Issued for DFS - ICN Gateway

SCOPE OF WORK AMMONIA UNLOADING & STORAGE

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Document No 140316-5420-45EW-5605 Revision 02 Date 20/04/2018 of 40

SNC-LAVALIN 140316-5420-45EW-5605_02 - Scope of Work - Ammonia Storage and Unloading Package Final.docx

REVISION CONTROL

Issued for Internal Review

Issued for Client Review

Issued for DFS

REVISION HISTORY Revision Date Pages Revised Remarks

01 23/03/2018 Various Modified intent to be equipment supply package excluding installation works

02 20/04/2018 Various Updated datasheet references for reduced NH3 storage & atmospheric vapourisers


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TABLE OF CONTENTS 1 SCOPE DESCRIPTION 6

1.1 INTRODUCTION 6 1.2 WORK INCLUDED 6

1.2.1 Engineering and Services 6

1.2.2 Civil Works 7

1.2.3 Concrete Works 7

1.2.4 Tankage and Structural Steel 7

1.2.5 Mechanical Equipment 7 1.2.6 Piping 8

1.2.7 Electrical Equipment 8

1.2.8 Instrumentation and Control Equipment 8

1.2.9 Lubricants 8

1.2.10 First Fills 8 1.3 FABRICATION AND SHOP ASSEMBLY 8

1.4 VERIFICATION AND TESTING DURING FABRICATION 9

1.5 SHIPPING, PACKING AND STORAGE 9

1.6 PERMITS, LICENSES, REGISTRATIONS AND APPROVALS 9

1.7 CONSTRUCTION 9

1.8 COMMISSIONING 10 1.9 SPARE PARTS, SPECIAL TOOLS AND EQUIPMENT 10

1.9.1 Spare Parts 10

1.9.2 Special Tools and Equipment 10

1.10 TRAINING 10

1.11 OPTIONAL WORK 11

1.12 RESPONSIBILITY MATRIX 11 2 WORK EXCLUDED 11

2.1 ENGINEERING AND SERVICES 11

2.2 SITE PREPARATION & ACCESS ROADS 11

2.3 CONCRETE 11

2.4 PIPING 11

2.5 ELECTRICAL AND INSTRUMENTATION 11 3 TRANSPORT ENVELOPE 11

4 BATTERY LIMITS 12

5 REFERENCE DOCUMENTS AND STANDARDS 12

5.1 DRAWINGS AND SPECIFICATIONS 12

5.2 CODES, STANDARDS AND REGULATIONS 12 5.3 LANGUAGE AND MEASUREMENT SYSTEM 14


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6 OPERATING ENVIRONMENT 14

7 DESIGN CRITERIA 14

7.1 PROCESS DESCRIPTION 14 7.2 OPERATING PHILOSOPHY 14

7.3 DUTY AND DESIGN CRITERIA 15

7.3.1 Package Design Basis 15

7.3.2 Anhydrous Ammonia Storage Capacity and Consumption Rate 15

7.3.3 Turndown 15

7.3.4 Anhydrous Ammonia Distribution System Start-up Time 15 7.3.5 Liquid Nitrogen Storage Capacity and Consumption Rate 15

7.3.6 Occupational Health and Safety 15

7.4 EQUIPMENT AND MATERIALS 16

7.5 UTILITIES AND SERVICES 16

7.5.1 Utility Stations 16 8 DETAILED TECHNICAL REQUIREMENTS 16

8.1 CONCRETE 16

8.2 STRUCTURAL 16

8.3 MECHANICAL 16

8.4 PIPING 17

8.5 ELECTRICAL 17 8.6 INSTRUMENTATION AND PLANT-WIDE CONTROL AND INSTRUMENTATION 18

8.6.1 Instruments 18

8.6.2 Control Systems 18

8.6.3 Functional Safety 19

8.6.4 Documentation 19

8.7 SURFACE PROTECTION 20 8.8 EQUIPMENT IDENTIFICATION, MARKING AND LABELLING 20

8.9 PROVISION OF TECHNICAL DATA, DRAWINGS AND INSTRUCTION MANUALS 20

8.9.1 General 20

8.9.2 Technical Data 21

8.9.3 Drawings 21

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

9.1 QUALITY SYSTEM 21

9.2 VERIFICATION & TESTING DURING FABRICATION 22

9.3 FINAL ACCEPTANCE 22

9.4 PERFORMANCE CRITERIA AND TESTING 23

9.4.1 Primary Performance Requirements 23


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9.4.2 Performance Assessment against Requirements 23

9.5 COMMISSIONING 23

9.5.1 Off Site Testing 23 9.5.2 On Site Testing 24

APPENDICES

Appendix A DRAWINGS AND SPECIFICATIONS 25

Appendix B CONTRACTOR’S QUALITY SYSTEM 26

Appendix C CONTRACTOR’S DRAWING AND DATA REQUIREMENTS 29

Appendix D RESPONSIBILITY MATRIX 36


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1 SCOPE DESCRIPTION

1.1 INTRODUCTION

This document sets out the scope of work and technical requirements for the design, supply and manufacture of a complete ammonia storage and unloading package on a supply only basis. The Contractor will further be required to provide technical support and guidance to the selected installation contractor for the erection, commissioning and performance testing of the completed installation on site. The facility will have the capability to supply vapourised ammonia to the project at the 3.74 t/h.

The facilities shall all form part of the Clean TeQ Sunrise Project in New South Wales, Australia.

1.2 WORK INCLUDED

The scope shall comprise the provision of all labour, materials, parts and services necessary to carry out the design, supply, manufacture, testing, commissioning, start up and performance testing support, together with the provision of all support services, training and site acceptance testing relating to the ammonia storage and unloading package for the Sunrise process plant.

The package scope of works shall consist of the following major components:

• Tanker unloading arms for liquid anhydrous ammonia, (to enable concurrent unloading of both trailers for a B-Double tanker)

• Tanker unloading arm for liquid nitrogen, (if unable to use unloading arm for ammonia service) • Ammonia unloading compressor/s and compressor knock-out vessel/s • Liquid ammonia storage bullets, (two vessels required) • Liquid ammonia transfer pumps • Ammonia vapouriser/s, (using hot water heat exchanger) • Nitrogen purging facility (for the Ammonia storage and distribution system as and when required) • Nitrogen unloading compressor/s and compressor knock-out vessel/s • Liquid nitrogen storage bullets, (maximum of two vessels required) • Liquid nitrogen purge transfer pumps • Nitrogen vapouriser, • Emergency shut-down (ESD) system • Fire detection system within the battery limits of the facilities • Design of bunded enclosure and truck unloading platform to the appropriate Australian and International

Standards and Safety Regulations.

The ammonia storage and unloading equipment package supplied shall be capable of meeting, or exceeding the specifications, design criteria and technical requirements listed within this scope of work.

The work shall include but not limited to the following:

1.2.1 Engineering and Services

All process and engineering design, comprising of drawings, detail design, calculations, equipment specifications, bills of materials, mass and energy balances, PFDs, P&IDs, plant layouts, equipment lists and all other design documents necessary to enable the complete design, specification, documentation, construction and commissioning of the Ammonia Storage and Unloading package (refer Appendix C for Contractor Drawing and Data Requirements).


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A Risk Analysis including a HAZOP (Hazard and Operability Study) and a CHAZOP (Control System HAZOP & SIL 1 verification) shall be conducted by the Supplier’s nominated Safety Specialist with participation from the Supplier’s Engineers. The Contractor will be solely responsible for overseeing the implementation of the solutions necessary to reduce or mitigate the consequences of identified hazards. The Client’s representative shall also participate in the HAZOP and CHAZOP.

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

Detailed technical requirements for the different engineering disciplines are included in section 8.

1.2.2 Civil Works

Civil works design and construction is excluded and is by others.

1.2.3 Concrete Works

Concrete works design and construction is excluded and by others.

The Contractor shall provide concrete foundation loading and baseplate/anchor bolt guidance for all foundations, process slabs, bunded areas and drainage channels within the bounds of the Ammonia Storage and Unloading package. Concrete detailed design and construction shall be by others.

The Contractor is encouraged to provide a design proposal for a low cost bunding alternative that complies fully with all statutory, regulatory and environmental standards applicable to the installation in New South Wales, Australia.

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

1.2.4 Tankage and Structural Steel

The contractor shall provide the following: • Structural steelwork, platework and all maintenance and operating access ways contained within the

package • Huts or enclosed areas to house ESD system and local control panel/s. • Staircases, platforms and walkways over and/or around the bunded area, ammonia and nitrogen storage

vessels and to allow access to all equipment, valves and instrumentation requiring routine access for operations and maintenance

• Pipe supports within the battery limits for the Ammonia Unloading and Storage package • Suitable surface protection of structural steel, platework and associated pipework and supports.

All structural steelwork provided for the facilities shall be provided – as far as is practically possible in a transportable modular form that will minimise site erection and installation works to the greatest extent possible.

1.2.5 Mechanical Equipment

The contractor shall provide the following: • All mechanical equipment including pressure vessels, unloading compressors, loading and unloading

arms, transfer pumps and ancillaries such as lubrication and heating / cooling systems; • Insulation for process and personnel protection for equipment at temperatures below freezing

temperature


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• Fixed overhead hoists and monorail cranes to facilitate routine maintenance activities within the ammonia storage bunded area where normal access by mobile crane would be considered difficult or dangerous

• Liquid ammonia transfer pump/s as required • Suitable surface protection of all equipment external surfaces.

1.2.6 Piping

The contractor shall provide the following: • All Interconnecting pipework, valves, fittings, supports including lining, painting and insulation within the

ammonia storage and unloading package.

All pipework, associated insulation and valving shall be provided pre-assembled to the greatest extent possible – with flanged ends for connections between adjacent modules and equipment to minimise site erection and installation works to the greatest extent possible.

1.2.7 Electrical Equipment

The contractor shall provide the following: • Pump motors and fin/fan heat exchangers • Local MCC

1.2.8 Instrumentation and Control Equipment

The contractor shall provide the following: • Equipment condition monitoring • Measurement and control field devices • Metering and totalising facilities for liquid ammonia flow into and out of the storage vessels • Emergency alarm facilities • Fire detection system • Ammonia Storage, unloading and distribution facilities control system/s.

1.2.9 Lubricants

The Contractor shall supply and install first fill lubricants required for shop testing of equipment, and provide a recommended lubricant schedule for the operation of the Ammonia Storage and Unloading package equipment.

1.2.10 First Fills

The Contractor shall provide all first fill anhydrous ammonia, nitrogen, lubricants and other materials and consumables required to enable plant commissioning.

1.3 FABRICATION AND SHOP ASSEMBLY

The Contractor and their nominated suppliers shall be responsible for the fabrication and the shop assembly of the liquid anhydrous ammonia storage and unloading package equipment, piping systems, structures, electrical/instrumentation/ control equipment and associated ancillaries. This is also inclusive of the nitrogen purge system.

In order to minimise site labour man-hours and infrastructure requirements, (by others), it is preferred that off-site modular assembly of the ammonia storage and unloading package components is maximised. The Contractor shall indicate this in the bid, detailing the extent of off-site modularisation, transportation methods and logistics strategy.


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The allowable transport envelope is described in section 3 of this scope of work.

1.4 VERIFICATION AND TESTING DURING FABRICATION

The Contractor shall allow for the provision of sufficiently experienced staff to expedite and inspect shop-fabricated items. It should be demonstrated in principle that items are inspected for satisfactory construction prior to leaving the fabricator’s shop or yard. This applies in particular to pressure vessels, pipe spooling, prefabricated steelwork, pipe supports, pumps, switchboards and PLCs.

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

The Contractor shall supply a Critical Equipment list and 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 Client’s Representative’s own inspectors as per agreed Inspection and Test Plan.

1.5 SHIPPING, PACKING AND STORAGE

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

1.6 PERMITS, LICENSES, REGISTRATIONS AND APPROVALS

The Client’s Representative shall arrange, obtain and pay for the following permits, licences, registrations and approvals as may be applicable to work under the Contract;

• Mining Leases • 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. The Contractor shall provide copies of such documents to the Client’s Representative upon request. These licences shall include but not be limited to:

• Licences associated with the Dangerous Goods Act • Approvals for all pressure vessels and gas appliances.

1.7 CONSTRUCTION

The Contractor shall be responsible for providing technical assistance to all construction activities across the following disciplines within the ammonia storage and unloading package battery limits:

• Structural • Mechanical, (including pressure vessels) • Piping • Electrical • Instrumentation and Control.

The Contractor shall ultimately be responsible for ensuring that the constructed and installed facilities operate as required and completely in conformance with the required safety and operational requirements.


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1.8 COMMISSIONING

The Contractor shall provide a team of suitably qualified personnel experienced in the commissioning and operation of ammonia storage and unloading facilities to plan, document and direct the transition from practically complete plant to satisfactory completion of performance runs.

During commissioning, the Contractor will be assisted by the Client’s Representative’s process and maintenance technicians on shift. This assistance will commence once piping, mechanical and electrical installation verification is complete to the punch listing stage.

The Contractor shall include costs to provide assistance during the installation and commissioning stages of the Ammonia Unloading and Storage Package based on their experience. The daily charge out rates for the supervision of installation and commissioning of Plant shall be provided and an anticipated visit schedule allowed for in that pricing. Accommodation in a nearby construction camp will be provided by the project.

The Contractor shall submit a Commissioning Plan together with his bid. This plan should address issues such as:

• Safety • Role of Commissioning Manager • Commissioning manning and schedule • Stages of Commissioning • Designation of sub-systems • Control of Construction/Commissioning interface • Preparation of Commissioning Check sheets, Instructions, Manuals • Commissioning materials (e.g. temporary strainers, hoses, spool pieces, bunting, tags and signs).

1.9 SPARE PARTS, SPECIAL TOOLS AND EQUIPMENT

1.9.1 Spare Parts

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

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

1.9.2 Special Tools and Equipment

The Contractor shall provide a priced list of any special tools which may be necessary for the on-going operation and maintenance of the Ammonia Unloading and Storage facilities.

1.10 TRAINING

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

The Contractor shall submit a training program which will be reviewed and approved by the Client’s representative and the Client. The Contractor shall include all costs and resources to provide for an agreed


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minimum number of contact hours of classroom and field training for the Client’s process and maintenance technicians to ensure an adequate level of competency for the trained personnel has been achieved.

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

1.11 OPTIONAL WORK

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

The 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.

1.12 RESPONSIBILITY MATRIX

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

2 WORK EXCLUDED

2.1 ENGINEERING AND SERVICES

• Environmental impact assessment and environmental licensing. • Site Risk Study • Provision of any pipe racks external to the ammonia storage and unloading facility bunded area including

any associated footings, structural steel, piping, electrical and instrumentation infrastructure design and supply beyond the battery limits defined in Section 4 of this scope of work.

2.2 SITE PREPARATION & ACCESS ROADS

Site preparation and bulk earthworks will be by others. Access roads around the ammonia storage and unloading facility will be by others.

2.3 CONCRETE

Concrete supply and construction will be by others.

2.4 PIPING

Input process and services piping up to the ammonia storage and unloading area battery limits and the output process and services piping from the ammonia facility will be by others.

Perimeter fire water ringmain supply and hydrants shall be supplied and installed by others

2.5 ELECTRICAL AND INSTRUMENTATION

415 V switch board / MCC / motor local control stations (LCS).

Substation housing the 415 V switch board / MCC.

3 TRANSPORT ENVELOPE

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


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

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

4 BATTERY LIMITS

The liquid anhydrous ammonia unloading and storage facility has been designated as Area 5420 and is indicated in the Process Plant Area Key Plan Dwg. No. 140316-0000-45D1-0004. The location and dimensions of this area are nominal and the Contractor is encouraged to propose a layout that they believe will provide an easily operable and maintainable facility and enable tanker unloading with no impact on through traffic in the immediate area.

The area occupied on site for the ammonia storage and unloading package on site shall include the truck unloading area, bunded area inclusive of storage bullets, distribution pumps and all other equipment required for the safe and efficient operation of the facilities. The perimeter of that area shall define the battery limits for all discipline engineering works included in this scope of works.

All piping will be connected to the Ammonia Storage and Unloading package from the plant east-west pipe rack which shall be located to the immediate south of the Ammonia Unloading and Storage facilities.

The 415 V substation supplied by others will be located nominally within 80 m of the ammonia storage and unloading package battery limit.

The battery limit for the ammonia vapour package discharge is the downstream flange of the vapouriser’s discharge isolation valve.

Battery limit conditions shall be captured in the Ammonia Unloading and Storage package datasheet.

5 REFERENCE DOCUMENTS AND STANDARDS

5.1 DRAWINGS AND SPECIFICATIONS

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

5.2 CODES, STANDARDS AND REGULATIONS

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

All work related to boilers and pressure vessels shall comply with the latest issue of the SAA Boiler Code and SAA Pressure Vessel Code.

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


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Table 1 Standards

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

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

AS 1670.4 Fire detection, warning, control and intercom systems - System design, installation and commissioning - Emergency warning and intercom systems

AS 1768 Lightning Protection AS 1940 The Storage and Handling of Flammable and Combustible Liquids AS 2022 Anhydrous Ammonia – Storage and Handling AS 2430.3.3 Classification of Hazardous Areas. Part 3.3: Examples of Area Classification –

Flammable Liquids AS 2700 Colour Standards for General Purposes AS/NZS 3000 Electrical Installations

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

AS 3008 Electrical Installations – Selection of Cables AS 3439 Low Voltage Switchgear Assemblies AS 3678 Structural Steel – Hot Rolled Plates, Floor Plates and Slabs AS 3780 Storage and Handling of Corrosive Substances AS 3990 Mechanical Equipment – Steelwork AS 4024.1 Safeguarding of Machinery – General Principles AS 4041 Pressure Piping AS 4343 Pressure Equipment – Hazard Levels

AS 4428 Fire detection and alarm systems - Emergency warning control and indicating equipment

AS 4991 Lifting Devices AS 5131 Fabrication & Erection of Structural Steelwork

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

AS 61511 Functional safety – Safety Instrumented Systems for the Process Industry Sector Framework, Definitions, Systems, Hardware and Software Requirements

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

NOHSC :1007-2000 National Standard for Occupational Noise AS/ACIF S009:2006 Installation Requirements for Customer Cabling (Wiring Rules) Australian Dangerous Goods Code 7th Edition (2012) NSW Dangerous Goods Act (2008) & Regulations (2014)


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Where there is no applicable Australian Standard the appropriate British, German, American or other approved standard shall apply. The order of precedence shall be:

• Australian • British • German (DIN) • American (US Industries) • Other codes.

5.3 LANGUAGE AND MEASUREMENT SYSTEM

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

6 OPERATING ENVIRONMENT

Refer to Project Specification Document No. 140316-0000-40EG-0001 for Site Conditions.

The Ammonia Storage and Unloading facilities will be located outdoors and will be exposed to dusty conditions as well as hose down with raw water.

7 DESIGN CRITERIA

7.1 PROCESS DESCRIPTION

Anhydrous ammonia will be delivered to site in B-Double tankers in liquid form. The ammonia will be displaced from the tanker vessels with the assistance of an unloading compressor.

A total of two interconnected storage bullets will be installed to receive the liquid anhydrous ammonia from the tankers.

The liquid ammonia will be pumped from the storage bullets using a duty/standby set of ammonia transfer pumps through a vapouriser using a hot water supplied heat exchanger to raise the temperature of the resulting ammonia gas to above zero degrees Celsius.

The ammonia gas will be directed through a network of piping to the various process plant users in Areas 4310, 4410, 4510 and 4920.

The ammonia gas pumped to Area 4920, (Scandium Refinery), will be used to create aqua ammonia at a strength of 25% w/w with demineralised water.

A liquid nitrogen storage facility will be maintained within the same compound as the liquid ammonia storage. The sole purpose of the nitrogen will be to meet the intermittent requirement to partially or fully purge the ammonia storage bullets, equipment and pipework to point of gaseous ammonia discharge during a full or partial ammonia system shutdown.

The liquid nitrogen will be unloaded, stored and ultimately distributed in the same fashion as the liquid anhydrous ammonia.

7.2 OPERATING PHILOSOPHY

The liquid anhydrous ammonia storage and unloading facility shall:

• Operate on a continuous basis • Require minimum manning for operation


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• Enable control of gaseous ammonia transfer operations to the process plant users areas from the PCS in the central control room

• Allow for locally controlled road tanker unloading attended by a process technician • Have provision for all personnel protection, safety and emergency alarms to report to the central control

room • Emergency alarms and shutdown system with static ammonia gas sensors in the facility.

The liquid anhydrous ammonia storage facility shall be designed to have a life of 20 years as a minimum.

The ammonia storage, unloading and distribution facility shall have a plant availability of not less than 98% allowing for scheduled and routine maintenance.

7.3 DUTY AND DESIGN CRITERIA

7.3.1 Package Design Basis

The Ammonia Storage and Unloading Package shall be designed on the basis of minimum capital cost with optimisation of operating and maintenance costs during the lifetime of the Plant.

7.3.2 Anhydrous Ammonia Storage Capacity and Consumption Rate

The storage capacity requirement on site for the anhydrous ammonia has been provided in the datasheet included in Appendix A.

The nominal and design (maximum) consumption rates for the anhydrous ammonia have been captured in the datasheet included in Appendix A.

7.3.3 Turndown

The Ammonia Unloading and Storage Package does not require a purpose built turndown of the nameplate capacity.

7.3.4 Anhydrous Ammonia Distribution System Start-up Time

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

7.3.5 Liquid Nitrogen Storage Capacity and Consumption Rate

The storage capacity requirement on site for the liquid nitrogen shall be determined by the Contractor to enable at least one complete purge of the ammonia storage and distribution system once per year. The consumption will therefore be intermittent and determined by the total calculated volume of the ammonia storage and distribution system. The Contractor shall design the nitrogen gas purging system to achieve a full purge of the ammonia system from the commencement of nitrogen purging flow by the safest and most efficient means possible.

7.3.6 Occupational Health and Safety

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

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


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7.4 EQUIPMENT AND MATERIALS

The Contractor shall use materials suitable for storage, pumps, piping and valves for the Ammonia Storage and Unloading package based upon in-house expertise and experience.

7.5 UTILITIES AND SERVICES

7.5.1 Utility Stations

The Ammonia storage and unloading facility will be equipped with utility stations and safety showers by others. The Contractor is to advise the required quantity and locations.

No fire water piping is required from the Supplier, however any recommended fire safety devices and portable extinguishers shall be nominated and provided by the Contractor as part of the scope of works.

8 DETAILED TECHNICAL REQUIREMENTS

8.1 CONCRETE

The design of all foundations, process slabs, bunds, sumps, sewers and drains within the Ammonia Unloading and Storage Package shall be by the Contractor.

For the purposes of the initial Tender, the Contractor is requested to provide overall estimated concrete quantities for all equipment within their scope of supply as noted in Appendix C. The Contractor is to provide foundation load guide drawings for civil construction by others.

The requirement and design of bunded enclosures and areas for the Ammonia Storage and Unloading Package shall be in accordance with AS1940 and AS2022.

8.2 STRUCTURAL

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

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

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

The Contractor shall maximise the use of mobile cranes and minimise fixed lifting devices. The Contractor shall provide suitably designed and certified monorails, davits or jib hoists to allow removal of machines and drives for maintenance where equipment items cannot be accessed by mobile crane.

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

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

8.3 MECHANICAL

The liquid anhydrous ammonia storage bullets and the liquid nitrogen storage bullet/s shall be designed and manufactured in accordance with the requirements of AS1210.


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The discharge pressure at the injection points for the anhydrous ammonia gas has been provided in the datasheet listed in Appendix A.

The Contractor shall supply an equipment list for all mechanical equipment which shows the equipment weight and overall dimensions. This list should be accompanied by the Ammonia Storage and Unloading Package layout drawings on which these equipment items are clearly identifiable.

An overall layout of the facilities showing required minimum clear distances from public space and other plant operating areas shall be based upon the guidance provided in AS1940 and a sketch provided with the Tender as a minimum.

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

8.4 PIPING

The Contractor shall supply all piping, fittings, piping specials, pipe supports, insulation, (where required), surface protection, temporary spools and strainers, safety showers and eyewash units, utility stations, gaskets and fasteners for all process and services piping systems within the liquid anhydrous ammonia unloading & storage facility battery limits.

The nitrogen purging storage and distribution system shall be fully integrated with the ammonia unloading, storage and distribution system to ensure safe and efficient purging operations can be implemented. The nitrogen purge pipework shall be fitted with appropriate failsafe isolation systems to ensure that the nitrogen and ammonia gas streams do not mix during normal operations.

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

8.5 ELECTRICAL

The Contractor will be responsible for the design, testing and commissioning of all field cabling, (including power, control, analogue, digital and fibre optic), drives, drive switching and control devices, lighting, (within the bunded area only)earthing (for power and instrumentation), that may be required for the Ammonia Unloading and Storage package.

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

The design, supply and testing of low voltage motor control centres shall conform to the appropriate Australian and International Standards.

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

Motors shall be MEPS compliant in accordance with AS 1359.5.

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

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

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


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

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

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

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

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 Zone 1 or Zone 2 areas shall be EX d, gas group IIB or IIC (as specified), temp class T3.

8.6 INSTRUMENTATION AND PLANT-WIDE CONTROL AND INSTRUMENTATION

The Contractor will be responsible for the design, supply, testing and commissioning of all instrumentation, communication and control systems within the Ammonia Storage and Unloading package.

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

8.6.1 Instruments

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

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

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

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

8.6.2 Control Systems

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

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

• 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)


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− function (covering all values and states of the signal) − engineering range − engineering units − data type − scaling factor (if required).

• the Contractor shall provide a take-out price for the supplied control system to allow the Client to consider the integration of the control of the supplied equipment into the site wide plant control system.

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

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

The Contractor shall ensure that sufficient resources are allowed to perform the PCS Factory Acceptance Test and the PLC or PCS Site Acceptance Test as discussed in section 9. The personnel nominated for this work shall be fully conversant with the Ammonia Storage and Unloading package Functional Description. Where PLC control is chosen then the Contractor must allow for acceptance testing of the PLC-PCS interface both at FAT and SAT stages.

8.6.3 Functional Safety

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

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

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

8.6.4 Documentation

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

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

requirements, set points) • P&IDs • Cause and Effect Matrix • Interlock Schedule • Alarm and Trip points schedule • Instrument Data Sheets • Cable Block Diagrams • Instrument list


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• I/O list • Electrical load list • Equipment layout drawings • Interconnection and field device termination diagrams • Junction box termination details.

8.7 SURFACE PROTECTION

All external surfaces of the Ammonia Storage and Unloading package equipment and structures, including base frames, guards and other ancillary equipment shall be provided with appropriate surface protection.

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

The 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:

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

8.8 EQUIPMENT IDENTIFICATION, MARKING AND LABELLING

Equipment numbering shall be in accordance with the Client Representative’s Drawing Standards. Spared 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 should be labelled in 150mm high letters; where labelling is over cladding the labelling shall be by removable signage. The Vendor shall make a suitable allowance for the provision of the above equipment number labelling in their bid.

The Contractor shall provide adequate signage warning plant personnel of the hazards within the Ammonia Storage and Unloading package.

8.9 PROVISION OF TECHNICAL DATA, DRAWINGS AND INSTRUCTION MANUALS

8.9.1 General

The Contractor shall submit information as identified in the Contractor Data Requirements Schedule in Appendix C.

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

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

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

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


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8.9.2 Technical Data

The Contractor shall allow for the provision of Manufacturer’s Data Reports (MDR) for all major equipment and piping systems of the Ammonia Unloading and Storage package. The MDRs shall include but not be limited to:

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

Qualification Record (WPQR) • Materials records • Non-destructive testing (NDT) reports • Hydrostatic test reports • Paint application monitoring records • Rubber lining application monitoring records • Statutory approvals and registrations • As built drawings for supplied equipment and components, (as-building of the general arrangement

drawings for the installed facilities shall be the responsibility of the installation contractor) • PLC programming checks • Shop test run performance monitoring.

8.9.3 Drawings

The Contractor shall provide drawings as set forth in Appendix C, which will form part of the Purchase Order.

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

8.9.4 Installation, Training, Operating and Maintenance Manuals

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

The IOM manuals shall be specifically written for the Ammonia Unloading and Storage package and supplied by the Contractor. Their format and content shall be reviewed and approved by the Client’s representative prior to final submission.

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

9 INSPECTION, TESTING AND ACCEPTANCE

9.1 QUALITY SYSTEM

The Contractor shall provide a quality system in accordance with ISO 9001 or approved equivalent, as well as a plan which shows how design, procurement, fabrication, installation and testing quality issues will be handled. The Quality Plan shall demonstrate how, for each of these aspects, an auditable trail can be established.

The Contractor shall arrange for sufficiently qualified personnel to provide auditing of the implementation of the ammonia storage and unloading facility Quality Plan.


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Refer to Appendix B for detailed requirements on the required Quality System.

9.2 VERIFICATION & TESTING DURING FABRICATION

The Contractor shall submit details of all tests to be carried out during manufacture of the equipment and structures for the Ammonia Storage and Unloading Package in the format of an Inspection and Test Plan with detailed Vendor/Sub-Vendor inspection points shown and test procedures clearly defined. Test results shall be collated and supplied for Client review.

The Contractor shall provide sufficiently experienced staff to expedite and inspect shop-fabricated items. It shall demonstrate that items are inspected for satisfactory construction prior to leaving the fabricator’s shop or yard. This applies in particular to pipe spooling, pre-fabricated steelwork, pipe supports, tanks, pumps, switchboards and PLC’s.

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

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

The Contractor shall inspect all shop welds prior to assembly and provide copies of the reports to the Client. The inspection of welds shall comply with AS 1554 category SP, or relevant codes, eg. AS1210.

All material heat numbers of all flanges and fittings, welding work shall be traceable on demand.

The Contractor shall submit copies of mill analyses and test reports of materials in the Manufacturer’s Data Report (MDR).

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

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

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

Where possible and practical to do so, key equipment for the Ammonia Storage and Unloading package shall be test run at the workshop witnessed by the Client’s Representative, in its fully assembled state, for a period of not less than 8 continuous hours.

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

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

9.3 FINAL ACCEPTANCE

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


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

Following completion of the work, the Contractor shall issue a Manufacturer’s Data Report (MDR) comprised of the quality certificates, inspection and test records, and any other relevant documents related to manufacture and testing for the Client Representative’s record files. This shall include all documents listed in the attached Contractor Data Requirements Schedule.

9.4 PERFORMANCE CRITERIA AND TESTING

9.4.1 Primary Performance Requirements

The Contractor shall ensure that the following parameters conform to the requirements listed in the datasheet listed in Appendix A.

• Capacity of liquid anhydrous ammonia storage bullets • Capacity of liquid nitrogen storage bullets for ammonia system purging • Achievement of required pressure and flow rate of anhydrous ammonia at the discharge of the

vapouriser • Achievement of full system purge with nitrogen gas for planned shutdowns using stored nitrogen

reserves. • Achievement of requirements of AS1940, AS2022 and other referenced Standards • Compliance with all relevant Dangerous Goods Acts, Regulations and Authorities • Power draw at design and maximum throughput rates for major equipment • Noise and Vendor specified vibration levels for the individual equipment and combined operating plant. • Demonstration that the ESD system functions correctly.

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

9.4.2 Performance Assessment against Requirements

Following successful commissioning, performance acceptance testing will be conducted to measure the performance of the Ammonia Storage and Unloading package against the requirements detailed above. The Contractor shall submit procedures for these test runs to be reviewed and approved by the Client’s Representative.

Commercial consequences for failure to successfully achieve all system performance requirements shall be detailed at the time of order placement.

9.5 COMMISSIONING

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

9.5.1 Off Site Testing

• Single component equipment shall be individually factory tested and certified by the manufacturers • Multi component equipment shall be factory tested in the assembled or inter-connected state


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

9.5.2 On Site Testing

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

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


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APPENDIX A DRAWINGS AND SPECIFICATIONS

Drawing / Specification No. Description 140316-5420-45ED-PK0001 Datasheet: Ammonia Storage & Unloading Package 140316-0000-45D1-0004 Mechanical General Process Plant – Area Key Plan 140316-0000-40EG-0001 Project Specification 140316-0000-46EC-0001 Piping Design Criteria 140316-0000-46EG-0001 Piping Material Specification 140316-0000-46EG-0004 Manual Valves Specification 140316-0000-47EC-0002 Design Criteria for Electrical & Automation for Minor Packaged Plant


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APPENDIX B 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, Vendors or Sub suppliers supplying goods and/or services under the terms of the Contract and these requirements shall apply with equal force and effect to each of these parties.

The 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 the table below or with a comparable alternative Standard.

Denotes Required Standard Rating Requirements X A AS/NZS ISO 9001 X B AS/NZS ISO 9002

Plus AS/NZS ISO 9001 Clauses 4.4.6 to 4.4.9 C AS/NZS ISO 9002 D AS/NZS ISO 9003

QUALITY SYSTEM DOCUMENTATION

The Contractor shall comply with the following requirements as indicated:

Document Description To be submitted for review 28 days from award

To be available for review on request

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

ACCESS

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

NON-CONFORMANCE/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.

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 Client’s Representative whose decision on the proposal shall be obtained in writing before the nonconforming material or work is covered up or incorporated into the Works, or is the subject of any other disposition.


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

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 in Table 3, the Contractor shall provide evidence of validation of the design that will satisfy the requirements of AS/NZS ISO 9001 and as defined in AS / ISO 8402.

The 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 Client’s Representative at the times and in the quantities specified in the Contract.

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

PREPARATION AND SUBMISSION OF PROJECT QUALITY PLAN

A Project Quality Plan (PQP) shall be prepared by the 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 Client’s Representative at least two weeks prior to the scheduled date of such audit. The Client’s Representative undertakes not to make these documents available to any third party without the express permission of the 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 Client’s Representative on request or when specified in the Contract.

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

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


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WITNESS AND HOLD POINTS

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

Refer to below clauses 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 Client’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 Client or its representative being present, except where the Client’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.


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APPENDIX C CONTRACTOR’S DRAWING AND DATA REQUIREMENTS

No. Description Document Required with

Feasibility Study Bid

Document Required

After Award

Issue Date

(weeks after

award)

Qty. /Version of

Issue

Remarks

CONTRACTOR DRAWINGS AND DATA REQUIREMENTS PART A - DRAWINGS

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

A2.0 DISCIPLINE DRAWINGS A2.10 Civil Drawings

A2.15 Foundation Guide Load, Baseplate & Anchor Bolt arrangement

X

A2.20 Structural Steel Drawings

A2.21 Structural Steel Arrangements & Details

X

A2.30 Mechanical Drawings

A2.31 General Arrangement, Plan and Elevation

X X

A2.40 Piping Drawings

A2.41 Piping and Instrument Diagrams

X X

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

X

A2.50 Electrical Drawings

A2.51 Equipment Layouts and Arrangements

X

A2.52 Cable and Cable Tray Layouts and Arrangement Drawings

X

A2.53 Single Line Diagrams X X

A2.54 Schematics X

A2.56 Electrical Standard Details

X

A2.57 Termination drawings X A2.60 Instrumentation and

Control Drawings

A2.61 Control System Block Diagrams or sequence tables

X X

A2.62 Instrument loop diagrams X


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Document Required

After Award

Issue Date

(weeks after

award)

Qty. /Version of

Issue

Remarks

A2.70 Infrastructure Drawings

A2.71 Buried Services General Arrangement and Layouts

X

A2.72 Buildings Layouts and Arrangements

X

A2.73 Air-conditioning Services X

A2.74 Utilities and Services Layouts, Arrangements and Details

X

A2.75 Communications Systems

X

A2.77 Fire Protection Systems X X A2.80 Vendor Drawings

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

X

A2.82 Foundation Loading Diagrams & Interface Drawings

X X

A2.90 OTHER

A2.91 Vendor to Nominate CONTRACTOR DRAWINGS AND DATA REQUIREMENTS

PART B – ENGINEERING DATA B ENGINEERING DATA B1.0 GENERAL

B1.1 Process Design Criteria X

B1.2 Engineering Design Basis X

B1.3 Drawing Register X

B1.4 Ammonia Storage & Unloading Package Data Sheet

X X

B2.0 KEY DOCUMENTS

B2.1 Mechanical Equipment List

X X

B2.2 Electrical Equipment List X X

B2.3 Cable Schedule X

B2.4 Instrument List X X

B2.5 Piping Line List X X

B2.6 Valve Schedule X

B2.7 Electric Motor List X X

B2.8 Preliminary I/O Count X

B2.9 I/O/List X

B2.10 Estimated Concrete MTO (Materials Take-Off) (m3)

X


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Document Required

After Award

Issue Date

(weeks after

award)

Qty. /Version of

Issue

Remarks

B3.0 ENGINEERING CALCULATIONS

B3.1 Process X

B3.2 Concrete

B3.3 Structural Steel

B3.4 Tankage and Platework X

B3.5 Mechanical Equipment

B3.6 Vendor Equipment Sizing

B3.7 Pipework

B3.8 Electrical Equipment and Cable Sizing

X

B3.9 Power Supply

B3.10 Pump Performance Curves X

B4.0 PLANT OPERATION

B4.1 Control Logic and Operating Philosophy and Functional Description

X

B4.2 Plant Installation, Operation and Maintenance Manuals

X

B4.3 Training Manuals & Presentations

X

B4.4 Distribution Control System Programme

X

B.5.0 SPECIFICATIONS

B5.1 Technical Specifications X

B5.2 Equipment Specifications X B.6.0 STATUTORY

APPROVALS

B6.1 Crane Certification X

B6.2 Monorail Certification X

B6.3 Pressure Vessels X

B6.4 Power Supply System X B.7.0 OTHER Contractor to nominate X

CONTRACTOR DRAWINGS AND DATA REQUIREMENTS PART C – CONTRACT DOCUMENTATION

C CONTRACT DOCUMENTATION

C1.0 GENERAL

C1.1 Commercial and Technical Non-Conformances

X X


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Document Required

After Award

Issue Date

(weeks after

award)

Qty. /Version of

Issue

Remarks

C2.0 ESTIMATE DOCUMENTS

C2.1 Capital Cost Estimate X

C2.2 Operating Cost Estimate

C3.0 REGISTERS

C3.1 Scope Change Register X

C3.2 Purchase Order Register X

C3.3 Inspection/Expediting Register

X

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

X

C4.0 SCHEDULES

C4.1 Overall Project Schedule X X

C4.2 Engineering Schedule X X

C4.3 Construction Schedule

C4.4 4 Week Look-Ahead Schedule

X

C4.5 Shutdown & Tie-in Schedules

C.5.0 REPORTS

C5.1 Monthly Project Reports X

C5.2 Manhour Reports – Home Office and Site

X

C5.3 Design Status Report X

C5.4 Drawing Status Report X

C5.6 Inspection Status Reports X

C5.7 Expediting Status Reports

X

C5.8 Cost Reports X

C5.9 Site Construction Progress Reports – Summary Level

C5.10 Site Safety Reports

C5.11 Site Goods Received Reports

C5.12 Commissioning Reports X

C5.13 Project Closeout Report X

C5.14 Manufacturer’s Data Reports (MDR)

X

C6.0 MEETINGS

C6.1 Project Meetings with Client’s Rep

X

C6.2 Site Construction Meetings

X


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Document Required

After Award

Issue Date

(weeks after

award)

Qty. /Version of

Issue

Remarks

C7.0 INSURANCE

C7.1 Workers Compensation X

C7.2 Public Liability X

C7.3 Motor Vehicle X

C7.4 Professional Indemnity X

C7.5 Marine Transit Cover X

C7.6 Other (Tenderer to Nominate)

C8.0. PROJECT IMPLEMENTATION

C8.1 Project Quality Plan X Only brief description required with Bid

C8.2 Project Procurement and Contracting Strategy

X Only brief description required with Bid

C8.3 Project Contracting Strategy

X X Only brief description required with Bid

C8.4 Industrial Relations Strategy

X

C8.5 Project Risk Analysis X

C8.6 HAZAN/HAZOP Review and Recommendations

X

C8.7 Environmental Review and Recommendations

X

C8.8 Constructability Review and Recommendations

X

C8.9 Maintainability Review and Recommendations

X

C8.10 Occupational Health And Safety Review And Recommendations

X

C8.11 Statutory Regulations Review And Checklist

X

C8.12 Security Systems Review And Recommendations

X

C.9.0 INTERNAL AUDITS

C9.1 Process Audits X

C9.2 Design Audits X

C9.3 Cost Control/Forecast Audits

X

C9.4 Project Schedule Audits


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Document Required

After Award

Issue Date

(weeks after

award)

Qty. /Version of

Issue

Remarks

C9.5 Quality Assurance/Control Audits

X

CONTRACTOR DRAWINGS AND DATA REQUIREMENTS PART D – SITE RECORDS

D SITE RECORDS

D1.0 Daily Diaries

D2.0 Inspection Records X

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

X

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

D5.0 Calibration Certificates

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

X

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

X

D8.0 Site Instruction Register X

D9.0 Site Instructions/Contract Variations

X

D10.0 Survey Data CONTRACTOR DRAWINGS AND DATA REQUIREMENTS

PART E – COMMISSIONING RECORDS E COMMISSIONING

PLAN, PROCEDURES & RECORDS

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

X

E2.0 Commissioning Procedures

X

E3.0 Commissioning Records including Construction Verification Checksheets, Direction of Rotation Checks, Electrical and Safety Device Checks, Equipment No-Load Runs, Group Starts, PCS

X


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Document Required

After Award

Issue Date

(weeks after

award)

Qty. /Version of

Issue

Remarks

Configuration Verification, System Upset Condition Checks, Facility or System Operational Verification, and Process Commissioning respectively.

E4.0 Performance Trial/Test Procedures

X

E5.0 Performance Trial/Test Data

X


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APPENDIX D RESPONSIBILITY MATRIX

DESCRIPTION Supply Contractor

Client’s Rep Comments

1.0 PROCESS DESIGN 1.1 Overall Plant Design Parameters X

1.2 Detailed Plant design X

1.3 Overall process Flow Diagram X

1.4 P&IDs X 2.0 ENGINEERING DESIGN 2.1 Ammonia Facility X 2.2 Utilities Design X 2.3 Effluent Treatment Plant 2.4 Civil & Structural Works 2.5.1 Design and specify all civil and structural

works, including any buildings/control rooms

X

2.5.2 Commission site survey X

2.5.3 Commission Geotechnical Survey X

2.5.4 Site preparation and Grading X 2.5 Electrical and Instrumentation 2.5.1 Design: Switchgear & MCC’S; Substations;

Switchrooms X

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

X

2.5.3 Specify: 415V MCC’s Transformers; Substations; Switchrooms; Control Room;

X

2.5.4 Instruments; Site Installation work X

2.5.5 Provide and programme distributed control system

X Client’s Rep to supply PCS Highway to Contractor

2.6 Drawing Approvals

2.6.1 Ammonia Facility Design Drawing X Client’s Rep to review and comment

2.6.2 Contractor Drawings X 3.0 SPECIFICATIONS 3.1 Provide specific Engineering Standards

where available X Client’s Rep to

provide

3.2 Prepare Equipment Specifications X

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

Maintenance Manuals from Sub Contractors

X Client’s Rep to provide site philosophy

4.2 Prepare overall Operating and Maintenance Manuals

X


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5.0 PERMITS AND APPROVALS 5.1 Obtain any permits and Approvals other

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

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

5.2 Mines Department Approvals and Building Approvals

X

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

6.1.1 Prepare Cost Schedule X

6.1.2 Maintain Cost Control X

6.1.3 Prepare Long Term and Monthly Cash Flow Forecasts

X

6.1.4 Prepare Variations X

6.2 Project Schedule

6.2.1 Prepare Project Schedule X

6.2.2 Prepare Summary Schedule with Critical Path

X

6.2.3 Update Schedules X

6.3 Progress Reports

6.3.1 Prepare progress Reports for Client’s Rep X One per month

6.4 Project Cost Reports

6.4.1 Prepare Cost Report for Client’s Rep X One per month

6.5 Project Meetings

6.5.1 Call and chair Project Meeting with Client’s Rep

X One per month

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

6.6 Project Procedures Manual

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

7.0 PROCUREMENT 7.1 Purchasing 7.1.1 Determine scope of enquiries X

7.1.2 Prepare list of tenderers X Client’s Rep to approve

7.1.3 Prepare commercial conditions X X Use Client Rep’s Terms and Conditions

7.1.4 Prepare enquiry X

7.1.5 Issue enquiry X

7.1.6 Receive enquiry X

7.1.7 Evaluate tenders and negotiate with tenderers

X


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7.1.8 Recommend supplier X Submit technical evaluation summary to Client’s Rep

7.1.9 Approve recommended supplier X

7.1.10 Prepare and issue contract to supplier X

7.1.11 Receive and approve Contractor documentation

X

7.1.12 Resolve Contractor technical queries X

7.1.13 Resolve Contractor commercial queries X

7.2 Expediting

7.2.1 Expedite progress of contracts X

7.2.2 Expedite Contractor documentation X In accordance with document data sheet

7.3 Shipping X

7.4 Approval and Payment of Contractor of Invoices

X

7.5 Spare Parts

7.5.1 Identify requirements (for commissioning, operation and capital)

X Submit to Client’s Rep

7.5.2 Purchase of spare parts Commissioning Operating Capital

X

X X

Option for Client’s Rep to buy balance

7.5.3 Special Tools Identification Purchase

X

X

7.6 Quality Assurance X

7.7 Quality Control X

7.8 Design Review and Audit

7.8.1 Process Design X

7.8.2 HAZOP Study X By Independent 3rd Party Client’s Rep to participate.

7.8.3 Environmental Integrity X By Independent 3rd Party

7.8.4 GA drawings X Client’s Rep option to carry out an independent review


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7.8.5 Detail design X Client’s Rep option to carry out an independent review

7.8.6 Control Logic and Interlock Diagrams X Client’s Rep option to carry out an independent review

8.0 INSURANCES X 9.0 UTILITY SUPPLY X As detailed in

specification

10.0 CONSTRUCTION 10.1 Provide construction management X

10.2 Set-up site offices/facilities X

10.3 Set-up lay down areas X Consult with Client’s Rep

10.4 Manage the work of Contractors X

10.5` Administer goods received X

10.6 Ensure that contractors provide and maintain adequate construction labour

X

10.7 Provide site access X

10.8 Construction interface with plant operations X

10.9 Provide construction labour camp X

10.10 Administer Industrial Relations in conjunction with the Client’s Policy

X Client’s Rep available for consultation

10.11 Maintain construction safety X

10.12 Prepare Project Safety Manual X

10.13 Provide power and services for construction X To battery limits construction

10.14 Verify contractors progress claims and variations

X

10.15 Monitor progress and quality of site X In accordance with QA plan

10.16 Arrange, conduct and record site meetings X 11.0 POST CONSTRUCTION

11.1 Monitor each contractor through defects liability period

X X

11.2 Deliver ‘as built’ drawings, including Contractor and sub-contractors

X X

12.0 COMMISSIONING 12.1 Prepare commissioning programme X

12.2 Perform and record pre-commissioning X

12.3 Perform and record commissioning X

12.4 Provide plant operators during commissioning and plant start-up

X


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12.5 Provide technical services team for co-ordination and supervision of plant start-up (24hr cover)

X

12.6 First fill of lubricants X

12.7 Provide raw materials for commissioning X

12.8 Provide general consumables for commissioning

X

13.0 TRAINING 13.1 Co-ordinate suppliers to train client

personnel X

13.2 Classroom and field training program and manuals.

X

13.3 Provide operators for training X 14.0 PERFORMANCE TESTING

14.1 Supervise performance test X

14.2 Provide operating personnel, supplies and services

X

14.3 Provide laboratory and field services X

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