. • Owner’s risk matrix. The completion of the SIL determination, functional safety, actions and approvals

for use shall remain with the Contractor. • Site assistance after issue of the Performance Certificate as defined in section 3.16.

6 BATTERY LIMITS

The Sulphuric Acid Plant has been designated as Area 5130. The Sulphuric Acid Storage and Unloading facility has been designated as Area 5140. The Cogeneration plant has been designated as Area 6120. These areas are indicated in the Process Plant Area Key Plan Dwg No. 140316-0000-45D1-0004. The locations and dimensions of those areas are nominal, but any changes of consequence must be justified in writing and Approved by the Owner’s Representative.

The Contractor shall coordinate and perform all connection Works at each battery limit.

The Contractor shall design, supply, install and commission all flowmeters and flow transmitters at each battery limit for all fluids.

The site will be provided cleared and levelled, with peripheral access roads and piperacks provided by Owner. The footprint allowed for the Sulphuric Acid Plant on site is nominally 70 m by 100 m.

The Sulphuric Acid Plant will be skirted by a major piperack (by the Owner) along the northern side within which the tie-ins to the services listed below shall be achieved.

Tie-in locations for power, communications and pipeline services are as follows:

NOTE: Line sizes nominated below are indicative only (Contractor to advise any recommended changes)




Table 4 Input services and process lines terminal points for the Permanent Works

Service Location (TBD) 11 kV incoming power Two coiled cables in location on the piperack PCS FOBOT cabinet in MCC by Contractor

External multicore fibre cable supplied and terminated by Owner to the FOBOT for external communication FOBOT and transceivers by Contractor

Boiler feed water (Demineralised water)

In east-west piperack; Class 150, 100NB S/S gate valve

Reverse osmosis water In east-west piperack; Class 150, 100NB S/S gate valve Potable water In east-west piperack; Class 150, 50NB S/S gate valve Firewater In east-west piperack; Class 150, 150NB C/S gate valve Instrument air In east-west pipe rack on south side of Sulphuric Acid Plant; Class 150,

80NB C/S gate valve Diesel fuel In east-west piperack; Class 150, 80NB C/S ball valve Diesel fuel return line In east-west piperack; Class 150, 80NB C/S ball valve Natural gas Not available. None Sulphuric acid (for start-up) In east-west piperack; Class 150, 80NB S/S ball valve Start-up LP steam In east-west piperack; Class 150, 100NB C/S gate valve Sulphur (refer to Note 1)

At discharge head pulley of the prilled sulphur conveyor. Chute and transfer point by Contractor. Conveyor head-end structure will rest on the Contractor’s structure.

Hydrated lime (refer to Note 2)

Bulk bags at grade near the feed point of the hydrated lime addition system

Filter aid Bulk bags at grade near the feed point of the filter aid addition system Front-end loader Removal of sulphur impurities during operation at filter press discharge bin

Note 1: The bulk materials handling of prilled sulphur from truck unloading through to delivery into the sulphur melter is being addressed by another turnkey package with scope of work: Sulphur & limestone bulk handling, document no. 140316-5200-45EW-0925. This system will either feed the conveyor from the open stockpile or directly from the truck. Note 2: The requirements for hydrated lime addition to the prilled sulphur stream are detailed in Section 9.4.2 of this scope of work document.

Table 5 Output services and process lines terminal points for the Permanent Works

Service Location Cooling water return In east-west piperack; Class 150, TBD HP (superheated) steam In east-west piperack; Class 600, 200NB Cr/Mo flanged gate valve

(TBD) MP saturated steam In east-west piperack; Class 150, 300NB C/S gate valve (TBD) Concentrated sulphuric acid In east-west piperack; Class 150, 150NB S/S ball valve Process tail gas Discharge to atmosphere from tail gas stack Sump pump discharge In east-west piperack; Class 150, 80NB CSRL butterfly valve Boiler blowdown In east-west piperack; Class 80, 80NB C/S gate valve




Service Location Discarded sulphur cake (solid effluent) from molten sulphur filter

Discharge into a skip and bunker all supplied by the Contractor. Front end loader by Owner

Sewerage Concrete sewer below grade at south-east corner of Sulphuric Acid Plant 300NB

Potable water (return) In east-west piperack; Class 150, 50NB S/S gate valve Effluent (oil free) In east-west piperack; Class 150, 150NB HDPE diaphragm valve

7 REFERENCE DOCUMENTS AND STANDARDS

7.1 DRAWINGS AND SPECIFICATIONS

The Drawings and Specifications listed in Appendix C are included in this document as a separate bound volume.

It is the responsibility of the Contractor to source the latest revision of the above mentioned drawings and specifications for the project from the Owner’s Representative. The Owner’s Representative shall advise the Contractor of any new revisions of the drawings and specifications that may occur during the bidding period.

7.2 CODES, STANDARDS AND REGULATIONS

The Contractor shall comply with all requirements outlined in the documentation referenced/stated in this SOW. Documentation shall take the following order of precedence in descending order:

• Acts; • Regulations; • Standards; • Scope of Works; • Design criteria; • Specifications; • Drawings.

Acts, Regulations, standards, SOW, design criteria, specifications, drawings. Should there be any ambiguity or conflicting requirements identified in those documents, then the Contractor shall request clarification from the Owner in writing.

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 by the Owner’s Representative ISO, US 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.

The Contractor shall comply with the Protection of the Environment Operations Act 1997. Subject to the emissions plume study (by the Owner), more stringent requirements regarding emissions tolerances may be applied.




The Contractor shall comply with all workplace occupational health and safety regulations as enforced by the Resources Regulator for New South Wales, Australia. The Contractor shall comply with all aspects of the following New South Wales work health and safety legislation:

• Work Health and Safety Act 2011 • Work Health and Safety Regulations 2017 • Work Health and Safety (Mines and Petroleum Sites) Act 2013 • Work Health and Safety (Mines and Petroleum Sites) Regulation 2014.

The Site shall fall under the jurisdiction and requirements of the Act and Regulations of Australia within the state of New South Wales. The Site is classified as a mine site.

The Contractor shall be responsible for managing all risks and carrying out all interfacing Works associated with all other Syerston Project Works.

The regulations set out requirements for a risk management system. It contains existing requirements for manual handling, hazardous substances, noise control, certificates of competency, business licensing, injury reporting and OH&S Committees and introduces revised requirements for the working environment, plant safety, inorganic lead, and carcinogenic substances. The regulations also rationalises administrative arrangements such as those for exemptions and appeals.

Under Work Health and Safety (Mines and Petroleum Sites) Act 2013 No 54, Regulation, Part 1A, clause 8, the Contractor shall be appointed as either the operator as enforced under clause 8(1) (b) or the operator’s representative as defined in Part 1A, division1 Clause 8.

The Contractor shall manage all risks as defined in Part 2 Managing risks under the Work Health and Safety (Mines and Petroleum Sites) Act 2013 No 54, Regulation.

Under Work Health and Safety (Mines and Petroleum Sites) Act 2013 No 54, Regulation, the Contractor shall appoint persons as enforced by the regulations, schedule 10 statutory functions at mines, Part 5. Under this clause, the Contractor’s appointments shall be for the following personnel:

• Operator (mine manager’s representative) in accordance with all Acts and Regulations • Quarry manager • Mining surveyor • Electrical engineer (if equipment is rated greater than 1 MW) • Qualified electrical tradesperson.

In addition to the requirements of the Work Health and Safety (Mines and Petroleum Sites) Act 2013, the Contractor shall appoint all other Works safety related personnel such as:

• Radiation officer • Certified rigger (s) • Ventilation and confined space entry officer • Safety representatives.

The Owner has full authority to remove any of the Contractor’s personnel from undertaking any part of the Works should the Owner deem those personnel to not be competent under the requirements of the Work Health and Safety (Mines and Petroleum Sites) Regulations 2014 in New South Wales.




The equipment manufactured both locally and overseas shall comply with the relevant requirements of the current issues of the Syerston Project standards, specifications, drawings, data sheets as included in the Contract and updated from time to time, and other documentation listed in section 7 of this document. Any conflicts identified between the specifications or with the standards shall immediately be brought to the attention of the Owner’s Representative for resolution and Approval.

The Work shall conform to the latest edition of the Acts, Regulations, Standards and Codes included in the project drawings and specifications (Section 7.1) and those listed in Table 6.

Table 6 Frequently used standards

Standard Description ASME I BPVC Section I – Rules for construction of power boilers ASME II BPVC Section II – Materials – ferrous materials specifications ASME V BPVC Section V – Non-destructive examination ASME VIII Div 1/Div 2 ASME Boiler and Pressure Vessel Code Section VIII Division 1 Rules for

Construction of Pressure Vessels / Division 2 Alternative Rules ASME IX ASME Boiler and Pressure Vessel Code Section IX Welding and Brazing

Qualifications API 12F Specification for shop welded tanks for storage of production liquids API 650 Welded steel tanks for oil storage AS 1200 Pressure equipment AS 1210 Pressure vessels AS 1228 Pressure equipment – boilers AS 1271 Safety valves, other valves, liquid level gauges and other fittings for boilers and

unfired pressure vessels AS 1318 Industry safety colour code. AS 1319 Safety signs for the occupational environment AS 1359.5 Rotating electrical machines – general requirements part 5: three-phase cage

induction motors – high efficiency and minimum energy performance standards requirements

AS 1375 Industrial fuel fired appliances code AS 1418.1 Cranes, hoists and winches – general requirements AS 1554 Structural steel welding AS 1657 Fixed platforms, walkways, stairways and ladders AS 1768 Lightning protection AS 1940 Storage and handling of flammable and combustible liquids AS 2419 Installation of fire hydrants AS 2430 Classification of hazardous areas AS 2593 Boilers – unattended and limited attendance AS 3000 Electrical installations (Australian/New Zealand wiring rules) AS 3570 Automotive diesel fuel AS 3600 Concrete structures AS 3653 Boilers – safety, management, combustion and other ancillary equipment




Standard Description AS 3780 Storage and handling of corrosive substances AS 3873 Boilers and pressure vessels – operation and maintenance AS 3892 Boilers and pressure vessels – installation AS 3920 Pressure equipment conformity assessment AS 4024.1 Safeguarding of machinery – general principles AS 4041 Pressure piping AS 4100 Steel structures AS 4323 Stationary source emissions: selection of sampling positions AS 4343 Pressure equipment – hazard levels AS 4761.1 Competencies for working with electrical equipment for hazardous areas AS 5131 Structural steelwork - fabrication and erection AS IEC 60079 Electrical apparatus for explosive gas atmospheres AS IEC 61508 Functional safety of electrical/electronic/programmable electronic safety-related

systems AS IEC 61511 Functional safety – safety instrumented systems for the process industry sector AS IEC 62061 Safety of machinery – functional safety of safety-related electrical, electronic and

programmable electronic control systems. NOHSC: 1007 National standard for occupational noise NACE SP0294 – 2006 Design, fabrication and inspection of tanks for the storage of concentrated sulphuric

acid and oleum at ambient temperatures NACE SP0391 – 2016 Materials for the handling and storage of concentrated (90% to 100%) sulphuric

acid at ambient temperatures NSW Dangerous Goods Act and Regulations Building Code of Australia and NCC 2017 ASME B16.5 Pipe flanges and flanged fittings ASME B16.47 Large diameter steel flanges ASME B31.1 Power piping ASME B31.3 Process piping ASME B73.1 Specification for horizontal end suction centrifugal pumps ASME B73.2 Specification for vertical in-line centrifugal pumps ASME-STS-1 Steel stacks API 520 Sizing, selection and installation of pressure relieving devices in refineries API 521 Pressure relieving and depressurising systems API 610 Centrifugal pumps for petroleum, petrochemical and natural gas industries API 660 Shell and tube heat exchangers API 661 Air cooled heat exchangers ISO 15926 Industrial automation system and integration: Integration of life-cycle data for

process plants including oil and gas production facilities TEMA Standards Standards of the Tubular Exchanger Manufacturers Association




Where there is no applicable Australian Standard the appropriate ISO, British, German, American or other Approved standard shall apply. The use of standards other than the Australian standards is subject to Approval by the Owner’s Representative. The order of precedence shall be:

• Australian standards • ISO standards • American (US industry standards) • German (DIN) standards • British • Other codes – subject to Approval by the Owner’s Representative.

7.3 LANGUAGE AND MEASUREMENT SYSTEM

All designs, drawings, specifications and correspondence shall be in the UK English language.

All dimensions on drawings, calculations, specifications and correspondence shall employ the SI system using MKS engineering units.

Normal conditions (Nm3) refer to a temperature of 0°C and a pressure of 101.3 kPa (absolute).

All references to tonne and/or t shall imply 1 000 kg.

8 OPERATING ENVIRONMENT

Refer to the Project Specification Document Number 140316-0000-40EG-0001.

9 DESIGN CRITERIA

The Sulphuric Acid Plant shall be designed to be suitable for continuous operation during long campaigns and to facilitate servicing and maintenance. In the design, importance shall be given to simplicity, accessibility and durability of the equipment and parts. The design shall incorporate all safety provisions required for the operation and maintenance of the Sulphuric Acid Plant.

The Sulphuric Acid Plant shall be designed to operate satisfactorily under all anticipated process variations of load, pressure and temperature and climatic conditions.

9.1 PROCESS DESCRIPTION

The purpose of the Sulphuric Acid Plant is to supply sulphuric acid and steam to the pressure acid leach area and the process plant. Excess high pressure superheated steam and medium pressure steam will be used to generate electricity in a steam turbine generator (by the Owner) for the site.

Sulphur will be received at the battery limit, melted, filtered and delivered to a molten clean sulphur storage tank. Molten sulphur from storage will be pumped to the sulphur furnace where it will be burned in the presence of dry process air provided by a blower. The Contractor shall be responsible for the process of delivering the air to the sulphur furnace. The gases will be cooled in a waste heat boiler and delivered to the contact section where commercial grade sulphuric acid of 98.5 % H2SO4 strength will be produced.

The design criteria in this document are based on the supply of a four pass, double contact, double absorption type acid plant that generates superheated high pressure steam from process gas heat recovery and saturated medium pressure steam from acid cooling heat recovery.

Alternative flowsheets can be proposed by the Contractor, but will only be considered if a tender bid conforming to this specification is also submitted. These offers have to be clearly highlighted in the tender bid.




9.2 OPERATING PHILOSOPHY

9.2.1 Sulphur Melting, Filtration, Burner, Conversion and Acid Production

The Sulphuric Acid Plant and melting facilities are required to operate continuously to meet the demands of the adjacent pressure acid leach plant. It is a requirement that there be minimal (<20 hours per annum) downtime outside of the required and planned catalyst screening shutdowns or statutory boiler inspections. Major mechanical equipment shall have a duty and standby configuration.

Strategic instruments such as pH monitoring shall facilitate on-line cleaning e.g. duty and standby pH monitoring equipment. All equipment and processes shall be free from fugitive gases and dust emissions

The melter and sulphur burner shall be self-cleaning. The Plant design shall eliminate the removal or cleaning of all vessels using labour or mobile equipment. This plant will only be stopped to replace refractory lining.

The Sulphuric Acid Plant shall be designed with a maximum amount of automation to eliminate the requirement for operators and minimise shift manning for maintenance technicians. The Contractor shall provide an estimate of the manning levels required for the operators and maintenance personnel for the plant based on operator performance in OECD countries.

The Works shall allow for the safe removal of sulphur impurities using a front-end loader, regardless of the sequence of the filter and with the filter on-line.

The Sulphuric Acid Plant shall have an adequate quantity of accessible sampling points throughout the facility in order to carry out quality control and emissions control activities.

9.3 DUTY AND DESIGN CRITERIA

9.3.1 Sulphur Melting, Filtration and Storage

The Sulphuric Acid Plant shall have a rated sulphur melting capacity which is 130 % of the design capacity.

The dirty molten sulphur storage tank shall be sized for 2 days of operation.

The filtered molten sulphur storage tank shall be sized for 5 days of operation.

9.3.2 Rated Production Capacity

The Sulphuric Acid Plant shall produce 2 700 tonnes per day of acid on a 100 % H2SO4 basis. The strength of the product sulphuric acid shall be 98.5 % ± 0.2 %.

9.3.3 Sulphuric Acid Product

Product sulphuric acid shall be delivered to the battery limit connection point for the acid storage tanks at a nominal temperature of 40 °C and pressure of 300 kPa(g) and be not less than 98.3% concentration of H2SO4.

9.3.4 Steam Production

High Pressure (HP) superheated steam and Medium Pressure (MP) saturated steam shall be produced and delivered from the Sulphuric Acid Plant to the battery limit. The Contractor shall provide in its Tender offer the HP superheated steam and MP saturated steam production capabilities (i.e. refer to steam pressure and temperature table below) of the Sulphuric Acid Plant given the technology it has chosen to utilise.




Table 7 Steam Production

Pressure Temperature HP Superheated Steam Normal X kPa(g) X °C MP Saturated Steam Normal Y kPa(g) Y °C

Data shall be quoted as gross and nett steam output, after steam and energy consumed by the Sulphuric Acid Plant has been deducted.

Recovery of HP superheated steam and MP saturated steam is to be maximised at their required pressure and temperature. The Contractor shall provide in its Tender offer, the anticipated steam production rates at the Sulphuric Acid Plant battery limit as per the following:

• >X t HP superheated steam per t acid, 100% H2SO4 basis • >Y t MP saturated steam per t acid, 100% H2SO4 basis.

The process plant requires HP saturated steam at nominal 6 000 kPa(g). This can be provided directly from the Sulphuric Acid Plant (by Contractor) or provided by de-superheating a portion of the export HP superheated steam produced (de-superheating by the Owner). The nominal requirement would be typically 52 t/h HP saturated steam (~41 t/h HP superheated) at full process plant production rates. The steam consumption will be half that when one process train is shutdown, but acid consumption would also be halved requiring a reduction in acid plant production rate. Under a single process train shutdown scenario, the acid plant would not run in excess of 85% capacity due to turbine limitations, but would typically be near to 50% capacity to match the acid being consumed.

9.3.5 Cooling

All coolers shall be provided by the Contractor for the cooling of acid and any other processes. As a minimum, the Contractor shall provide cooling systems for direct acid cooling, final acid product temperature trim cooling and blower bearing cooling. For acid cooling, direct fin fan coolers shall be used.

The Contractor shall limit the use of a hybrid wet/dry cooling system for acid product trimming cooling and blower bearing cooling. This hybrid wet/dry cooling system shall be provided with a closed cooling tube bundle and a wet open circuit with fans. The complete system, pumps, bleeds and chemical dosing system supplied by the Contractor shall be constructed inside a bunded area.

The Sulphuric Acid Plant and its cooling systems shall be capable of delivering acid to the acid storage tank at a nominal temperature of less than 40°C.

General Requirements

• Anodic protection shall be avoided • Noise attenuation and fan cowlings shall be used • The fin fan cooler system for product acid cooling shall be a standalone cooling system • The fin fan cooler system for product acid cooling shall be contained within an acid proofed concrete

bunded area and all associated Works shall be done by the Contractor • For Operating Environmental data refer to section 8.




Hourly readings of weather data for the last 25 years from the Condobolin Agricultural Weather Station for the Bureau of Meteorology Australia is available upon request for the Contractor’s use. This weather data covered air temperature (dry bulb), wet bulb temperature, dew point and relative humidity. Table 8 summarises the distribution of wet and dry bulb temperatures from this set of weather data.

Table 8 Distribution of maximum wet and dry bulb temperatures

Hourly Readings Dry Bulb Temperature (°C) Wet Bulb Temperature (°C) Absolute Maximum 46.4 28.6 99% Percentile 37.1 22.0 95% Percentile 32.2 20.0 80% Percentile 25.0 16.7

9.3.6 Turndown

The Sulphuric Acid Plant shall be designed for a turndown to at least 40% of Nameplate Capacity to 1080 t per day. A turndown of 30% or 810 t per day is preferred.

9.3.7 Emissions

Following emission parameters and requirements or better than those specified shall be met at stack discharge prior to atmospheric mixing.

Table 9 Emissions

Pollutant Maximum

Concentration (dry, 273 K, 101.3 kPa)

Monitoring Frequency

Requirements1

Minimum Stack

Height (m)

Stack Diameter (m)

Main stack Sulphuric acid mist (H2SO4) plus sulphur trioxide (SO3) [as SO3 equivalent]

≤ 45 mg/Nm3 Periodic 80 Contractor to advise

Sulphur dioxide (SO2) Contractor to advise Continuous Nitrogen Oxides (NOx) X ppm v/v (Contractor to

advise emissions capabilities)

Continuous

Temperature - Continuous Moisture - Continuous Flowrate - Continuous Oxygen - Continuous Sulphur melter stack Volume Temperature Moisture H2S SO2 / SO3




Notes: 1. For all emission points listed, periodic monitoring of velocity, volumetric flowrate, temperature, moisture, dry gas

density/molecular weight of stack gases and oxygen is required. AS1657 compliant access platforms and sampling points compliant with AS4323 shall be provided to facilitate the monitoring requirements.

2. Pollutant concentrations shall be met for all operation conditions excluding start up.

For evaluation purposes, the Contractor shall provide in its Tender submission, typical details of the emissions figures during plant start up and operation using its best available and proven technology.

9.3.8 Occupational Health and Safety

The Contractor shall comply with all requirements outlined in all Work Health and Safety Act and Regulations outlined in this Scope of Works with regards to noise levels, machine guarding and all design aspects of workplace safety in general.

Noise levels of equipment (any single source) 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). Should the noise level exceed as described in 9.3.8, the Contractor shall implement measures such as acoustic enclosure, attenuation or building for its Works to ensure that this criteria is met.

9.4 EQUIPMENT DESIGN

9.4.1 Sulphur Melting and Storage Plant

The Owner will provide a prilled sulphur feed conveyor. The Contractor shall receive prilled sulphur from the conveyor, add lime and deliver into the melter.

The melting facility shall be equipped with the following units:

• The sulphur melter shall be an above ground, circular, carbon steel tank or concrete tank, with agitator, vapour vent, steam heating coils and acid-resistant lining wherever a wet-dry tide line can occur as part of normal operation. The melter and filter feed system shall be designed to avoid accumulation of agglomerates and blockages which impede the flow of molten sulphur to the filtration stage. Large man ways and/or removable roof sections shall be available for maintenance access. The vapour vent shall be insulated and heat traced to minimise internal build-up of sulphur and sized to ensure negative pressure at the feed chute to prevent escape of steam and possible consequential chute blockages due to sulphur build up. Tie-in points for start-up LP steam and condensate return shall be provided at the battery limit. Contractor to nominate required nozzle sizes.

• All assembled agitators shall be removable from outside and without emptying a vessel/tank and shall be fitted with stainless steel or suitable shaft protection sleeves. The melter shall have adequate freeboard to accommodate foaming when handling sulphur with high moisture content.

• All heating shall be of the external bare tube design. Alternative heating system arrangements shall be submitted to the Owner for review and Approval. Internal elements shall be removable through the roof from the outside and without emptying of a vessel/tank. Consideration shall be given to upgraded materials of construction to resist external acid corrosion of the heating coils and elements.

• Dirty liquid sulphur storage tank, fully insulated, complete with agitator, pumps and LP steam coils or internal blades. Foreign matter or debris which could block sulphur pumps shall be removed by a basket screen at the dirty tank inlet. The basket screen shall be removable and cleanable from outside the vessel.

• Precoat tank, jacketed and insulated, complete with agitator, pump and filter aid feed facility • Dust control measures shall be provided at the bag splitting operation • Sulphur filter(s), jacketed and insulated. Two sulphur filter trains shall be provided. Each sulphur filter

train shall have sufficient capacity to filter the entire day’s requirement with a complete spare 100% filtration line available at all times.




• The sulphur filters shall be of the pressure-leaf type. Filter leaf carriages shall have back end scrapers to clean the shell bottom accumulations on opening. A mechanical interlock shall be provided to prevent accidental opening. The gasket shall be located on the head, rather than the body of the filter, so that it is less exposed to fouling as the filter discharges and to subsequent damage as the mating surfaces are cleaned prior to filter closure. The filter design shall satisfy the requirements of AS 1210 and shall be fitted with a pressure relief device if required. As an option, the Contractor may offer an automated horizontal press filter.

• The opening, cleaning and closing of the filters shall be accomplished without the use of labour. An enclosed area, with containment walls on three sides and safety gates on the fourth side for access, shall be provided to contain hot, molten filter cake and facilitate its removal by skip. A water spray system shall be provided to assist cooling of the filter cake and hose down water provided for washing down the area.

• All sources of filter cake, polishing filters, pre-coat spillage, candle filter cake and alike shall discharge into a removable skip, with no less than one day’s capacity, within a bunker to prevent any spillage from the skip, which is all to be supplied by the Contractor. This skip and bunker shall enable removal of the sulphur impurities and cake using a standard front-end-loader while the filter is in operation. The skip itself may be removed with a suitable forklift. The Sulphuric Acid Plant shall be designed to permit a standard front end loader and forklift to carry out these operations as well as enter and exit this area safely. The use and supply of a front-end loader will be provided by the Owner during the commissioning phase and operation of the plant. All other Works shall be provided by the Contractor. Other than the skip, splashing or build-up of filter cake on any structure, containment walls, flooring or any other Permanent Work is not permitted.

• Filter feed pumps shall have a pumping characteristic suitable for efficient precoating of the filter leaves and subsequent filtration of the molten sulphur

• Polishing filter; one polishing filter shall be provided to handle total production from the primary sulphur filters. The filter shall be installed to prevent blockage of feed nozzles in the event of leaf filter cloth failure or bypass and to ensure the guaranteed maximum plant pressure drop increase is not exceeded.

• The polishing filter shall be cleaned online by flushing with steam back to the dirty sulphur tank • Clean molten sulphur storage tank, insulated, complete with steam heating coils. This storage tank shall

be located as close as practicable to the sulphur furnace. The tank shall be above ground and clear access to all equipment shall be provided. The tank shall have stair access to the top of the tank and shall be provided with secondary egress routes. Vents shall be heat traced.

• Sulphur tank heat tracing shall be designed to prevent the formation of iron sulphide (pyrophoric) and igniting sulphur fires. The Contractor shall perform a computational fluid dynamics study to ensure that there are no cold spots in the sulphur tank (s).

• Sulphur distribution pumps. These shall be selected, supplied and installed so that sulphur can be pumped to the sulphur furnace. Sulphur pumps shall be heat traced.

• Sulphur melting area sumps and pumps • All piping shall be routed to optimise access to all areas and equipment and minimise obstructions • Steam pipe runs shall be designed to promote free draining of condensate to assist in eliminating cold

spots • Melter and all transfer points shall be actively maintained at a slight negative pressure following by an

off-gas scrubber and stack • All equipment shall be free from secondary gases and dust emissions • Snuffing steam shall be provided as required to extinguish fires in tankage containing molten sulphur • Properly designed and located steam-jacketed vent stacks of sufficient height shall be provided for all

tanks containing molten sulphur to avoid fumigation of working areas under all wind conditions and to avoid the potential for build-up of explosive atmospheres within all tanks.

• All tanks shall be insulated, heat traced and vented. Piping shall be heat traced or jacketed. • The Sulphuric Acid Plant shall be designed for ease of cold start-ups with minimal input by operations

personnel after an unplanned shutdown. All sulphur distribution piping shall be steam jacketed.




• Adequate and accessible sulphur sampling points shall be included. • All pumps shall be adequately sized to accept variability in sulphur viscosity.

9.4.2 Sulphur & Hydrated Lime Addition

A hydrated lime addition system complete with storage system shall be supplied by the Contractor. This will also include an offloading facility, storage and transfer.

Furthermore, a dosing system for the prilled sulphur (c/w hydrated lime) supplied to the sulphur melter shall be supplied by the Contractor.

The Contractor shall determine a suitable size and design for the prilled sulphur and hydrated lime dosing system.

All battery limit requirements for utilities and services for these systems shall be as per Section 6. Services and utilities not specifically nominated by the Owner shall be provided by the Contractor.

9.4.3 Sulphur Combustion

It is envisaged that the sulphur combustion area will be supplied with the following equipment items (as a minimum) which may be varied at the Contractor’s discretion to provide a fit for purpose offer:

• Incoming air filter • Drying Tower to remove moisture from the air using concentrated sulphuric acid • Main air blower(s) inclusive of VSDs. The main air blower(s) and inlet guide vanes shall be provided by

Siemens (KK&K) or Owner Approved equivalent. Blowers shall be fitted with surge control. • Sulphur furnace:

- A minimum of two temperature measuring devices shall be installed in the sulphur furnace, at least one of which shall be a thermocouple with a protective sheath proven reliable for the service

- Dry air-purged sight glasses shall be provided to allow observation of all burners - A rain shelter shall be provided over the burner platform - All burner instrumentation and electrics shall be located clear of any splash or drip of molten

Sulphur. • Diesel fired start up burner:

- The changeover from diesel to sulphur burning and vice versa shall be accomplished with a minimum of effort. Automated dampers shall be supplied and installed to prevent moisture from the atmosphere and combustion reporting to the catalyst. This shall include the diesel supply and return pipelines within the battery limits.

• Waste heat boilers complete with steam drum • Steam superheaters • Boiler feed water deaerator • Boiler feed water pumps • Blowdown flash drum • Blowdown cooler • Blowdown discharge pump • Economiser • Draft control, offgas cleaning and stack.




9.4.4 Catalytic Converter

It is envisaged that the sulphuric acid converter area shall be supplied with the following equipment items which may be varied by the Contractor, with Approval by the Owner’s Representative, in order to provide a fit for purpose offer.

• Converter – The Contractor shall provide an arrangement which best suits the intent of the plant design and shall be cost-effective. Internally placed gas heat exchanger and/or superheaters are acceptable. Heat retention capabilities of the contact section shall permit the plant to be re-started without use of preheating following sixteen hours standing time without burning sulphur.

• A platform shall be provided at each level for manhole access and for catalyst screening and on top of the converter for access to dampers and spades where applicable. A stair tower in accordance with AS 1657 shall be provided from grade to serve all platforms and to access instrumentation throughout.

• Superheater • Economiser • Hot interpass heat exchanger • Cold interpass heat exchanger • Intermediate absorption tower • Final absorption tower • Common acid pump tank(s) • Common acid pumps (with rack spare pumps as required) • Absorbing tower acid cooler(s) (cooling water provided by the Owner using fin-fan type coolers) • Boiler feed water preheater • Product acid cooler • Wet/dry hybrid cooling system for the blower bearings and the final acid product temperature trim • Product acid pump • Strong acid sump and pump • Strong acid drain pump • Tail gas stack complete with auto and manual emission monitoring.

9.4.5 Materials

The materials of construction for the Sulphuric Acid plant shall be suitable to meet the required plant availability and the shutdown requirements stated in section 9.2.

9.4.6 Analysis and Monitors

The Contractor shall provide analysis and monitoring equipment and instrumentation for:

• H2SO4, SO2, NOX, O2, flow, temperature and particulates at all stacks • SO2, O2 and gas flow at the converter inlet.

• All other process related analysis and monitoring equipment e.g. density meters

The Contractor shall provide all analysers, sampling systems and ancillary equipment (e.g. heat tracing) with a maximum level of diagnostics. When analyser damage or analysis errors could occur as a consequence of other equipment failures, the relevant analyser shall automatically shutdown and be isolated. The Contractor shall provide comprehensive calibration, maintenance and fault finding instruction manuals.




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

9.4.7 Plant Hygiene System

The Contractor shall provide a fume extraction system to aspirate the process locations where sulphur fume, sulphuric acid mist or sulphur dioxide gas emissions are likely. The fume extraction system shall include appropriate ducting, fans (if required) and gas scrubbing system.

9.4.8 Equipment Design Life

The major vessels and structures of the Sulphuric Acid Plant shall be designed for a life of 25 years. Wearing parts of these vessels, such as brickwork and other items of equipment with moving parts, such as pumps, valves, etc. shall be designed for a maximum life commensurate with routine maintenance practices and subject to normal wear and tear.

9.4.9 Vessels in Bunded Areas

All vessels containing any process fluids shall be situated within concrete bunds. The Contractor shall ensure that the requirements under AS 3780 and AS 1940 (Note: inclusive of all standards referenced in AS 3780 and AS 1940) is complied with especially in relation to the height of the bund wall and the minimum containment volume.

9.5 PREFERRED EQUIPMENT

The Contractor shall submit a list for Approval by the Owner’s Representative of prospective suppliers for the following classes of equipment (Note: The country of manufacturing origin and manufacturer’s details shall be provided for Approval by the Owner). This can typically include:

• Atmospheric storage tanks • GRP vessels and piping • Filters • Pressure vessels and boilers • Heat exchangers • Valves • Special alloy pipe work • Refractory, acid resistant tiling • Pumps.

Main air blower(s) shall be provided by Siemens KK&K or Owner Approved equivalent.

9.6 UTILITIES AND SERVICES (PERMANENT WORKS)

All supply pressures are specified relative to grade level for the Sulphuric Acid Plant.

9.6.1 Boiler Feed Water (Demineralised Water)

Demineralised water will be supplied to the Sulphuric Acid Plant battery limit at a pressure of 300 kPa(g) under normal condition, (maximum 400 kPa(g), minimum 250 kPa(g)), for use as make-up to the boiler feed water system.




9.6.2 Reverse Osmosis Water

RO Water (RO second permeate) will be supplied to the Sulphuric Acid Plant battery limit at a pressure of 300 kPa(g) under normal condition (maximum 400 kPa(g), minimum 250 kPa(g)) for acid dilution.

9.6.3 Potable Water

Potable water will be supplied at the Sulphuric Acid Plant battery limit at a pressure of 400 kPa(g) under normal condition (maximum 600 kPa(g), minimum 350 kPa(g)) and a normal temperature of 25 °C and a maximum temperature of 50 °C.

9.6.4 Raw Water

Raw water will be supplied at the Sulphuric Acid Plant battery limit at a pressure of 300 kPa(g) under normal condition (maximum 400 kPa(g), minimum 250 kPa(g)) and a normal temperature of 25 °C and a maximum temperature of 50 °C.

9.6.5 Incoming Electric Power

A dual 11 kV +/- 10 %, 50 Hz, 3 phase, 3 wire, neutral point resistance earthed power supply shall be provided to a battery limit location specified by the Owner for connection into the Contractor’s provided main sub-station and switchroom.

9.6.6 Diesel Fuel

Diesel fuel shall be supplied to the Sulphuric Acid Plant battery limit at a pressure of 600 kPa(g).

The Contractor may utilise a typical low heating value of 36 MJ/L.

9.6.7 Sulphur

Prilled sulphur will be supplied at the inlet of the sulphur melter dosing system.

An allowance of 0.05% wt ash on a dry basis is to be made for contamination in transport from port to melter. This does not include any hydrated lime addition to be made at the melter.

Table 10 Sulphur (Indicative)

Constituents % Dry Tolerance % Sulphur Particle size Sulphur Melting Point Sulphur Pour Point % Moisture

9.6.8 Hydrated Lime

Hydrated lime will be added by the Contractor to the prilled sulphur prior to entry into the sulphur melter. The analysis of the hydrated lime supplied will be as indicated in Table 11.




Table 11 Hydrated Lime (indicative)

Constituents % Dry Tolerance Calcium Hydroxide Ca(OH)2 96.0 TBA Calcium Carbonate CaCO3 1.5 TBA Magnesium Oxide MgO 0.6 TBA Ferric Oxide Fe2O3 0.2 TBA Aluminium Oxide Al2 O3 0.3 TBA Silicon Dioxide SiO2 1.0 TBA Available Lime Index (as Ca(OH)2 ) 94.0 TBA

Residue (75µm) 1.0 TBA

Specific Gravity: 2.2 – 2.3 Bulk Density: 450 – 560 kg/m3 Moisture content

9.6.9 Instrument Air

Instrument air will be supplied to the Sulphuric Acid Plant battery limit and will also be used as plant air where required.

10 DETAILED TECHNICAL REQUIREMENTS

10.1 SITE

The proposed location for the Sulphuric Acid Plant is indicated in Dwg No. 140316-0000-45D1-0002: Mechanical General Plant Site Plot Plan. A plot plan showing contours is available upon request.

10.2 CIVIL WORKS, FOUNDATIONS AND BUILDINGS

The Site excavation and backfilling for the Sulphuric Acid Plant hardstands will be carried out by the Owner. The Works for this levelled graded pad shall include all earthworks verifications. The Contractor shall supervise the Owner’s civil Works Contractor as well as review and verify that the civil Works carried out by the Owner is acceptable for the Contractor carry out the remaining Works as required in the Contract.

Any detailed, buried services and finishing civil Works for the Sulphuric Acid Plant shall be carried out by the Contractor. The finishing civil Works shall be done with engineered fill. The Plant and internal road runoff and water drainage system shall be designed and constructed by the Contractor.

Detailed and finishing civil Works for the Sulphuric Acid Plant shall comply with 140316-0000-41EF-0001 and 140316-0000-41EF-0002. The Contractor shall implement quality control measures and verification during the backfilling of the area. Should the excavation and backfilling not comply with the standard, the Contractor has to notify the Owner to this non-compliance. Upon completion of the backfilling, the Contractor is to sign-off acceptance of the earthworks. The earthworks by the Owner will be to natural ground level (NGL). The profile will be flat with no more than 1% slope. The Contractor shall conduct tests to validate the backfilling compliance.

Should the Contractor require piling, additional backfilling, settlement allowance or compaction, installation of underground services, all changes and corrective actions shall be implemented by the Contractor. Profiling of the earthworks to be done by the Contractor. Filling-in of earthworks post underground services and concrete will be by the Contractor.




Engineering backfill material is available on a stockpile within 2km of the general site area. Backfill material will be backcharged by the Owner to the Contractor as per the rate in the Contract.

Suitable concrete protection shall be provided by the Contractor and shall include protective polymer coverings and acid resistant tiling for concreted areas.

The Contractor shall design, supply, install and commission all foundations, process slabs, bunds, sumps, sewers and drains within the Sulphuric Acid Plant site. This shall include works such as profiling, compaction, shuttering, formwork, pouring, vibration, quality control, rebar, curing, finishing and protection.

A preliminary borehole log which shows borehole log data (i.e. GABH104) is available from the Owner’s Representative. The location of this borehole (i.e. GH-03) is shown in the drawing ‘General Plant Site Geotechnical Plan Sketch 140316-0000-40DK-0005’, which is where the Sulphuric Acid plant is planned to be situated. It is the sole responsibility of the Contractor to verify the accuracy as well as the interpretation of the data provided.

An historical Geotechnical Investigation Report (March 2000) by Golders is attached in Appendix C.

Sumps and sump pumps shall be designed to be adequate for a 20 year storm event. The local operator control station shall be capable of housing all operator screens, operational computers and permanent tables. This control station shall also include two additional screens to be used only during plant commissioning. The plant and its road runoff water design and construction is to be by the Contractor

The Contractor shall arrange for any building, plumbing and wiring inspections required by the Lachlan Shire Council. The Contractor shall arrange any occupancy permits required by the Lachlan Shire Council.

10.3 STRUCTURAL

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

The Contractor shall maximise the use of fixed lifting devices. The Contractor shall provide suitably designed and certified cranes, monorails, davits or jib hoists to allow removal of machines and drives for maintenance. The use of a mobile crane for maintenance shall be avoided when possible.

The Contractor shall provide any temporary bracing required for transportation and lifting of tanks and structures. The Contractor shall clearly mark this temporary bracing and arrange for removal once the relevant equipment items are in position.

The Structural Design Criteria for the project is document 140316-0000-43EC-0001. However the Contractor is encouraged to use in-house standards and best practices that meet or exceed the guidelines and standards nominated within this Scope of Work document after receiving Approval from the Owner’s Representative.

The Project steel standard specifications refer to structural steel being fully compliant with relevant Australian Standards for materials, testing, fabrication and erection. The Contractor shall be responsible to demonstrate and document that the structural steel and building design, materials, fabrication, testing, assembly and erection is fully compliant with the Building Code of Australia and AS5131.

All structural steel shall be certified for impact energy greater than 34 J at 0°C.

In general cat ladders and vertical ladders will not be allowed, unless approved by the Owner.

Allowance to be made on the main stack for online gas analysis and well as monthly manual isokinetic sampling.




10.4 MECHANICAL

The Contractor is responsible for meeting the steam turbine manufacturer’s criteria for pipe cleanliness as well as cleanliness of process steam prior to export to the battery limit. Steam from outside the battery limits will not be available for use by the Contractor for steam blows. The Contractor must supply all temporary steam piping and valves. If required, the Contractor shall supply silencers for the steam blows.

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

All maintainable items, actuated equipment, and valving shall be readily accessible to personnel for operation and maintenance without the need of equipment such as ladders, step ladders, elevating work platforms and the like.

The Contractor shall design, supply and install all (plus an additional 5% amount) Fasteners throughout the Sulphuric Acid Plant.

10.5 PIPING

The Contractor shall provide all piping and ducting, fittings, piping and ducting specials, pipe and ducting supports, lining, insulation, surface protection, temporary spools and strainers, safety showers and eyewash units, gaskets and fasteners for all process and services piping and ducting systems within the Sulphuric Acid Plant battery limits.

The Contractor shall comply with Piping Design Criteria 140316-0000-46EC-0001, Piping Materials Specification Document 140316-0000-46-EG-0004, and the Manual Valves Specification Document 140316-0000-46-EG-0004. Should the Contractor seek alternatives to the criteria, or additional valves outside the specification, Approval shall be obtained from the Owner’s representative.

Manual and automated valves containing dangerous goods such as acid shall be designed to be operated with the operators outside the splash zone.

10.6 ELECTRICAL

The Contractor shall be responsible for the design, supply, installation, testing and commissioning of 11 kV switchgear, distribution transformers, HV and LV distribution, cabling (including power, control, analog, digital and fibre optic), drives, drive switching and control devices, process lighting, lightning protection, earthing (for power and instrumentation), battery backup.

A dual 11 kV feeder will be provided to the Sulphuric Acid Plant 11 kV switchgear. Design, supply and installation of the HV and LV substation, transformer yard, oil containment provisions, fencing and signage shall be part of the Contractor’s Scope of Work.

HV and LV substations shall be air-conditioned specifically to provide for the scrubbing of inlet air to remove air borne acid mist and SO2 which could corrode contactors and terminals.

The electrical design prepared by the Contractor shall address the issue of Hazardous Area zoning and the Contractor shall produce a set of zoning plot plans and elevation drawings. Motors installed in Zone1 or Zone 2 areas shall be Exd, gas group IIB or IIC (as specified), temp class T3.

The Contractor shall implement all requirements within the Design Criteria for Electrical Engineering, document number 140316-0000-47EC-0001. Should the Contractor seek alternatives to the criteria or the specification, prior Approval shall be obtained from the Owner’s representative.




The Contractor shall nominate emergency power requirements for instances where the plant power generation system trips out. The Contractor shall provide for devices and programming to enable power load shedding under conditions of reduced power availability.

The Contractor shall give due consideration to the identification of major access constraints (e.g. support structures for cable trays and junction boxes) which shall dictate the electrical installation Work schedule.

10.7 CONTROL AND INSTRUMENTATION

The Contractor shall be responsible for the design, supply, installation, testing and commissioning of all instrumentation, communication and control systems within the Sulphuric Acid Plant.

The PCS shall control the process under steady state condition, sequence start, sequence stop, emergency stop and power management.

The Contractor shall implement the criteria project Design Criteria for Field Instruments and Control Valves, document number 140316-0000-48EC-0001. Should the Contractor seek alternatives to the criteria or additional valves outside of the specification, prior Approval shall be obtained from the Owner’s Representative.

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

All instruments shall be installed in locations that are readily accessible for maintenance to personnel without the need of equipment such as ladders, step ladders, elevating work platforms and the like.

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

Supply and use of wireless instrumentation may be used upon request, with Approval by the Owner.

It is envisaged that there shall be a single PCS system across the Plant which shall be designed according to 140316—0000-48ES-0001. Whilst the Sulphuric Acid Plant will in the long term be controlled from the Central Control Room, the Contractor’s system design shall allow for the installation of a fully functional autonomous system which shall 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.

Prior to hot commissioning using product (refer to section 3.14), the Contractor, shall transfer control to the PCS in the central control room and the local node shall be removed. The Contractor shall declare tags on the control system and make it available on the IT layer, information on the Scada layer and/or control layer for use between the central control system and local control system. This information and permission between the acid plant and the plant outside this scope perimeter shall be used for interlocks, overall plant control, power management, safety circuits and alike.

The Contractor shall ensure that sufficient resources are allowed to perform the PCS Factory Acceptance Test (FAT) and the PCS Site Acceptance Test (SAT) in accordance with Section 3.14. The personnel nominated for this Work shall be fully conversant with the Sulphuric Acid Plant functional description.

Dampers, including the start-up dampers, shall be air actuated.

10.8 SURFACE PROTECTION

The Contractor shall specify protective coating systems for equipment and areas within the Plant.

Carbon steel vessels and piping with anodic protection shall be avoided. Alternative and suitable materials of construction shall be utilised for such equipment.




The Contractor 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:

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

10.9 EQUIPMENT IDENTIFICATION, MARKING AND LABELLING

Equipment numbering shall be in accordance with the Owner’s Representative’s Drawing Standards. Equipment items shall be numbered from North to South and from East to West. Numbering and labelling should be clear and easily visible. Large vessel and equipment items shall be labelled in 150 mm high letters; where labelling is over cladding the labelling shall be by removable signage.

The Contractor shall provide adequate signage warning plant personnel of the hazards within the Sulphuric Acid Plant Area and its roads.

All equipment shall be uniquely identified by hard stamped or engraved numbering system at an accessible position for quality assurance, life cycle management and inventory management. As a minimum the tag shall be stamped with the Client Representative’s equipment number, the equipment name, the manufacturer’s name, the equipment model number, materials of construction, capacity, speed (if relevant), motor kW rating (if relevant), the serial number, recommended lubricants and the date of manufacture with letters not less than 8 mm high in English. Nameplates shall be 3mm thick 316 SS plate.

All safety and information signage shall be provided and shall be in accordance with AS1319. These signs shall generally advise workplace health and safety and other statutory requirements/obligations and site-specific requirements.

All pumps shall have a direction of rotation arrow indicated on a plate mounted close to the drive units.

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 is placed on 316 S/S junction boxes and is spot-welded, then the welds shall be passivated.




APPENDIX A CONTRACTOR’S QUALITY SYSTEM

In the context of the quality system requirements detailed herein, the word ‘Contractor’ shall be taken to embrace Contractor, Subcontractor, Consultant, Sub consultant, Suppliers, Contractors 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 Contractor 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 Contractor shall maintain throughout the life of the Contract a quality system that complies with the requirements of the particular Standard nominated in Table 12 or with a comparable alternative Standard.

Table 12 Quality Rating Requirements

Denotes Required Standard Rating Requirements A AS/NZS ISO 9001: 2016

X B AS/NZS ISO 9002 C AS/NZS ISO 9003

QUALITY SYSTEM DOCUMENTATION

The Contractor shall comply with the following requirements as indicated:

Table 13 Quality System Documentation Requirements

Document Description To be submitted for review 28 days from Commencement

Date

To be available for review on request

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

ACCESS

The Contractor shall provide the Owner’s Representative, and its agents, access to the Contractor’s and each of its Suppliers and Subcontractors quality systems to enable monitoring and quality auditing.

DEFECT/CORRECTIVE ACTION

If the Contractor discovers material or work which is not in accordance with the specification or Contract, the Contractor shall promptly initiate the non-conformance procedure required by the Contract, for Approval by the Owner’s Representative.




If the Contractor 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 Owner’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 and Defects which do not vary the requirements of the Specification or the Contract may be Approved by the Owner’s Representative.

QUALITY RECORDS

The Contractor 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 Contractor shall provide evidence of validation of the design that shall satisfy the requirements of AS/NZS ISO 9001 and as defined in AS/ISO 8402.

The Contractor 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 Contractor shall submit nominated Quality Records to Owner’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 Contractor to provide the Owner’s Representative with such originals, and the reasons for this are acceptable to the Owner’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 digital scanning or further copying.

PREPARATION AND SUBMISSION OF PROJECT QUALITY PLAN

A Project Quality Plan (PQP) shall be prepared by the Contractor where its quality system is required to comply with AS/NZS ISO 9001 or AS/NZS ISO 9002. The PQP shall supplement the Contractor’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 Contractor Inspection and Test Plan (ITP) detailing in chronological order, the tasks, activities, and procedures serving to implement and record the Contractor’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 Contractor 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 Owner’s Representative at least two weeks prior to the scheduled date of such audit. The Owner’s Representative undertakes not to make these documents available to any third party without the express permission of the Contractor and to return them to the Contractor at the conclusion of the audit.

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

The ITP shall be completed and signed off progressively by the Contractor’s quality control personnel and the appropriate representative of the Owner’s Representative and shall be submitted to the Owner’s Representative with all progress claims and periodic progress reports, and prior to completion of the service or dispatch or the equipment.




The Contractor may propose the use of its own standard forms, which must contain all information required by the Owner’s Representative. Copies of any proposed Contractor ITP forms shall be submitted to the Owner’s Representative for review and acceptance. The Owner’s Representative reserves the right to request an ITP to be correctly completed on the Owner’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 Owner’s Representative in the ITP as a Witness or Hold Point, the Contractor shall notify the Owner’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 Contractor 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 Contractor obligations relating to Witness and Hold Points.

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

In the case of a Hold Point, the Contractor shall not proceed with the work without the Owner’s Representative or its representative being present, except where the Owner’s Representative has notified the Contractor, 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 Contractor.

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

GENERAL

• All welding shall be done by qualified welders • All welds shall be NDT or DT tested. Should a failure be detected, an increase of testing frequency has

to be implemented. • All special steel such as stainless steel shall be welded and tested in accordance with all standards

referenced in this Scope of Works and used for modern Sulphuric Acid Plants. • All ferritic stainless steels including SX shall be tested for 100% positive material identification • Heat treatment graphs shall be made available • All accessible welding exposed to the process shall be flush and smooth • All equipment shall be cleaned to limit contamination to the process.




APPENDIX B CONTRACTOR DRAWING AND DATA REQUIREMENTS

The Contractor shall nominate the issue date, quantity & version of document issue, and any remarks for all documentation and data for the Owner to review. The Contractor shall submit its bid with this completed Contractor Drawings and Data Requirements Table.

The Contractor shall submit all documentation for review and Approval by the Owner. Approvals by the Owner does not relieve the Contractor of its obligations in relation to the Contract. The Contractor shall carry out revisions and submissions of all documentation and incorporate all corrections, comments and the like from the Owner at all stages of the Works up to and including the as-building stage. All as-built documentation shall reflect all changes made throughout the entirety of the Works and shall totally reflect all final dimensions, positions, geometry, data, and any other information and elements of the Works completed under the Contract.

CONTRACTOR DRAWINGS AND DATA REQUIREMENTS PART A – DRAWINGS

No. Description Document Required with

Tender Bid

Document Required

After Commenc

ement Date

Issue Date (weeks

after Commenc

ement Date)

Qty. /Version

Remarks

A DRAWINGS A1.0 GENERAL A1.1 Overall site plan X X A1.2 Process block flow Diagrams X X A1.3 Process flow diagrams X X A1.4 Mass / energy balance

diagrams X X

A1.5 Sample P&ID (one off) X A1.6 P&ID (set) X 25 A1.7 P&ID’s with vendor P&ID X 52 A1.8 Process control philosophy X 25 A1.09 All drawings X 52 A2.0 DISCIPLINE DRAWINGS A2.10 CIVIL DRAWINGS A2.11 Roads, pads, drainage &

earthworks X

A2.12 Fencing X A2.13 Concrete details X A2.14 Reinforcement schedules X A2.20 STRUCTURAL STEEL

DRAWINGS

A2.21 Structural steel arrangements

X

A2.22 3D model unconnected X 25 Monthly






Tender Bid

Document Required

After Commenc

ement Date

Issue Date (weeks

after Commenc

ement Date)

Qty. /Version

Remarks

A2.23 3D model connected X 52 Every 2 months

A2.24 3D model with concrete, structure, piping, mechanical equipment, cable racks and selected electrical

X 52 Every 2 months

A2.25 3D viewer model X 10 Monthly A2.30 MECHANICAL DRAWINGS A2.31 General arrangements, plan

and elevation X X Monthly

A2.32 3D model X 52 Monthly A2.40 PIPING DRAWINGS A2.41 Piping and instrumentation

diagrams X X Monthly

A2.42 In-Plant piping layout and general arrangement drawings, details, etc

X Monthly

A2.50 ELECTRICAL DRAWINGS A2.51 HV switchyards, substations,

transformer compounds, motor control centre rooms, equipment layouts and arrangements

X Monthly

A2.52 Cable and cable tray layouts and arrangement drawings

X Monthly

A2.53 Single line diagrams X X Monthly A2.54 Schematics X Monthly A2.56 Electrical standard details X Monthly A2.57 HV power reticulation and

transmission lines X 25 Monthly

A2.58 Earthing, step-touch and equal potential

X 52 Monthly

A2.59 Protection and protection coordination and arc flash containment certificates

X 52 Monthly

Loadlist X 25 Monthly Hazardous Area drawings

and dossier X 16

Emergency power loadlist X 25 Monthly THD (V) and THD (I) X 25






Tender Bid

Document Required

After Commenc

ement Date

Issue Date (weeks

after Commenc

ement Date)

Qty. /Version

Remarks

Fault level model X 25 Lux study X 52 Lux survey results X Before Taking-

Over Typical electrical starter (one

off, as a sample) X

Electrical starter (HV & LV) X 25 Electrical starter wiring

diagram (set) X 25

LV and HV panel wiring (set) X 32 A2.60 INSTRUMENTATION AND

CONTROL DRAWINGS

A2.61 INSTRUMENTATION AND CONTROL DRAWINGS

X 10

A2.62 PCS wiring X 25 A2.63 Taglist X 52 Monthly A2.64 Network architect layout X 10 A2.65 Network drawing X 25 A2.66 Control system block

diagrams X X X

A2.70 INFRASTRUCTURE

DRAWING

A2.71 Buried services general arrangement and layouts

X X 32

A2.72 Buildings layouts and arrangements

X

A2.73 Air-conditioning services X 25 A2.74 Utilities and services layouts,

arrangements and details X

A2.75 HV cable and pipe line containment

X

A2.76 Communications systems X X 25 A2.77 Fire protection Systems X A2.80 CONTRACTOR DRAWINGS A2.81 General arrangement,

installation, assembly, parts identification drawings

X






Tender Bid

Document Required

After Commenc

ement Date

Issue Date (weeks

after Commenc

ement Date)

Qty. /Version

Remarks

A2.90 OTHER A2.91 Contractor to nominate

CONTRACTOR DRAWINGS AND DATA REQUIREMENTS PART B – ENGINEERING DATA


Tender Bid

Document Required

After Commenc

ement Date

Issue Date (weeks after Commencement Date)

Qty. /Version of Issue

Remarks

B ENGINEERING DATA B1.0 GENERAL B1.1 Process design criteria X X B1.2 Engineering design basis X X B1.3 Drawing register X Monthly B1.4 Sulphuric Acid Plant data sheet

(Appendix D) X X

B2.0 KEY DOCUMENTS B2.1 Mechanical equipment list (incl.

information on preferred equipment make and models)

X X Monthly

B2.2 Electrical equipment list (incl. information on preferred equipment make and models)

X X Monthly

B2.3 Cable schedule X B2.4 Instrument list X (draft) X B2.5 Piping line list X B2.6 Valve schedule X B2.7 Electric motor list X X B2.8 Preliminary I/O count X B2.9 I/O count X 52 Monthly B2.10 PCS source code X Taking-Over

Certificate

B2.11 All PLC source code X Taking-Over Certificate

B2.12 Network and firmware setup X Taking-Over Certificate






Tender Bid

Document Required

After Commenc

ement Date



Remarks

B3.0 ENGINEERING CALCULATIONS

B3.1 Process X B3.2 Concrete X B3.3 Structural steel X B3.4 Tankage and platework X B3.5 Mechanical equipment (incl

boiler and pressure vessel calculations)

X

B3.6 Contractor equipment sizing X B3.7 Pipework (incl. pipe stress

analysis) X

B3.8 Electrical equipment and cable sizing

X

B3.9 Power supply X Monthly B4.0 PLANT OPERATION Control logic and operating

philosophy X 25

Plant installation, operation and maintenance manuals

X 52 At least 12 weeks before

commissioning

Distribution control system programme

X

Isolation and equipment lockout procedures – during construction

X At least 6 weeks

before site establishme

nt Isolation and equipment

lockout procedures – during commissioning

X At least 6 weeks before

commissioning

B.5.0 SPECIFICATIONS Technical specifications X Equipment specifications X B.6.0 STATUTORY APPROVALS Crane certification X






Tender Bid

Document Required

After Commenc

ement Date



Remarks

All lifting equipment certification & registration

X

Pressure vessels and it’s installation, registration documentation

X

Power supply system and Electrical Submission documents

X

Boilers X Nuclear sources X Statutory Approvals not listed X B.7.0 OTHER B7.1 Noise 3D matrix and level X 25 B7.2 Noise level for significant

equipment X X

B7.3 Noise measurements X Before Taking-Over Certificate

B7.4 Computational fluid dynamics model and study report

X 15

B7.5 Contractor to nominate X




CONTRACTOR DRAWINGS AND DATA REQUIREMENTS PART C – CONTRACT DOCUMENTATION


Tender Bid

Document Required

After Commenc

ement Date

Issue Date (weeks

after Commenc

ement Date)


Remarks

C CONTRACT DOCUMENTATION

C1.0 GENERAL C1.1 Commercial non-

conformances X X

C1.2 Battery limit drawing X 25 Monthly C1.3 Battery limit table

(All services including IT) X 25 Monthly

C1.4 Battery limit flow rates and line size confirmation

X X 25

C1.5 Battery limit key dates and Owner supplied matter dates

X X 25

C2.0 DOCUMENTS C2.1 Capital cost estimate X X C2.2 Operating cost estimate X X 25 C2.3 Maintenance plan X 52 C2.4 Operation manning plan X (Draft) X 52 C2.5 Commissioning spare X 52 C2.6 Consumables X X 25 C2.7 2 year spares X X 25 C2.8 Long lead and insurance

spares X 25

C3.0 REGISTERS C3.1 Proposed variation register X Monthly C3.2 Variation register X Monthly C3.3 Purchase order register X Monthly C3.4 Inspection/expediting register X C3.5 Contract exposures register,

variation claims, extension of time claims, etc.

X

C3.5 Asset register for Owner’s tax and depreciation

X 52

C4.0 SCHEDULES C4.1 Overall project schedule –

Level 1 and significant milestones.

X X 2 Monthly

C4.2 Overall project schedule Level 3

X 8 Monthly






Tender Bid

Document Required

After Commenc

ement Date

Issue Date (weeks

after Commenc

ement Date)


Remarks

C4.3 Critical Path X (draft) X 12 Monthly C4.4 4 week look-ahead schedule X Progressive C4.5 S curves: total project,

engineering, construction, commissioning on cost and man hours

X 8 Monthly

C4.6 Engineering schedule: Level 1 X X Monthly C4.7 Engineering schedule: Level 3

Baseline and Actual X 8 Monthly

C4.8 Construction schedule Level 1 X X 25 Monthly C4.9 Construction schedule Level 3

Baseline and Actual X 25 Monthly

C4.10 Construction manning histogram for Approval

X 25 Monthly

C4.11 Critical Path Construction X (draft) X 12 Monthly C4.12 Accommodation manning X X 25 Weekly C4.13 Commissioning schedule

Level 1 X X 25 Weekly

C4.14 Commissioning schedule Level 3 Baseline and Actual

X 21 weeks prior

commissioning

Daily during commissioning

C4.15 Commissioning Critical path X 52 Weekly C4.16 Shutdown & tie-in schedules X 25 Monthly C4.17 Battery limit key dates, tie-in

and Owner supplied matter dates

X (draft) X 25 Monthly

C4.18 Engineering and Design QMR: Quantity and hours report against Dates

X 8 Monthly

C4.19 Construction QMR: Quantity and hours report against Dates

X 25 Monthly

C4.20 Long Lead Schedule X 8 Monthly C4.21 Freight and Logistic Schedule X 25 Monthly C.5.0 REPORTS C5.1 Fortnightly project reports X Fortnightly C5.2 Manhour reports – home

office and site X Monthly

C5.3 Design status report X Monthly C5.4 Drawing status report X Monthly






Tender Bid

Document Required

After Commenc

ement Date

Issue Date (weeks

after Commenc

ement Date)


Remarks

C5.5 Procurement status reports X Monthly C5.6 Inspection status reports X Monthly C5.7 Expediting status reports X Monthly C5.8 Cost reports X Monthly C5.9 Site construction progress

reports – summary level X Monthly

C5.10 Site safety reports X Monthly C5.11 Site goods received reports X Monthly C5.12 Commissioning reports X Monthly C5.13 Project closeout report X C5.14 Manufacturer’s Data Reports

(MDR) X Progressiv

e At least 6 weeks

before commencement of

commissioning C5.15 Training manuals and any

other materials X Until Approval

C5.15 Factory acceptance testing results and reports

X

C5.16 Site acceptance testing results, records and reports

X At least 5 weeks before

commencement of commissioning

C6.0 MEETINGS C6.1 Project meetings with Owner’s

Representative X Weekly

C6.2 Site construction meetings X Weekly C6.3 Design review 10% X Design review 30% X Design review 60% X Design review 90% X Design review 100% X C6.4 E&I design review 10% X E&I design review 30% X E&I design review 90% X C6.5 Operability review X C6.6 Maintenance review X C6.7 Constructability review X C6.8 Commissioning review X






Tender Bid

Document Required

After Commenc

ement Date

Issue Date (weeks

after Commenc

ement Date)


Remarks

C7.0 INSURANCE C7.1 Workers compensation X X 3 C7.2 Public liability X X 3 C7.3 Motor vehicle X X 3 C7.4 Professional indemnity X X 3 C7.5 Marine transit cover X X 3 C7.6 Other (tenderer to nominate) X X 10 C8.0. PROJECT

IMPLEMENTATION

C8.1 Project procurement and contracting strategy

X X

C8.2 Project contracting strategy X X C8.3 Industrial relations strategy X C8.4 Project risk analysis X C8.5 HAZAN/HAZOP review,

recommendations and close-out report.

X

C8.6 CHAZOP (E&I) X C8.7 All functional safety

deliverables (management plan, SIL study and determination, LOPA, and any other reports)

X

C8.8 Environmental review and recommendations

X

C8.9 Constructability review and recommendations

X

C8.10 Maintainability review and recommendations

X

C8.11 Occupational health and safety review and recommendations

X

C8.12 Statutory regulations review and checklist

X

C8.13 Security systems review and recommendations

X

C8.14 Environmental compliance certificate (e.g. washdown of light vehicles on entry/exit of the Site)

X Ongoing






Tender Bid

Document Required

After Commenc

ement Date

Issue Date (weeks

after Commenc

ement Date)


Remarks

C8.15 Equipment preservation procedures and reports

X Progressive

Submission upon receipt of each

equipment

C8.16 Dig permits X Submission at least 4 weeks

before any Site civil works

C8.17 Safety management plan X Submission at least 6 weeks

before any Site civil works and

delivery of equipment

C9.0 QUALITY C9.1 Project quality plan X X 4 C9.2 Quality rating as per Appendix

A X X 4

C9.3 Inspection & test plan (ITP) X 25 C9.4 Critical equipment inspection X 8 C9.5 Quality procedure X 10 C9.6 Design validation X 10 C9.7 Technical procedure for

quality X 10

C9.8 Quality records X 25 C9.9 Geotechnical compaction test

results X Weekly

C9.10 Concrete compression test X Weekly C9.11 Concrete slump test X Weekly C9.12 Concrete core tests X Weekly C9.13 NDT (NDT) and Destructive

Testing certificates X 25 Weekly

C9.14 Heat treatment records X 25 Monthly C9.15 Refractory inspection X 25 Monthly C9.16 Transport compliance X 25 Monthly C9.17 Welding procedure

specification (WPS) X 25 Monthly

C9.18 Welding procedure qualification & tests and records (WPQR)

X 25 Monthly

C9.19 Manufacturing Defects list X






Tender Bid

Document Required

After Commenc

ement Date

Issue Date (weeks

after Commenc

ement Date)


Remarks

C.10.0 INTERNAL AUDITS C10.1 Process audits X Ad Hoc C10.2 Design audits X Ad Hoc C10.3 Cost control/forecast audits X Ad Hoc C10.4 Project schedule audits X Ad Hoc C10.5 Quality assurance/control

audits X Ad Hoc

C10.6 Import duty and declaration X Ad Hoc C10.7 Tax, GST and VAT paid X Ad Hoc C10.8 Personnel remuneration X Ad Hoc C10.9 Patent and licenses for the

work and technologies X X

C11 Transport and Freight C11.1 Packing list

Including dimensions and ± value

X

C11.2 Fragile load list X C11.3 Dangerous goods list X Monthly C11.4 Largest load #1 X X C11.5 Largest load #2 X C11.6 Heaviest load #1 X X C11.7 Heaviest load #2 X




CONTRACTOR DRAWINGS AND DATA REQUIREMENTS PART D – SITE RECORDS


Tender Bid

Document Required

After Commenc

ement Date

Issue Date (weeks

after Commenc

ement Date)


Remarks

D SITE RECORDS D1.0 Daily diaries X Daily D2.0 Inspection records X Weekly D3.0 Equipment check sheets,

mechanical, electrical, functionality, etc.

X Weekly

D4.0 Installation verification records, alignment checks, lubrication, fastener tensions, belt tensions, etc.

X Weekly

D5.0 Calibration certificates X Weekly D6.0 Lubrication schedule including

all equipment items rationalised for Owner’s Representative preferred lubricant

X Weekly

D7.0 Site testing results including, geotechnical, concrete, paint thickness, electrical, instrumentation, etc.

X Weekly

D8.0 Site instruction register X Weekly D9.0 Site instructions/ contract

variations X Weekly

D10.0 Survey data D10.1 Survey data X Monthly D10.2 Datum and coordinate over-

inspection X

D11.0 I/O testing results and reports X At least 5 weeks before

commissioning

D20.0 Punchlist D20.1 Punchlist register construction D20.2 Punchlist register pre-

commissioning

D20.2 Punchlist register cold commissioning

D20.3 Punchlist register hot commissioning simulation

D20.4 Punchlist register hot commissioning




CONTRACTOR DRAWINGS AND DATA REQUIREMENTS PART D – SITE RECORDS


Tender Bid

Document Required

After Commenc

ement Date

Issue Date (weeks

after Commenc

ement Date)


Remarks

D20.5 Punchlist summary for Taking-Over Certificate




CONTRACTOR DRAWINGS AND DATA REQUIREMENTS PART E – COMMISSIONING RECORDS


Tender Bid

Document Required

After Commenc

ement Date

Issue Date (weeks

after Commenc

ement Date)


Remarks

E COMMISSIONING PLAN, PROCEDURES & RECORDS

E1.0 Commissioning plan (integrated commissioning plan identifying logical and sequenced approach to overall plant commissioning)

X 52 No later than 12 weeks

before commencem

ent of commissioni

ng

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 E6.0 Operational involvement plan X 52 No later than

12 weeks before

commencement of

commissioning

E7.0 Equipment calibration records X No later than 8 weeks before

commencement of

commissioning




APPENDIX C DRAWINGS AND SPECIFICATIONS

(bound as a separate volume)

Document Number Description Specifications 140316-0000-40EG-0001 Project Specification 140316-0000-41EF-0001 Technical Specification for Excavation and Fill - General 140316-0000-41EF-0002 Technical Specification for Excavation and Fill - Sitework 140316-0000-43EC-0001 Structural Design Criteria 140316-0000-43EF-0001 Specification - Structural Steelwork Supply and Fabrication 140316-0000-43EF-0002 Specification - Erection of Fabricated Structural Steelwork 140316-0000-46EC-0001 Piping Design Criteria 140316-0000-46EG-0001 Piping Materials Specification 140316-0000-46EG-0004 Manual Valves Specification 140316-0000-47EC-0001 Design Criteria for Electrical Engineering 140316-0000-48EC-0001 Design Criteria Field Instruments and Control Valves Drawings 140316-0000-40DK-0005 General Plant Site Geotechnical Plan 140316-0000-45D1-0001 Mechanical General Overall Site Plot Plan 140316-0000-45D1-0002 Mechanical General Plant Site Plot Plan 140316-0000-45D1-0004 Mechanical General Process Plant Area Key Plan For Information Only Reports 99631001 (D) March 2000 Geotechnical Investigation for the Plant Site, Mine Pits & Limestone Quarry 054-1524361m Geotechnical Plant Site Interim Assessment 062-1524361R Geotechnical Interpretive Report Rev A GABH104 Preliminary report of borehole: 140316-000-40DK-0005-PA Golder 2017 Borehole Location Sketch Route Survey MMG-P17-016-001 Syerston Project Route Survey Rev.0 with Appendix 1 - 6 MMG-P17-016-015 MMG Preliminary Construction Materials Transport Report Rev. A Documents Available on request SYR-ENX-SPC-0001 Work Breakdown Structure Number and Naming Specification SYR-ENX-SPC-0002 Project Document Numbering Specification 140316-0000-47EC-0001 Design Criteria for Electrical Engineering




Document Number Description 140316-0000-47ES-0001 Transformers 140316-0000-47ES-0002 HV Switchgear 140316-0000-47ES-0003 LV Switchboards and MCCs 140316-0000-47ES-0004 Ring Main Units 140316-0000-47ES-0005 Transportable Switchrooms 140316-0000-47ES-0006 Electrical Equipment Installation Standards 140316-0000-47ES-0007 Motors 140316-0000-47ES-0008 Lighting 140316-0000-47ES-0010 Approved E&I Equipment 140316-0000-48ES-0001 Process Control Systems 140316-0000-45ES-0001 Approved Mechanical Equipment Health & Safety Management Plan Environmental Management Plan Human Resources Management Plan Contractor’s Quality Assurance Requirements Specification Construction Programme and Reporting Requirements Installation specifications for E&I Works Installation specifications for Structural, Mechanical & Piping Works Requirements for Commissioning Stages 1,2,3 & 4 Training Requirements Contractor responsibilities for the Site Owner’s rules and requirements for the Site




APPENDIX D SULPHURIC ACID PLANT DESIGN DATA

The Contractor shall populate the ‘Data By Contractor’ column in the Table below as part of their Tender submission.

The Contractor shall confirm in writing that their Sulphuric Acid Plant complies with the performance requirements stipulated in this Scope of Work and that all heat exchangers, pumps, boilers, tankage and pressure vessels have been designed in accordance with the Codes and Standards referenced within this document and in the table below.

Any exceptions, deviations and exclusions shall be clearly identified and noted as part of the Contractor’s Tender.

Item Units Owner Rep’s Specification

Data by Contractor

PERFORMANCE Design life Yrs 25 Operating availability % 95 (Note 1) Operating downtime (excluding shutdown) h <20 per year Turndown capacity % of normal load 40 Total heat recovery MJ/tonne of acid Contractor to advise DESIGN ALLOWANCE Sulphur melter % of normal load 0 to 130 Sulphur burn rate % of normal load 0 to 110 (Contractor

to confirm capability)

Sulphuric acid production % of normal load 100 Main air blower dirt allowance (over and above the design clean plant air operating discharge pressure)

kPa 7.5

PRODUCTION Nameplate capacity (H2SO4 output at 100% purity basis)

tpd 2 700

H2SO4 output minimum (2,700 x 40%) tpd 1 080 Acid product temperature (Max, Normal) °C 40, 30

Product acid concentration (Normal) %w/w 98.5% Impurities: SO2 content ppm 30 Impurities: Fe content ppm 20 HP superheated steam to be delivered to the cogeneration plant (steam turbine generator)

kPa(g), °C 6500, Contractor to advise temperature

tph Normal HP saturated steam to be exported to the battery limit for process requirements

kPa(g), °C 6 500, saturated (275°C) plus 5°C

superheat preferred

tph 52 MP saturated steam to be utilised within the Sulphuric Acid Plant

kPa(g), °C Contractor to advise

tph Normal





Data by Contractor

MP saturated steam available to be exported to the battery limit for process (crystallisation)

kPa(g), °C 1000, saturated temperature plus

5°C superheat

tph DISCHARGE BFW blowdown tph Filter cake tpd SULPHURIC ACID PLANT EQUIPMENT AIR BLOWER Flow rate Nm3/h Differential pressure kPa(g) Blower fitted with inlet guide vanes Yes/No Air intake silencer / filter Yes/No Motor rating kW Motor voltage / phases / frequency kV/3/50Hz Motor fitted with variable speed drive Yes/No Make & model Materials of construction DRYING TOWER Size Diameter(mm) x

height (mm) Contractor to advise

Materials of construction SULPHUR MELTER Material of construction Design code Tank capacity m3 Anodic protection system included Yes/No Design pressure / temperature kPa(g)/ oC Sulphur tank heating medium Steam Sulphur tank, roofed vents (jacketed / steam coils) Snuffing steam flow rate in sulphur tank Contractor to advise Sulphur feed pumps capacity m3/h Contractor to advise Sulphur pumps total dynamic head m Contractor to advise Sulphur feed pumps type Contractor to advise No of sulphur feed pumps Contractor to advise Pumps design code API / ASME Contractor to advise Motor rating kW/3 phase/ 50Hz Contractor to advise Sulphur pumps (jacketed / electrically heat traced)

Contractor to advise

Sulphur piping (jacketed / electrically heat traced)





Data by Contractor

SULPHUR BURNER Type, make & model Design air fuel (sulphur) ratio Design sulphur burning rate tph Contractor to advise Heat rate for burner MJ/h Contractor to advise Materials of construction Diesel consumption rate (on Plant start up) L/h WASTE HEAT BOILER Type of boiler Water tube / fire tube HP superheated steam generated @ 6000 kPa(g) 6000 kPa(g)/X oC Contractor to advise MP saturated steam generated @ 1000 kPa(g) 1000 kPa(g)/Y oC Contractor to advise Boiler design code ASME Contractor to advise Economiser Yes/No Contractor to advise Deaerator Yes/No Contractor to advise Condensate collection tank Yes/No Contractor to advise Boiler feed pumps capacity m3/h Contractor to advise Boiler feed pumps total dynamic head m Contractor to advise Boiler feed pumps type Contractor to advise No of boiler feed pumps Contractor to advise Pumps design code API / ASME Contractor to advise Motor rating kW/3 phase/ 50Hz Contractor to advise Materials of construction GAS TO GAS HEAT EXCHANGER Design code ASME Type of heat exchanger (TEMA Classification) Material of construction Shell Material of construction Tubes SO2 to SO3 CONVERTOR No of passes Contractor to advise Materials of construction Contractor to advise Catalyst type Contractor to advise Catalyst life Years Contractor to advise Reaction temperature oC Contractor to advise Hot gas filters included Yes/No OLEUM TOWERS Materials of construction Brick lining type and thickness (mm)





Data by Contractor

Design pressure / temperature kPa(g) / oC Tower internals Tower size Diameter (mm) x


ABSORBING TOWERS Materials of construction Brick lining type and thickness (mm) Tower internals Tower size Diameter (mm) x


Design pressure / temperature kPa(g) / oC DILUTION TOWERS Materials of construction Brick lining type and thickness (mm) Tower internals Tower size Diameter (mm) x


Design pressure / temperature kPa(g) / oC Dilution water required tph ACID MIST SCRUBBERS Equipment details Materials of construction ACID COOLERS - Drying acid cooler Type of cooler Design code Material of construction - Absorbing acid cooler Type of cooler Design code Material of construction - Oleum cooler Type of cooler Design code Material of construction Oleum feed pumps capacity m3/h Contractor to advise Oleum pumps total dynamic head m Contractor to advise Oleum feed pumps type Contractor to advise Number of oleum feed pumps Contractor to advise





Data by Contractor

Pump design code API / ASME Contractor to advise Motor rating kW/3 phase/ 50Hz Contractor to advise OLEUM STORAGE TANKS Materials of construction Design code NACE SP0294 Tank capacity m3 Design pressure / temperature kPa(g)/ oC Number of tanks Anodic protection system included Yes/No MAIN STACK AND MELTER STACK Material of construction ACID STORAGE TANKS (within battery limits) Material of construction Design code NACE SP0294 Tank capacity m3 Design pressure / temperature kPa(g)/ oC Number of tanks Anodic protection system included Yes/No CONSUMPTION Sulphur melter (instantaneous capacity) tpd Contractor to advise Electricity, Installed load kW Average Consumed Power (kW) when running kW Blower installed kW Blower average electrical energy consumption when running at plant design capacity

kWh

Acid dilution (RO water at 300 kPa(g)) m3/h Contractor to advise Boiler feed water (demin water at 300 kPa(g)) tph Contractor to advise Cooling water (RO water at 300 kPa(g)) m3/h Contractor to advise Potable water at 400 kPa(g) and 35 °C m3/h Contractor to advise Demineralised water at 400 kPa(g) and 35 oC Contractor to advise Total water consumption m3/h Diesel fuel at 600 kPa(g) tph Start up steam @ 600 kPa(g) tph Instrument air @ 600 kPa(g) Nm3/h Hydrated lime kg/h Pre-coat kg/h Catalyst tonnes per x yrs Catalyst manufacturer





Data by Contractor

Period between catalyst screening needed months Plant shutdown duration from acid production stop to acid production(after refractory, catalyst screening & replacement)

Days

Diesel consumption during idle at 0% S input and 0% output

Litre

Steam consumption during idle m3/hr Maximum duration of idle time hours 48 Duration from Nameplate production to reach steady state in idle conditions

hours 12

Duration for operations, from cold start to Nameplate production (post Performance certificate been issued)

hours 36

EMISSIONS during Cold Plant Re-Start Up Sulphur dioxide (SO2): maximum concentration under dry, 273 K, 101.3 kPa condition

ppmv

Sulphur trioxide (SO3) ; maximum concentration under dry, 273 K, 101.3 kPa condition

mg/Nm3

Sulphuric acid mist (H2SO4); maximum concentration under dry, 273 K, 101.3 kPa condition

mg/Nm3

Main stack plume colour & duration EFFICIENCY & EMISSIONS (during Hot Commissioning)

Sulphur capture rate throughout the process between the sulphur feed conveyor to the main stack outlet

% Contractor to advise

SO2 conversion rate throughout the process between the converter inlet to the main stack outlet

% > 99.8

HP superheated steam production rate at battery limit

t steam / t acid Contractor to advise

MP saturated steam production rate at battery limit

t steam / t acid Contractor to advise

Main stack velocity and temperature ms-1 / °C Sulphur dioxide (SO2): maximum Concentration under dry, 273 K, 101.3 kPa (a) condition (not to exceed value)

ppmv 280

Sulphuric acid mist (H2SO4) or sulphur trioxide (SO3) or both (as SO3 equivalent): maximum concentration under dry, 273 K, 101.3 kPa (a) condition

mg/Nm3 <45

Air humidity at drying tower outlet, (total H2O) mg/Nm3 <50 CO mg/Nm3 CO2 mg/Nm3 NOX mg/Nm3 Contractor to advise





Data by Contractor

Tail gas volume flow Nm3/h (dry) Stack plume colour Melter emission flue gas scrubber composition (during re-start up and stable operation)

Melter stack velocity and temperature ms-1 / °C Melter sulphur and H2S emissions ppmv / ppmv EFFICIENCY & EMISSIONS (during stable operation after issue of Performance Certificate)

Sulphur capture rate throughout the process between the sulphur feed conveyor to the main stack outlet

% Contractor to advise

SO2 conversion rate throughout the process between the converter inlet to the main stack outlet

% > 99.8%

HP superheated steam production rate at BL t steam / t acid Contractor to advise MP saturated steam production rate at BL t steam / t acid Contractor to advise Main stack velocity and temperature ms-1 / °C Sulphur dioxide (SO2): maximum concentration under dry, 273 K, 101.3 kPa (a) condition (not to exceed value)

ppmv 280

Sulphuric acid mist (H2SO4) or sulphur trioxide (SO3) or both (as SO3 equivalent): maximum concentration under dry, 273 K, 101.3 kPa (a) condition

mg/Nm3 <45

Air humidity at drying tower outlet, (total H2O) mg/Nm3 <50 CO mg/Nm3 CO2 mg/Nm3 NOX mg/Nm3 Contractor to advise Tail gas volume flow Nm3/h (dry) Stack plume colour Melter emission flue gas scrubber composition (during re-start up and stable operation)

Melter stack velocity and temperature ms-1 / °C Melter S and H2S emissions ppmv / ppmv BATTERY LIMIT ELECTRICAL CHARACTERISTICS

Voltage kV 11 RMS fault level kA 40 Phases 3 Earthing A 100A for 1 second GENERAL ELECTRICAL CHARACTERISTICS Control voltage VDC 24





Data by Contractor

UPS duration hours 2 Maximum installed load MVA Maximum normal consumed load MVA Maximum motor starting voltage drop at 11kV battery limit

%

GENERAL Estimated quantity and details of Plant SIS/SIF’s and anticipated their SIL ratings and AS (IEC) compliance

Concrete volume for installation (batching by Owner)

m3

Competent/engineered fill type and quantities (if required)

m3

Estimated total structural steel weight kg Estimated total weight of all equipment including steel, tanks, equipment and refractories (excluding concrete and backfilling)

kg

Annual maintenance % of capital cost Permanent works area excluding coolers m x m 100 x 70 Direct acid cooling system area m x m NOISE Noise level of blower before attenuation dBA at 1 m Noise level of blower after attenuation dBA at 1 m <82 OTHER First fill acid (supplied by Owner) quantities required

t

First fill hydrated lime (supplier by Owner) quantities required

t

Sulphur (supplied by Owner) quantities required t Diesel fuel (supplied by Owner) quantities required

l

Main stack height and diameter (minimum) m / mm 80 / X Melter stack height and diameter m / mm DIRECT ACID COOLING SYSTEM Fin fan acid cooling capacity kWt Number of fin fan cooling units Number of bays / unit Number of fans / bay kW / fan kW kWt / fin fan cooling unit kWt / Fin fan overall footprint m x m Fin Fan noise level at 1 m dBA Fin fan noise level at 50 m dBA





Data by Contractor

Fan speed control VSD, two speed / fan cycling

Materials of construction tubes HYBRID WET/DRY SYSTEM FOR PRODUCT ACID TEMPERATURE TRIMMING AND AUXILIARY EQUIPMENT

Overall footprint m x m Noise level at 1 m dBA Noise level at 50 m dBA Fan speed control VSD, two speed / fan

cycling

Materials of construction Product acid temperature trimming and auxiliary cooling load (e.g. blower bearing cooling): Hybrid wet/dry cooling system capacity

kWt

Product acid temperature trimming and auxiliary cooling load (e.g. blower bearing cooling): Water consumption per year

m3/year

Maximum water usage m3/hr Hybrid wet/dry cooling system type (e.g. precooled air, water on tube), make and model

Ducting throughout – Materials of construction

Note 1: If the Contractor does not believe this availability can be achieved, they are expected to provide justification for their stated availability achievable based upon the performance of actual installations and listed maintenance requirements.

a




APPENDIX E RESPONSIBILITY MATRIX

Description Contractor Owner’s

Rep Owner’s Rep Approval or

Review 1.0 PROCESS DESIGN 1.1 Overall plant design parameters X R 1.2 Detailed plant design X A 1.3 Overall process flow diagram (PFD) X A 1.4 P&IDs X A 2.0 ENGINEERING DESIGN 2.1 Acid plant X A 2..2 Utilities design X A 2.3 Effluent treatment plant X 2.4 Civil & structural Works X A 2.4.1 Design and specify all civil and structural works, including

buildings/control rooms X A

2.4.2 Site survey X R 2.4.3 Commission geotechnical survey X X R 2.4.4 Site preparation and grading X X 2.5 Electrical and instrumentation 2.51 Design: switchgear & motor control centres; substations;

switchrooms; site installation comprising power/control, Cabling; plant lighting and GPO’s; instrumentation

X A

2.5.2 Specify: 11 kV switchgear; 415 V motor control centres; transformers; substations; switchrooms; control room; instruments; site installation work

X A

2.5.3 Provide and programme distributed control system X A 2.6 Drawing approvals 2.6.1 Acid plant design drawings X A 2.6.2 Supplier and vendor drawings X A 3.0 SPECIFICATIONS 3.1 Provide specific engineering standards where available X X 3.2 Equipment specifications X A 3.3 General specifications X A 4.0 OPERATING AND MAINTENANCE MANUALS 4.1 Specify and obtain Installation, Operating and Maintenance

Manuals (IOM) Owner’s Representative to provide general site philosophy

X A

4.2 Overall operating and maintenance manuals X A 4.3 Operating and Maintenance Manuals for vendor equipment X R 4.4 Spares manual and assembly manual X A 4.5 Suppliers of spares and equipment X A 4.6 Training manuals and other materials X A




Description Contractor Owner’s

Rep Owner’s Rep Approval or

Review 5.0 PERMITS AND APPROVALS 5.1 Obtain any permits and Approvals other than for the Mines

Department Approvals advise as required and building approvals Owner’s Representative to assist and advise as required.

X A

5.2 Mines Department Approvals and Building Approvals X 5.3 Provide Plant operating permits X 5.4 Registered Plant equipment permits/Approvals X A 5.5 Functional safety activities, SIL determination and regulatory

compliance for combustion equipment X A

6.0 PROJECT CONTROLS 6.1 Cost control 6.1.1 Prepare cost schedule X A 6.1.2 Maintain cost control X A 6.1.3 Prepare long term and monthly cash flow forecasts X A 6.1.4 Prepare variations X A 6.2 Project schedule A 6.2.1 Prepare project schedule X A 6.2.2 Prepare summary schedule with critical path X A 6.2.3 Updated schedules (two per month) X A 6.3 Progress reports 6.3.1 Prepare progress reports for Owner’s Representative (Two per

month) X A

6.4 Project cost reports 6.4.1 Cost report for Owner’s Representative (one per month) X 6.5 Project meetings 6.5.1 Call and chair project meeting with Owner’s Representative (one

per week) X A

6.5.2 Issue minutes for project meetings. Contractor to prepare minutes for Approval

X X A

6.6 Project procedures manual 6.6.1 Prepare project procedures manual X A