SCOPE OF WORK Revision APRON FEEDER

SCOPE OF WORK APRON FEEDER

Document No 140316-3110-45EW-5501 Revision 00 Date 15/05/17 of 22

REVISION CONTROL

Issued for Internal Review

Issued for Client Review

Issued for Study Use

REVISION HISTORY

Revision Date Pages Revised Remarks

SNC LAVALIN 140316-3110-45EW-5501_00 - SOW Apron Feeder.docx



TABLE OF CONTENTS 1 SCOPE OF WORK 6

1.1 Introduction 6

1.2 Work Included 6

1.2.1 Engineering and Services 6 1.2.2 Procurement and Supply 6

1.2.3 Fabrication 6

1.2.4 Shop Assembly 6

1.2.5 Provision of Technical Data, Drawings and Instruction Manuals 7

1.2.6 Shipment, Packing and Preparation 7

1.2.7 Spare Parts, Special Tools and Equipment 7 1.2.8 Lubricants 7

1.2.9 Installation and Commissioning Assistance 7

1.3 Optional Work 7

1.3.1 Alternatives 7 2 WORK EXCLUDED 7

Engineering, Services and Supply 7 Free Issue Items 8

Battery Limits 8 3 REFERENCE DOCUMENTS AND STANDARDS 8

Drawings and Specifications 8

Codes, Standards and Regulations 8 3.2.1 Government Acts, By-Laws and Regulations 8

3.2.2 Standards 8

Language and Measurement System 9 4 OPERATING ENVIRONMENT 9

5 DESIGN CRITERIA 10

Ore Preparation Apron feeder 10 5.1.1 Process Description 10

5.1.2 Operating Philosophy 11

5.1.3 Duty and Throughput Rate 11

Equipment Design Life 11

Other 11

5.3.1 Lifting Lugs 11 5.3.2 Noise Level 11

5.3.3 Safety Guards 11 6 DETAILED TECHNICAL REQUIREMENTS 11




Engineering and Services 11

Materials of Construction 12

Mechanical 12 6.3.1 Pans 12

6.3.2 Chains and Sprockets 12

6.3.3 Carry and Return Rollers 12

6.3.4 Drive Unit 12

6.3.5 Automatic Grease Lubrication System 13

6.3.6 Chain Tensioning Unit 13 6.3.7 Bearings and Housings 13

6.3.8 Frame 13

Structural 13

Electrical 14

Instrumentation and Plant-wide Control System Integration 14

6.6.1 Instruments 14 6.6.2 Control Systems 14

6.6.3 Functional Safety 15

6.6.4 CCTV 15

6.6.5 Fire Monitoring 15

6.6.6 Conformal Coating 15 6.6.7 Documentation 15

Surface Protection 16

Equipment Identification, Marking and Labelling 16

Technical Data, Drawings and Manuals 16

6.9.1 General 16

6.9.2 Responsibility 17 7 INSPECTION, TESTING AND ACCEPTANCE 17

Quality System 17

Verification and Testing During Fabrication 17

Final Acceptance 18

Performance Criteria and Testing 18

LIST OF TABLES

Table 1 Standards 8

APPENDICES

Appendix A: REFERENCE DOCUMENTS 19




Appendix B: VENDOR DATA REQUIREMENTS SCHEDULE 20




1 SCOPE OF WORK

1.1 INTRODUCTION

This document sets out the scope of work and technical requirements for the supply of the apron feeder and ancillary equipment for the Syerston Project in New South Wales, Australia.

1.2 WORK INCLUDED

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

Qty Description Datasheet No. 2 Apron Feeder 140316-3110-45ED-FE0001

1.2.1 Engineering and Services

The Vendor shall design the apron feeder in accordance with this document, the applicable codes and standards, reference specifications, drawings, duty requirements stated in the data sheet and local government regulations.

1.2.2 Procurement and Supply

The Vendor shall supply and deliver the apron feeder and the works specified in Section 1.2, and shall furnish all materials, accessories and services required for the complete testing and commissioning of the same.

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

• Apron feeder • Spillage conveyor • Hydraulic chain tensioning unit • Drive unit • Field instrumentation.

1.2.3 Fabrication

The Apron Feeder shall be fabricated in accordance with this document, the applicable Australian codes and standards, reference specifications, drawings, equipment data sheet and Australian local government regulations.

1.2.4 Shop Assembly

The Apron Feeder shall be shop assembled to the greatest extent practical required for FAT and prior to final inspection and delivery.

Where not practicable to provide a fully assembled unit for delivery, the Vendor shall supply equipment in discrete sub-assemblies to minimise site assembly time. The sub-assemblies shall be capable of being transported in a standard 40 ft shipping container or have a footprint of similar size. The Vendor shall nominate the extent of pre-assembly in the tender.




1.2.5 Provision of Technical Data, Drawings and Instruction Manuals

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

1.2.6 Shipment, Packing and Preparation

The Vendor shall shop assemble components to the maximum extent practical, such that field assembly is both minimised and simplified, and matching of components is assured. The Vendor shall shop fit, drill, identify and match mark parts that cannot be shop assembled prior to shipment.

The Vendor shall provide the equipment “Ex Works” and prepare the equipment for shipment, preserve, pack and transport the equipment.

1.2.7 Spare Parts, Special Tools and Equipment

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

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

1.2.8 Lubricants

The Vendor shall provide a recommended lubricant schedule including initial fill and consumption quantities for the operation of the Apron feeder.

1.2.9 Installation and Commissioning Assistance

The Vendor shall include costs to provide assistance during the installation and commissioning stages of the Apron Feeder based on their experience. The daily charge out rates for the supervision of installation and commissioning of the Apron Feeder 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.

1.3 OPTIONAL WORK

1.3.1 Alternatives

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

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

2 WORK EXCLUDED

ENGINEERING, SERVICES AND SUPPLY

• Apron feeder feed bin, feed bin skirts and discharge chute will be supplied and installed by Others • Apron feeder support steelwork will be designed, supplied and installed by Others • Apron feeder anchor bolts will be designed by the Vendor, but supplied and installed by Others SNC LAVALIN 140316-3110-45EW-5501_00 - SOW Apron Feeder.docx



• Equipment will be off-loaded, handled and stored at the site by Others • Equipment will be installed, commissioned at the site by Others • Equipment access platforms, walkways, hand railing, ladders and stairways will be designed, supplied

and installed by Others • Power supply, control and instrument wiring will be supplied and installed by Others • Electrical variable speed unit will be supplied and installed by Others • Electric motor starters will be supplied and installed by Others • Instrument air, plant air, water piping external to the Apron Feeder (if required) will be supplied by Others • Concrete foundation design and construction will be by Others.

FREE ISSUE ITEMS

There are no free issue items supplied by the Client’s Representative to the Vendor for inclusion with the Apron Feeder.

BATTERY LIMITS

The Vendor’s battery limits of supply for the Apron Feeder are:

• Underside of skirting on the feed bin • Underside of the Apron Feeder main frame and associated equipment • Terminal flanges or fittings on cooling water and plant/instrument air (if required) • Drive electric motor terminal boxes • Instrumentation junction box terminals.

3 REFERENCE DOCUMENTS AND STANDARDS

DRAWINGS AND SPECIFICATIONS

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

CODES, STANDARDS AND REGULATIONS

3.2.1 Government Acts, By-Laws and Regulations

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

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

3.2.2 Standards

Table 1 Standards

Standard Number Title AS 1448 Carbon Steels and Carbon Manganese Steels – Forgings AS 1554 Structural Steel Welding AS 1830 Iron Castings – Grey Cast Iron AS 2027 Iron Castings – Abrasion Resistant White Iron




Standard Number Title ISO 9001: 2015 Quality Management Systems AS 2074 Steel Castings AS 2700 Colour Standards for General Purposes AS 2729 Rolling Bearings – Dynamic Load Ratings and Rating Life AS 3679.1 Structural Steel – Hot Rolled Bars and Sections AS 3890 Rolling Bearings – System Life Reliability AS 5131 Fabrication and Erection of Structural Steelwork AS 4024.1 Safeguarding of Machinery – General Principles AS 4171 Rolling Bearings – Static Load Ratings NOHSC :1007-2000 National Standard for Occupational Noise AS 1023 Low Voltage Switchgear and Control gear – Protection of Electric Motors AS 1768 Lightning Protection AS/NZS 3000 Electrical Installations

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

AS/NZS 3008 Electrical installations - Selection of cables AS 3439 Low Voltage Switchgear Assemblies

AS 61508.0-2006 Functional Safety of Electrical/Electronic/programmable Electronic Safety Related Systems

AS 61511.1-2004 (R2015)

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

AS 62061-2006 Safety of Machinery – Functional Safety of Safety-related Electrical, Electronic and Programmable Electronic Control Systems

AS 62271 High Voltage Switchgear and Control Gear IEC 61233 High Voltage Alternating Current Circuit-Breakers – Inductive Load switching AS/ACIF S009:2006 Installation Requirements for Customer Cabling (Wiring Rules)

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

LANGUAGE AND MEASUREMENT SYSTEM

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

4 OPERATING ENVIRONMENT

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

The Apron Feeder will be located outdoors. It will be exposed to dusty conditions and subjected to hose down with raw water.




5 DESIGN CRITERIA

The Apron Feeder design shall be in accordance with the criteria specified within this document and the equipment data sheet 140316-3110-45ED-FE0001.

As indicated in the datasheet, the Apron Feeder shall be sized with a 20% capacity allowance above the steady state material balance flows to provide for the control of operation cycles and for ‘catch up capacity’ in the case of unexpected slowdowns.

The Apron Feeder loads shall take into account the following resistance:

• Static bulk solids shear • Gravity forces • Skirt plate friction within the hopper and area beyond the hopper • Hopper outlet resistance including outlet restraining chains • Support roller and sprocket friction.

Initial fill (break-out) and flow conditions shall be considered in the calculation of chain tensions and drive power.

The design of the Apron Feeder shall take into account the heavy impact loading by the falling materials in the ROM bin. The material drop height is defined in the equipment data sheet.

All design calculations for the Apron Feeder shall be based on industry accepted standards. The Apron Feeder design calculations shall be submitted to the Client’s Representative for approval.

ORE PREPARATION APRON FEEDER

5.1.1 Process Description

There will be two identical dump pockets, each consisting of a 140 cubic metre live volume ROM bin fed by either a dump truck or a front end loader (FEL) through a ROM bin fixed grizzly of 600mm spacing. Both dump pockets will be operated in parallel, with dump trucks alternating between the two ROM bins to ensure that both pockets continue operating in parallel.

Each Apron Feeder will withdraw the ore from the ROM bin and feed it to a dedicated Ore Roller Screen. Undersize from the Roller Screen will be directed onto the feed conveyor into the Ore Scrubber, whilst the balance will be fed into a dedicated Ore Sizer. Crushed ore from the ore sizer will then be directed onto the same feed conveyor into the Ore Scrubber.

The discharged ore from each of the two Ore Sizers will be directed onto a single feed conveyor into the Ore Scrubber.

The rate of ore delivery from each Apron Feeder will vary between 25% and 100% of the nominal figure provided in the datasheet, with the total combined nominal throughput not exceeding the 100% figure under normal operating conditions.

Spillage from each Apron Feeder will be collected by a spillage conveyor which will in turn discharge into the ore sizer feed chute dedicated to that Apron Feeder.

Each Apron Feeder shall have a variable speed drive which shall be controlled by the Ore Scrubber feed rate set point.




5.1.2 Operating Philosophy

Neither of the two Apron Feeders will have a stand-by unit. Each Apron Feeder will operate 24 hours per day on a continuous basis, with stoppages only for planned and breakdown maintenance activities.

5.1.3 Reliability

The Vendor shall advise the anticipated availability of the Apron Feeder for the first two years of operation as a minimum, citing recent examples of actual installations of similar sized Apron Feeders and stating the nature, duration and frequency of all routine maintenance activities that will be required during that period.

5.1.4 Duty and Throughput Rate

Refer to the equipment data sheet 140316-3110-45ED-FE0001.

EQUIPMENT DESIGN LIFE

All equipment, components and assemblies shall be designed and constructed by the Vendor to ensure a minimum equipment design life of 20 years.

OTHER

5.3.1 Lifting Lugs

Where practical all assemblies and components of the Apron Feeder shall be provided with suitable lifting lugs or eye bolts to allow for easy off-loading and installation. Lifting lugs shall be tested, certified and stamped with Working Load Limit (WLL).

5.3.2 Noise Level

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

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

5.3.3 Safety Guards

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

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

6 DETAILED TECHNICAL REQUIREMENTS

ENGINEERING AND SERVICES

The Vendor shall design, select and supply all specified equipment, materials, special tools, spare parts and services as outlined in this scope of work, the Project Specification, (140316-0000-40EG-0001), and the duties specified in the equipment data sheet.

The Vendor shall provide the necessary technical data for the selection and supply of the electrical variable speed drive for electro-mechanical drive system.




MATERIALS OF CONSTRUCTION

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

Once a purchase order has been issued, the Vendor shall not substitute materials without prior written approval from the Client’s Representative.

The Vendor shall fabricate the Apron Feeders using only new materials of first grade quality, free from defects impairing strength, durability and appearance.

MECHANICAL

The Vendor shall design and construct the equipment in accordance with this document, with due regard to ease of operation, inspection, cleaning, maintenance and repair. The Apron Feeder will be subject to high abrasion, impact, shock and severe wear. Maintenance of the equipment is a prime concern and the Vendor shall ensure that the equipment supplied is of robust construction and that components requiring regular maintenance are easy to inspect, adjust, maintain or replace.

The Apron Feeder shall be the Vendor’s standard design for the specified service and duty. Standard replacement parts shall be readily available.

The Apron Feeder shall be capable of inching at low speed in forward and reverse directions for maintenance purposes.

The Apron Feeder design shall avoid pockets and ledges where dust or water may accumulate.

6.3.1 Pans

Rigid section pans shall be used for maximum resistance to impact and abrasion. The pans shall be designed to be overlapping with close fit to prevent leakage of fine material. Side flanges shall be integral with the pans. Contact surfaces for chain attachments shall be machined. Impact pads shall be provided on all pans.

6.3.2 Chains and Sprockets

Heavy duty Caterpillar or approved equivalent earth moving equipment chains shall be used with four master links per strand. Chain attachments to the pans shall be of bolted construction.

Sprockets shall be of matching half tooth design to the chains with an odd number of teeth. They shall be segmented and shall allow replacement of tooth segments without the need to remove drive chains or pans.

6.3.3 Carry and Return Rollers

Carry and return rollers shall be heavy duty Caterpillar or approved equivalent earth moving equipment rollers to match the chains. The rollers shall have sealed for life bearings.

All roller assemblies shall be capable of replacement without the need to remove any major feeder components. Special tools required for the removal of rollers shall be provided.

Carry roller spacing may be indexed with closer spacing at the feed end to account for higher loading and impact from the material fall.

Return rollers shall be spaced to ensure proper tracking of the chains and avoid undue sagging.

6.3.4 Drive Unit

Apron Feeder drives shall be electromechanical or hydraulic, however electromechanical drives are preferred.




The design of the drive unit shall allow start up from a bogged condition of the Apron Feeder.

The gearbox (on electromechanical drives and high speed hydraulic motors) or the hydraulic motor (on low speed hydraulic motors) shall be shaft mounted, fixed with shrink disc coupling. A torque arm assembly with restrain capability in both forward and reverse directions shall be provided.

6.3.5 Automatic Grease Lubrication System

An automatic grease lubrication system shall be provided for the Apron Feeder bearings. Grease points shall be piped to accessible location.

6.3.6 Chain Tensioning Unit

A manual hydraulic chain tensioning unit consisting of a hydraulic jack, cylinder, valves and pressure gauge shall be provided. The cylinder stroke shall be greater than one chain pitch. The chain tensioning unit shall be mounted on the Apron Feeder frame.

6.3.7 Bearings and Housings

All bearings on the Apron Feeder head and tail sprocket assemblies shall be heavy duty anti-friction self-aligning double row roller bearings. Grease purged labyrinth type dust seals shall be fitted to all bearings to prevent ingress of dust and water. Bearings shall be fitted with pressure injection type sleeves to facilitate bearing replacement.

Anti-friction type bearings shall have a B10 basic rating life in excess of 100,000 hours for bearing loads encountered at design duty, calculated in accordance with AS 2729 and AS 3890. Adjusted rating life B10 shall be calculated according to AS 2729 or modified theories by bearing manufacturers. Static load ratings shall be determined from AS 4171.

All bearing plumber blocks shall be cast steel, four bolt type and fitted with grease purged triple path radial ‘Taconite’ labyrinth seals.

Grease lubrication of bearings and purging of labyrinth seals shall be by an automatic grease lubrication system.

6.3.8 Frame

An integral, fully load bearing main frame for the Apron Feeder shall be provided for mounting on steel support structure.

The frame shall be designed to withstand the maximum equipment torques and forces without permanent deflection or distortion. They shall have machined pads for the mounting of drive and driven equipment, through bolts for equipment fixture and provision for horizontal adjustment using jacking bolts.

The Apron Feeder frame shall have provision for the mounting of the chain tensioning unit and the automatic grease lubrication system.

The base frames shall be designed with boxed in sections to prevent retention of water, dust and shall be self-draining.

All support reaction loads shall be provided to facilitate the design of the concrete support foundation.

STRUCTURAL

Structural steel used for the construction of the Apron Feeder 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 or AS 1554 Category SP (Structural Purpose), or an approved international equivalent.

ELECTRICAL

Rated voltage and frequency of electrical motors shall be as per Section 17 of the Project Specification (140316-0000-40EG-0001).

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 shall be provided with anti-condensation heaters.

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

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

INSTRUMENTATION AND PLANT-WIDE CONTROL SYSTEM INTEGRATION

The Vendor shall state with the tender any additional instrumentation and controls required for the safe operation of the Equipment.

6.6.1 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 of wireless instruments will be subject to the approval of the Client’s Representative.

6.6.2 Control Systems

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

The Vendor shall also 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 in wired to terminals in a Vendor supplied junction boxes. To ensure compatibility with the Plant Control System, the signals and instruments shall be

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




6.6.3 Functional Safety

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

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

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

6.6.4 CCTV

Any supplied CCTV systems shall be IP based, full colour + 720p HD picture and suitable for operating day and night in outdoor environments.

6.6.5 Fire Monitoring

Fire Indication panels shall be suitable for integration into a site wide Fire Monitoring System using either a standard digital communication protocol or a set of hardwired signals using voltage free contacts. The minimum number of signals from a Fire Indication Panel shall be

• Alarm • Fault • Isolated.

6.6.6 Conformal Coating

Polymeric Conformal Coating is not required for printed circuit boards as there is no Hydrogen Sulphide (H2S) in the process.

6.6.7 Documentation

The documentation shall include as a minimum a control function specification including:

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

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




SURFACE PROTECTION

All external surfaces of the Apron Feeder including base frame, guards and other ancillary equipment shall be provided with appropriate surface protection.

The Vendor should refer to the Client’s Specification for Corrosion Protection, 140316-0000-45EG-0002, for guidance on the preferred paint system and colours, but may adopt their own internal standards subject to approval by the Client’s Representative.

EQUIPMENT IDENTIFICATION, MARKING AND LABELLING

The Vendor shall provide the Apron Feeder with a nameplate including the following:

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

The Apron Feeder shall also have a direction of rotation arrow indicated on a plate mounted close to the drive units.

TECHNICAL DATA, DRAWINGS AND MANUALS

6.9.1 General

The Vendor shall submit information as identified in the Vendor Data Requirements Schedule in Appendix B: of this scope of work.

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

The Vendor shall complete and return the included Equipment Data sheet with his tender otherwise the tender will not be considered.

The Vendor 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, 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.

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




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

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

• Magnitude and location of all operating live loads with contents at maximum design density (including separate weights of rotating parts and their WR²)

• Magnitude and location of any out-of-balance forces • Magnitude and location of upset operating loads due to equipment being filled to maximum capacity,

scale accumulation, plugged chutes, etc • Impact factors to be applied to support reactions. • Provide loads and details for the design of the Apron Feeder support structure, including dynamic design

requirements, operational requirements, allowable deflections and differential settlements • Equipment operating frequencies and natural frequencies of vibration • Installation, Operating and Maintenance (IOM) manuals shall be prepared and supplied by the Vendor.

6.9.2 Responsibility

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

7 INSPECTION, TESTING AND ACCEPTANCE

QUALITY SYSTEM

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

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

VERIFICATION AND TESTING DURING FABRICATION

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

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

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

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

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

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

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




Factory tests shall not constitute a waiver of field commissioning requirements and the requirement to pass field tests under the specified operating conditions as per Sections 7.3 and 7.4.

The Apron Feeder 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.

FINAL ACCEPTANCE

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

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

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

PERFORMANCE CRITERIA AND TESTING

The Apron Feeder shall be capable of meeting performance requirements against the following parameters as detailed in the equipment data sheet:

• Ore throughput and sizing • Ability to handle feed particle sizes and the material drop • Power draw at design and maximum throughput rates • Noise levels • The Vendor shall demonstrate the full range of controls, operating functions and compliance with the

performance criteria.

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




APPENDIX A: REFERENCE DOCUMENTS

Document Number Document Title 140316-3110-45ED-FE0001 Data sheet for Apron Feeder 140316-0000-40EG-0001 Project Specification 140316-0000-45EG-0002 Specification for Corrosion Protection 140316-0000-47EC-0002 Design Criteria for Electrical and Automation for Minor Packaged Plant 140316-3110-49D1-0001 Process Flow Diagram: Ore Preparation - Scrubbing & Classification




APPENDIX B: VENDOR DATA REQUIREMENTS SCHEDULE

This section specifies information to be provided by the Tenderer as part of the tender submission and by the Vendor after acceptance of tender.

Documents shall be supplied in the quantity and type as indicated where –

O= Original

P= Print/photocopy

E= electronic media

Example: 1E = 1 electronic copy

* To be confirmed Post-Award

Format for all electronic media other than drawings – Microsoft Office 2010 software

Format for electronic media drawings – Microsoft CAD file format (dgn)

Storage – CD or flash drive

Item No. Description

Req’d per

each copy of Tender

Req’d for

review

Period*

(Days)

As-built req’d

Final copies req’d

Req’d after Acceptance of Tender

A. DRAWINGS A1 Vendor Drawings and Document List 1E 7 1E 1E A2 General Arrangement Drawings 1E 1E 7 1E 1E A3 Foundation Load Plan and Anchor Bolt Location 1E 1E 7 1E 1E A4 Assembly Drawings 1E 1E 7 1E 1E A5 Installation Drawings A6 Structural Steel Shop Details

A7 Detail Drawings Mechanical Electrical 1E 7 1E 1E

A8 Hydraulic Schematic Diagrams 1E 28 1E 1E A9 Hydraulic Assembly Details 1E 28 1E 1E A10 Electric Motor Details 1E 1E 7 1E 1E A11 Electrical Wiring Diagrams and Schematics 1E 7 1E 1E A12 Cable Block Diagrams A13 Piping and Instrumentation Diagrams (P&IDs)

A14 Electrical/Instrument Location and Layout Drawings 1E 28 1E 1E

A15 Electrical / Instrument Termination Drawings 1E 28 1E 1E A16 Single Line Diagrams B. DATA B1 Code and Material Specifications





Req’d per

each copy of Tender

Req’d for

review

Period*

(Days)

As-built req’d



B2 General Description of Equipment, Operation & Duties 1E

B3 Catalogue and Technical Brochures of Components 1E

B4 Itemised List of all Auxiliary Equipment 1E 1E 7 B5 Approvals of Relevant Authorities

B6 Design Calculations for mechanical & structural design including bearing life 1E 28

B7 Performance Curves and Data

B8 Completed Technical Questionnaire & Equipment Data Sheets 1E 1E 14 1E

B9 Bills of Material

B10 Welding Procedures and Qualification Tests Reports 1E 14 2E

B11 Inspection and Test Plan (ITP) 1E 14 B14 Calibration Procedures 1E 28 B15 Hydrotest Procedures B18 Commissioning Procedures 1E 42 3E B19 Label Schedule 1E 28 B20 Nameplate Details 1E 28 B22 Instrument Index 1E 28 1E 1E

B23 Control & Instrument Equipment Specifications Sheets (Instrument Data Sheets) 1E 28 1E 1E

B24 I/O Schedules 1E 28 1E 1E B25 Intrinsic Safety Dossiers B26 Software Documentation 1E 28 1E 1E

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

B28 Test Manual 1E 28

B29 Vendor/ Sub Vendor’s standard surface treatment and painting procedures 1E 28

B30 Vendor/Sub Vendor’s standard rubber lining procedures

B31 Electric Motor Data Sheet 1E 28 1E

B32 Technical data for the selection and supply of the electrical variable speed drive 1E 28 1E 1E

C. MANUALS

C1 Installation and Commissioning Instructions (note 2 & 3) 1E 28 6P

C2 Operating Manual (note 2 & 3) 1E 28 6P





Req’d per

each copy of Tender

Req’d for

review

Period*

(Days)

As-built req’d



C3 Maintenance Manual including Lubrication Instructions and Complete Parts List (note 2&3) 1E 28 6P

C4 Manufacturer’s Data Report (note 3) 2E Notes: 1. Period = calendar days following acceptance of tender for delivery of review documents 2. Items C1, C2 and C3 may be combined into one manual 3. Refer Instruction to Tenderers for minimum requirements for Manufacturer’s Data Report (MDR) and Installation,

Operating and Maintenance (IOM) Manuals


SCOPE OF WORK Revision APRON FEEDER

Documents

Transcript of SCOPE OF WORK Revision APRON FEEDER