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SCOPE OF WORK SOLVENT EXTRACTION PLANT

Document No 140316-4000-45EW-5609 Revision 01 Date 20/03/2018 Page 2 of 40

SNC-LAVALIN 140316-4000-45EW-5609_01 - Scope of Work - Solvent Extraction Plant.docx

REVISION CONTROL

Issued for Internal Review

Issued for Client Review

Issued for DFS

REVISION HISTORY

Revision Date Pages Revised Remarks

00 21/7/2017 various

Document was formerly 140316-4300-45EW-0445 rev PA. Updated to reflect design changes in the flow sheet, process design criteria, WBS changes, and package number change.

01 20/03/2018 various

Rewrote the scope of work as an Engineering and Procurement Package. The initial scope of work was written as Engineering, Procurement and Construction / Turnkey Package




TABLE OF CONTENTS 1 SCOPE DESCRIPTION 6

1.1 Introduction 6

1.2 Work Included 6

1.2.1 Engineering and Services 6 1.3 Procurement and Supply 7

1.4 Fabrication and Shop Assembly 7

1.5 Quality System 7

1.6 Verification and Testing During Fabrication 7

1.7 Technical Data, Drawings and Instruction Manuals 8

1.7.1 Technical Data 8 1.7.2 Drawings 8

1.7.3 Installation, Operating and Maintenance Manuals 8

1.8 Permits, Licences Registrations and Approvals 9

1.9 Commissioning Support 9

1.10 Spare Parts, Special Tools and Equipment 10

1.10.1 Spare Parts 10 1.10.2 Special Tools and Equipment 10

1.10.3 Site Assistance 10

1.10.4 Training 10

1.10.5 Performance Assessment against Guarantees 10

1.11 Responsibility Matrix 10 2 WORK EXCLUDED 10

2.1 Engineering and Services 10

2.2 Free Issue Items 11

2.3 Other 11 3 BATTERY LIMITS 11

4 REFERENCE DOCUMENTS AND STANDARDS 12

4.1 Drawings and Specifications 12

4.2 Codes, Standards and Regulations 12

4.3 Language and Measurement System 14 5 OPERATING ENVIRONMENT 14

6 DESIGN CRITERIA 14

6.1 Process Description 15 6.2 Operating Philosophy 15

6.3 Duty and Design Criteria 15

6.3.1 Plant Design Basis 15




6.3.2 Plant Process Design Criteria 15

6.3.3 Turndown 15

6.3.4 Plant Start up Time 16 6.3.5 Noise Level 16

6.4 Materials Selection 16

6.5 Preferred Equipment 16

6.5.1 Preferred Mechanical Equipment 16

6.5.2 Preferred Piping & Valving Selection 16

6.5.3 Preferred Electrical Equipment 16 6.6 Utilities and Services 16

7 DETAILED TECHNICAL REQUIREMENTS 17

7.1 Site 17

7.2 Structural 17

7.3 Mechanical 17

7.4 Piping 18 7.5 Electrical 18

7.6 Instrumentation and Plant-Wide Control System Integration 18

7.6.1 Instruments 19

7.6.2 Control Systems 19

7.6.3 Functional Safety 19 7.6.4 Analysis and Monitors 20

7.6.5 CCTV 20

7.6.6 Fire Monitoring 20

7.6.7 Documentation 20

7.7 Fire Protection 21

7.7.1 Hazardous Area Zoning 21 7.7.2 Organic Scuttle 21

7.8 Surface Protection 21

7.9 Equipment Identification, Marking and Labelling 21

7.10 Provision of Technical Data, Drawings and Instruction Manuals 22

7.10.1 General 22

7.10.2 Technical Data 22 7.10.3 Drawings 22

7.10.4 Installation, Operating and Maintenance Manuals 23 8 INSPECTION, TESTING AND ACCEPTANCE 23

8.1 Quality System 23

8.2 Verification and Testing During Fabrication 23 8.3 Final Acceptance 24




8.4 Performance Criteria and Testing 24

8.4.1 Primary Guarantees 24

8.4.2 Secondary Guarantees 24 8.5 Commissioning 24

8.5.1 Off-Site Testing 24

8.5.2 On-Site Testing 25

APPENDICES

Appendix A: CONTRACTOR’S QUALITY SYSTEM 26

Appendix B: CONTRACTOR DRAWING AND DATA REQUIREMENTS 29

Appendix C: DRAWINGS AND SPECIFICATIONS 35

Appendix D: RESPONSIBILITY MATRIX 36




1 SCOPE DESCRIPTION

1.1 INTRODUCTION

This scope of work covers the requirements for the design, supply, manufacture, commissioning support and performance testing of the Solvent Extraction Plant which is part of the Clean TeQ Sunrise Project near Parkes in New South Wales, all on an Engineering and Procurement basis.

1.2 WORK INCLUDED

The Contractor shall supply all process equipment, project documentation, services and materials other than the free issue materials listed in Section 2.2 and include all works necessary for the design, supply, fabrication, commissioning support and performance testing of the Solvent Extraction Plant. Training of operating and maintenance personnel also forms a part of Contractors scope of supply.

The Solvent Extraction Plant shall consist of three sequential circuits, being impurity removal followed by cobalt and nickel metal extraction. A schematic figure of the circuits are shown in Section 7.1.

The Works cover the requirements for the design, supply, manufacture, commissioning support and performance testing required to supply the complete Solvent Extraction Plant for the Clean TeQ Sunrise refinery as follows:

Qty. Package No. Description 1 431-PK-0001 Impurity Solvent Extraction 1 441-PK-0001 Cobalt Solvent Extraction 1 451-PK-0001 Nickel Solvent Extraction

The Plant supplied shall be capable of achieving or exceeding the duties specified in the datasheet, specifications, design criteria and technical requirements listed within this scope of work and Appendix C:.

The scope of work shall include but not be 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, civil, structural, mechanical, piping, electrical and instrumentation design and detail drawings, equipment lists and all other design documents necessary for the complete design, specification, documentation, construction and commissioning of the Solvent Extraction Plant (refer Appendix B: for Contractor‘ Drawing and Data Requirements)

A Risk Analysis conforming to Functional Safety Processes and IEC 61508 including a HAZOP (Hazard and Operability Study) and a CHAZOP (Control System HAZOP) shall be conducted by the Contractor’s nominated Safety Specialist with participation from the Contractor’s Engineers. The Contractor will be responsible for overseeing the implementation of the solutions necessary to reduce or mitigate the consequences of identified hazards. The Client 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 must be formally 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 7.




1.3 PROCUREMENT AND SUPPLY

Procurement and Supply shall include but not be limited to the following:

• Structural steel work, tanks, plate work, pre-fabricated buildings, maintenance and operating access ways

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

• Pipe and duct work, valves, fittings, supports including lining, painting and insulation • Standardised Electrical equipment, including power step down transformers, substations, MCCs and

variable speed drives • Instrumentation and control equipment, including control panels & stations • Fire detection and suppression system • First fills for organic removal filters • Lubricants.

1.4 FABRICATION AND SHOP ASSEMBLY

The Contractor shall be responsible for the fabrication and the shop assembly of the Solvent Extraction Plant equipment, piping and ducting systems, structures and pre-fabricated buildings, electrical/instrumentation/ control equipment and associated ancillaries.

In order to minimise site labour man-hours and infrastructure requirements, it is preferred that off-site modular assembly of the Solvent Extraction Plant components is maximised. The Contractor shall indicate in their bid, the extent of off-site modularisation, transportation methods and logistics and the predicted reduction of site man-hours by the use of these methods.

1.5 QUALITY SYSTEM

The Contractor shall provide a Quality System and 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 Solvent Extraction Plant Quality Plan.

Refer to Appendix A: for detailed requirements on the expected Quality System.

1.6 VERIFICATION AND TESTING DURING FABRICATION

The Contractor shall provide 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 pipe spooling, ducting sections, prefabricated steelwork, pipe supports, vessels, heat exchangers, 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 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.

The Contractor shall allow inspection, monitoring and control by the Client’s own inspectors as per an agreed Inspection and Test Plan (ITP) with nominated witness and hold points.




1.7 TECHNICAL DATA, DRAWINGS AND INSTRUCTION MANUALS

The Contractor shall provide technical data, drawings and installation, training, operating and maintenance manuals in accordance with Contractor Drawing and Data Requirements (Appendix B:) which forms part of the Contract.

All data, drawings, calculations and any other technical document provided to, created by or otherwise assembled, are the property of the Client and as such shall be made available along with any technical, operating and instruction manuals, at the completion and acceptance of the works. The operating and instruction manuals must be available before commissioning to allow operation and maintenance personnel to be fully conversant with the process.

1.7.1 Technical Data

The Contractor shall provide Manufacturer’s Data Reports (MDR) for all major equipment and piping systems of the Solvent Extraction Plant that are completed off-site and shall oversee the MDR’s provided for the site works. The MDRs shall include but not be limited to:

• Design calculations • ITPs • Weld traceability, mapping, WPS and WPQR • Materials records • NDT reports • Hydrostatic test reports • Paint application monitoring records • Statutory approvals and registrations • As built drawings • PLC programming checks • Shop test run performance monitoring.

1.7.2 Drawings

The Contractor shall provide drawings as set forth in the Contractor Drawings and Data Requirements (Appendix B:) which forms part of the Contract.

The Contractor shall submit to the Client drawing standards for approval. The Contractor shall use a reputable design software package. Electronic copies of all drawings shall be handed over to the Client at the time of practical completion.

1.7.3 Installation, Operating and Maintenance Manuals

The Contractor shall, after award, provide three sets in hard copy and one set in electronic format of Installation, Operating and Maintenance (IOM) manuals which will include all drawings, specifications, technical and safety data, vendor manuals, installation, operating and maintenance instructions.

The IOM manuals shall be specifically written for the Solvent Extraction Plants supplied by the Contractor and their format and content shall be reviewed and approved by the Client’s Representative after award of contract.




1.8 PERMITS, LICENCES REGISTRATIONS AND APPROVALS

Further to the General Conditions, the Client 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 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 as per Australian Regulatory Requirements.

1.9 COMMISSIONING SUPPORT

The Contractor shall provide a team of suitably qualified commissioning support personnel experienced in Solvent Extraction Plant operations to plan, document and direct the transition from practically complete plant to satisfactory completion of process guarantee runs. Commissioning to use Client’s operating personnel under Client’s direction.

The minimum requirement for the staged testing and commissioning of the Solvent Extraction Plant is shown in Section 8.5.

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

The Contractor shall submit a conceptual Commissioning Plan after award. This plan should address issues such as:

• Safety • Role of Commissioning Engineer/Supervisor • Commissioning manning and schedule • Stages of Commissioning • Designation of sub-systems • Control of Construction/Commissioning interface • Role of Owner’s team in acceptance of systems and in commissioning tasks • Preparation of Commissioning Check sheets, Instructions, Manuals • Pre-operation testing • Commissioning materials (e.g. temporary strainers, hoses, spool pieces, bunting, tags and signs).




1.10 SPARE PARTS, SPECIAL TOOLS AND EQUIPMENT

1.10.1 Spare Parts

The Contractor shall nominate two categories of spares and specify the items for each. These are commissioning spares and spares for ongoing operation. The Contractor shall provide a priced list for the purchase of the remaining commissioning spares by the Client’s Representative on behalf of the Client once practical completion is given. The Contractor shall also provide a proposal for the purchase and delivery of operating and capital spares for operations.

1.10.2 Special Tools and Equipment

The Contractor shall provide a priced list of any special tools which may be necessary for the on-going operations and maintenance of the Solvent Extraction Plant. Any special tools required for construction and commissioning shall be retained by the owner.

1.10.3 Site Assistance

The Contractor shall provide a schedule of engineering man-hour rates for ongoing site assistance for a period of up to three months after practical completion and acceptance of the works.

1.10.4 Training

The Contractor shall be responsible for the training of the Client’s process and maintenance technicians in the appropriate methods of plant operation and maintenance under normal and emergency operating conditions. The training shall be carried out with reference to the 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 provide for a minimum of 40 contact hours of classroom training for the Client’s process and maintenance technicians, or as determined necessary by the Contractor and agreed with the Client.

1.10.5 Performance Assessment against Guarantees

Following successful commissioning, performance acceptance testing will be conducted to measure the performance of the plant against the primary and secondary guarantees detailed in Section 8.4. The Contractor shall submit procedures for these guarantee runs to be reviewed and approved by the Client.

1.11 RESPONSIBILITY MATRIX

Refer to Appendix D: for the Responsibility Matrix.

2 WORK EXCLUDED

The following items are excluded from the Scope of Work.

2.1 ENGINEERING AND SERVICES

• Environmental impact assessment and environmental licensing • Site Risk Study • Site geotechnical survey, soil testing and grading plan • Pipe racks on the western and northern sides of the Solvent Extraction Plant including any footings,

structural steel, piping and cables and cable supports.




2.2 FREE ISSUE ITEMS

Diluent, extractants and any additives for the organic will be supplied by the Client.

2.3 OTHER

• Site preparation, road works, perimeter drainage and underground services • Provision of all service streams to the Solvent Extraction Plant up to the battery limit connection points

discussed in section 3 of this scope of work • Provision of all pipework for discharge streams beyond the battery limit connection points discussed in

section 3 of this scope of work • Site preparation, access road works, perimeter drainage and underground services.

Input Services and Process Lines up to the Solvent Extraction Plant battery limits:

• Potable water supply • RO water supply • Process condensate supply • Plant/Instrument air supply • Anhydrous ammonia gas supply • Extractant solvent supply via IBC • Diluent solvent supply • Dilute sulphuric acid supply • Hydrochloric acid supply.

Output Services and Process Lines beyond the Solvent Extraction Plant battery limits:

• Impurity SX strip product • Cobalt SX Strip Product • Nickel SX Strip Product • Nickel SX Raffinate.

3 BATTERY LIMITS

The Solvent Extraction Plant Area has three separate designations within the Clean TeQ Sunrise Process Plant, being Area 4300 for Impurity Solvent Extraction, Area 4400 for Co Solvent Extraction and Area 4500 for Ni Solvent Extraction. These areas are indicated in the Process Plant Area Key Plan Dwg No. 140316-0000-45D1-0004.

The locations and dimensions of the designated footprint areas are nominal, but any changes of consequence must be justified in writing and subsequently approved by the Client’s Representative.

The boundaries indicated for the Areas define the battery limits of all civil, structural, mechanical, piping, electrical and instrumentation works.

All piping and electrical/instrumentation cables will be connected to the Solvent Extraction Plant from the East-West pipe rack located between the Ni and Co SX areas. Tie-in locations and line sizes are as follows:

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




Input Services and Process Lines

SERVICE LOCATION

415V Power LV feeder from the nearest LV substation located nominally 100m away from the Solvent Extraction Plant.

PCS (Process Control Systems)

PCS junction boxes to be installed by Client’s nominated installation Contractor and field connected Dual coiled fibre optic (control system communications) cable in a Substation located nominally 100m away from the Solvent Extraction Plant

Potable Water In East-West Pipe rack; Class 150, 50NB S/S gate valve RO Water In East-West Pipe rack; Class 150, 100NB S/S gate valve

Firewater In East-West Pipe rack, Class 150, 100NB C/S gate valve, (perimeter hydrant system by others)

Raw Water Supply In East-West Pipe rack; Class 150, 50NB C/S gate valve. Plant / Instrument Air In East-West Pipe rack; Class 150, 50NB C/S gate valve. Anhydrous ammonia gas In East-West Pipe rack; Class 300, 150NB C/S gate valve Dilute sulphuric acid In East-West Pipe rack; Class 150, 150NB S/S ball valve. Hydrochloric Acid In East-West Pipe rack; Class 150, 50NB Nil-Cor type ball valve. Extractants (D2EHPA, Cyanex 272 & Versatic 10 Acid) 1m3 IBC

Diluent In East-West Pipe rack; Class 150, 100NB S/S ball valve.

Output Services and Process Lines

SERVICE LOCATION Impurity SX strip product In East-West Pipe rack; Class 150, 50NB alloy ball valve Co SX strip product In East-West Pipe rack, Class 150, 50 NB S/S ball valve Ni SX strip product In East-West Pipe rack, Class 150, 80 NB S/S ball valve Ni SX Raffinate In East-West Pipe rack, Class 150, 150 NB S/S ball valve

4 REFERENCE DOCUMENTS AND STANDARDS

4.1 DRAWINGS AND SPECIFICATIONS

The Drawings and Specifications applicable to and referenced within this scope of work are listed in Appendix C:.

The process flow diagrams (49D1 series) are indicative only.

4.2 CODES, STANDARDS AND REGULATIONS

The equipment and materials supplied under this specification 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 Contractor shall appraise himself of the workplace occupational health and safety regulations as administered by WorkCover Authority (WorkCover Authority, OHS Division, 92-100 Donnison Street, Gosford,, NSW 2250 phone (02) 4231-5000 website: www.workcover.nsw.gov.au). Where any uncertainty exists the ‘Occupational Health and Safety Regulation 2011’ should be consulted. This is available via download or hard copy from WorkCover.

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

The equipment manufactured both locally and overseas shall comply with the relevant requirements of the current issues of the Clean TeQ Sunrise Project standards, specifications, drawings, data sheets, and other documentation listed in section 4 of this specification. Any conflicts identified between the specifications or with the Standards shall immediately be brought to the attention of the Client’s Representative for resolution.

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

STANDARD DESCRIPTION ISO 9001: 2015 Quality Management Systems API 620 Design and Construction of Large Welded Low Pressure Storage Tanks AS 1023 Low Voltage Switchgear and Control gear – Protection of Electric Motors AS 1210 Pressure Vessels AS 1252 High Strength Steel Bolts AS 1271 Protective Devices

AS 1359 Rotating Electrical Machines (including all sub standards) AS 1768 Lightning Protection

AS 1940 Flammable and Combustible Liquids Storage 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/NZS 3000 Electrical Installations AS 3008 Electrical Installations – Selection of Cables AS 3439 Low Voltage Switchgear Assemblies AS 3990 Mechanical Equipment - Steelwork

AS 4024.1 Safeguarding of Machinery – General Principles

AS 4041 Pressure Piping AS 5131 Fabrication and Erection of Structural Steelwork NOHSC 1007-2000 National Standard for Occupational Noise

AS 60529 Degrees of Protection Provided by Enclosures (IP Codes)

http://www.workcover.nsw.gov.au/




STANDARD DESCRIPTION AS 61508.0 Functional Safety of Electrical/Electronic/programmable Electronic Safety Related

Systems AS 61511.1 Functional safety – Safety Instrumented Systems for the Process Industry Sector

Framework, Definitions, Systems, Hardware and Software Requirements AS 62061 Safety of Machinery – Functional Safety of Safety-related Electrical, Electronic and

Programmable Electronic Control Systems AS 62271 High Voltage Switchgear and Control Gear IEC 61233 High Voltage Alternating Current Circuit-Breakers – Inductive Load switching AS/ACIF S009 Installation Requirements for Customer Cabling (Wiring Rules) Australian Dangerous Goods Code NSW Dangerous Goods Act & Regulation EN 13121 GRP tanks and vessels for use above ground. Design and workmanship. ASME B31.3 Process Piping ASME VIII Division 1

ASME Boiler and Pressure Vessel Code, Section VIII, Division 1: Rules for Construction of Pressure Vessels

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 (ASME) • Other codes.

4.3 LANGUAGE AND MEASUREMENT SYSTEM

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

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

5 OPERATING ENVIRONMENT

The Solvent Extraction Plant 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 Project Specification 140316-0000-40EG-0001.

The Solvent Extraction Plant will be predominantly located outdoors and will be exposed to direct sunlight, dusty conditions and hose down with water.

6 DESIGN CRITERIA

The data sheet and relevant process data for the equipment design and selection for the Solvent Extraction Plants are listed in Appendix C:




6.1 PROCESS DESCRIPTION

The purpose of the Solvent Extraction Plant is to purify and concentrate nickel and cobalt contained in a neutralised eluate liquor arising from an upstream leach and resin-in-pulp process. The first SX circuit will extract essentially all zinc, calcium and manganese. These impurities are then transferred to a strip product which is sent to waste. The second SX circuit will extract essentially all cobalt and copper. These elements are transferred to a strip product which is sent to further purification, followed by crystallisation of a high purity cobalt sulphate product. The third circuit will essentially extract all nickel. This element is transferred to a strip product which is then crystallised to produce a high purity nickel sulphate product. The final raffinate from the SX Plant will feed a third crystalliser which will produce an ammonium sulphate product.

The solvent extraction plant consists of three SX circuits in series. Each circuit will have its own crud treatment and organic recovery equipment. Furthermore, the package will include equipment required to prevent cross contamination of extractants between the three circuits.

The Solvent Extraction Plant shall be designed to proven process technologies and equipment selection in the unit processes which together comprise the complete and operable facilities operating at the designated capacity and purity.

6.2 OPERATING PHILOSOPHY

The Solvent Extraction Plant is required to operate continuously in series as indicated above.

The Solvent Extraction Plant shall be designed to have a life of 20 years.

The Solvent Extraction Plant shall be designed to be suitable for frequent shutdowns and start-ups, (up to 2 (two) times per month), in the first year of operation.

6.3 DUTY AND DESIGN CRITERIA

6.3.1 Plant Design Basis

The Solvent Extraction Plant shall be designed on the basis of minimum capital cost with optimisation of operating and maintenance costs during the lifetime of the plant.

6.3.2 Plant Process Design Criteria

The process design criteria for the Solvent Extraction Plant is described in the datasheet 140316-4000-45ED-PK0001.

6.3.3 Turndown

The Contractor should design the Solvent Extraction Plant to produce on specification products for an operating throughput range as specified in the Solvent Extraction Plant datasheet 140316-4000-45ED-PK0001.

Aq Feed (ex eluate) final raffinate to amsul

crystallisation

Impurities Metal Chlorides

raffinate raffinateImpurity SX

(DEHPA)Cobalt SX

(Cyanex 272)Nickel SX

(Versatic 10)

Cobalt Sulphate Recovery

Nickel Sulphate Recovery




6.3.4 Plant Start up Time

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

6.3.5 Noise Level

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

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

6.4 MATERIALS SELECTION

The materials of construction for the Solvent Extraction Plant shall be suitable to meet the required plant availability and the shutdown requirements stated in section 6.2 and the datasheet.

It is expected that FRP material of construction will be Derakane 510 A/C for the structural layer and Derakane 510N as the chemical barrier for surfaces in direct contact with the solvents. The Contractor shall advise the Client of any deviation from these preferred materials with an accompanying statement of justification.

6.5 PREFERRED EQUIPMENT

6.5.1 Preferred Mechanical Equipment

The Contractor is encouraged to select and offer equipment from within their standard range to meet the scope intent. In the absence of clear direction, the Client’s will provide guidance.

6.5.2 Preferred Piping & Valving Selection

The Contractor should select piping materials and valves in accordance with their own in-house standards and specifications to suit the scope requirements. In the absence of clear direction – particularly in situations where exotic materials are likely to be needed – refer to Section 7.4 for further guidance.

6.5.3 Preferred Electrical Equipment

In the absence of any direct guidance from the Client, the Contractor is encouraged to select and offer electrical and instrumentation equipment from within their standard range to meet the scope intent. In the absence of clear direction, the Client can provide some guidance.

6.6 UTILITIES AND SERVICES

Refer to Project Specification 140316-0000-40EG-0001 for utility water properties as well as direction on electrical power supply availability.

Properties of other reagents noted below are available upon request:

• Anhydrous Ammonia Gas • Hydrochloric Acid • Dilute Sulphuric Acid • Potable Water • RO (reverse osmosis) Water




• Fire Water • Plant/Instrument Air • Electric Power.

7 DETAILED TECHNICAL REQUIREMENTS

7.1 SITE

The Solvent Extraction Plant site is located as discussed in Section 3 of this scope of work. The designated location for the facilities will be cleared and levelled as mentioned elsewhere in this document.

The Mechanical General Process Plant Area Key Plan, Dwg No. 140316-0000-45D1-0004, provides a plan view of the Process Plant that indicates where the Solvent Extraction Plant is located in relation to other areas of the plant.

7.2 STRUCTURAL

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

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

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

The Contractor shall maximise the use of mobile cranes and minimise the requirement for 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 the nominated 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 reuse and removal of them 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 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.

7.3 MECHANICAL

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 Solvent Extraction Plant layout drawings on which these equipment items are clearly identifiable.

The Mechanical Design Criteria for the project, document number 140316-0000-45EC-0001, 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.

There is an expectation that the mixer-settlers for all Impurity SX and Nickel SX stages to be the same size. The Cobalt SX mixer-settlers should also be the same size. Therefore the SX Plant would only contain mixer-settlers of two sizes. Deviations from this mixer-settler sizing philosophy will need to be justified to the Client.




7.4 PIPING

The Contractor shall provide all piping, fittings, piping specials, pipe supports, insulation, 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 Solvent Extraction Plant battery limits.

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 should be reviewed by the Contractor, however the Contractor shall only use in-house standards for piping material and valve selection using best practices that typically meet or exceed the standards and specifications listed within this Scope of Work document.

7.5 ELECTRICAL

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

The Contractor will be responsible for the design, supply, commissioning support and performance testing of cabling, (including power, control, analogue, digital and fibre optic), drives, drive switching and control devices, lighting, earthing (for power and instrumentation), that may be required for the Solvent Extraction Plant.

Rated voltage and frequency of electrical motors shall be as per 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.

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

The Design Criteria for Electrical Engineering 140316-0000-47EC-0001, is available upon request and provides a comprehensive list of all Standards and Guidelines the electrical design should follow. The Contractor shall only use in-house standards and best practices that meet or exceed the guidelines and standards nominated elsewhere within this document and the design criteria for electrical engineering 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.

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

7.6 INSTRUMENTATION AND PLANT-WIDE CONTROL SYSTEM INTEGRATION

The Contractor will be responsible for the design, supply, commissioning support and performance testing of all instrumentation, communication and control systems within the Solvent Extraction Plant.

The Design Criteria for Field Instrumentation and Control Valves, document number 140316-0000-48EC-0001 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.




7.6.1 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.

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

Contractor shall consider using wireless instruments provided that reliability, productivity and safety is not compromised.

7.6.2 Control Systems

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

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

It is envisaged that there will be a single PCS system across the plant. The Contractor’s system design shall allow for the installation of a fully functional autonomous system which will merge into the plant wide system in a seamless manner. It is also essential that the system selection and configuration conform to the site wide practice from a maintenance perspective. The Contractor shall allow for a fully functional and tagged sequence panel for the Solvent Extraction Plant to assist in commissioning and trouble shooting. Once performance tests have been completed, then control will be transferred to the PCS in the central control room and the local node will be removed.

The Contractor shall ensure that sufficient resources are allowed to perform the PCS Factory Acceptance Test and the PLC or PCS Site Acceptance Test in accordance with Section 8. The personnel nominated for this work shall be fully conversant with the Solvent Extraction Plant 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.

7.6.3 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.




7.6.4 Analysis and Monitors

The Contractor shall provide analysis and monitoring equipment and instrumentation for the on-line analysis of the solution streams.

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

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

7.6.5 CCTV

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

7.6.6 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.

7.6.7 Documentation

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




7.7 FIRE PROTECTION

The Contractor should provide – as an optional inclusion - a suitable foam-based fire suppression and detection system for the Solvent Extraction Plant including sensors, monitors, foam sprinklers, cannons and all necessary fire-fighting equipment in and around the facilities.

All fire water network piping and hydrants required around the perimeter of the facility shall be by others.

7.7.1 Hazardous Area Zoning

The Solvent Extraction Plant shall have a Zone 2 hazardous area rating extending nominally 8 metres vertically above all sources of release and 15 metres in all directions around the plant periphery.

Trenches, pits, sumps and the inside of tanks within the Solvent Extraction Plant shall have a Zone 1 hazardous area rating.

7.7.2 Organic Scuttle

In the event of fire detection the Solvent Extraction Plant shall have the ability to scuttle via gravity the contents of all mixer boxes, organic tanks and the organic phase within settlers to dedicated scuttle ponds. There will be a scuttle pond for each of the three SX circuits. Recovery of the scuttle pond contents will be done using portable pumps by others.

7.8 SURFACE PROTECTION

All exposed surfaces of the Solvent Extraction Plant equipment and structures shall be provided with appropriate surface protection.

The Contractor may adopt their own standards for surface protection subject to approval by the Client’s Representative. The Contractor may refer to the Client’s Specification for Corrosion Protection, 140316-0000-45EG-0002, 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 as a minimum:

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

7.9 EQUIPMENT IDENTIFICATION, MARKING AND LABELLING

Equipment numbering shall be in accordance with 140316-0000-30AG-0001_00 Equipment Numbering Instructions. This document is for reference only. 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 Contractor shall provide adequate signage warning plant personnel of the hazards within the Solvent Extraction Plant Area.




7.10 PROVISION OF TECHNICAL DATA, DRAWINGS AND INSTRUCTION MANUALS

7.10.1 General

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

The Contractor shall submit a list of current users of similar equipment with their tender, detailing duty, company 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 document provided to, created by or otherwise assembled, are the property of the Client and as such shall be made available to him together with any technical, operating and instruction manuals, at the completion and acceptance of the works.

7.10.2 Technical Data

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

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

Qualification Record (WPQR) • Materials records • Non-destructive testing (NDT) reports • Hydrostatic test reports • Paint application monitoring records • Statutory approvals and registrations • As built drawings • PLC programming checks • Shop test run performance monitoring • Resin and Glass Traceability including certificates for each type and drum used.

7.10.3 Drawings

The Contractor shall provide drawings as set forth in the Contractor Drawings and Data Requirements Appendix B: which forms part of the Purchase Order.

The Contractor shall submit the drawing standards for approval to the Client. The Contractor shall use a reputable design software package such as AutoCAD or Microstation. Electronic copies of all drawings shall be handed over to the Client at the time of practical completion.




7.10.4 Installation, Operating and Maintenance Manuals

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

The IOM manuals shall be specifically written for the Solvent Extraction Plant and supplied by the Contractor. Their format and content shall be reviewed and approved by the Client’s representative prior to final submission.

8 INSPECTION, TESTING AND ACCEPTANCE

8.1 QUALITY SYSTEM

The Contractor shall provide a Quality Plan in accordance with ISO 9001 or approved equivalent.

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

8.2 VERIFICATION AND TESTING DURING FABRICATION

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

The ITP index and ITP’s shall be submitted for Client approval prior to the commencement of manufacture. This is a mandatory requirement and shall be approved by Client prior to commencement of manufacture.

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

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 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 8.3 and 8.4.

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

Following the successful completion of the shop tests the Contractor will be assisted by the Client 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 Solvent Extraction 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.




8.3 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.

For equipment subject to inspection by a government ministry, 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 final field inspection of the equipment by the government ministry, 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.

8.4 PERFORMANCE CRITERIA AND TESTING

The Solvent Extraction Plant shall be capable of meeting performance requirements against the following parameters, as detailed in the Equipment Data Sheet:

8.4.1 Primary Guarantees

• Volumetric throughput at minimum, nominal and maximum flow rates of the three SX circuits • Amount of entrainment generated by mixer-settlers aqueous and organic discharge process streams • Volumetric throughput at minimum, nominal and maximum flow rates of the SX Plant operating as a

single whole system • Terminal organic content in raffinate and strip product aqueous streams after organic recovery

treatment • Organic in aqueous and aqueous in organic entrainment from each and every stage • Final organic in aqueous concentration in the three strip product and raffinate streams • Stable pH control in the stages • Safety and equipment protection interlocks for major equipment • Noise and Contractor specified vibration levels for the individual equipment and combined operating

plant.

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

8.4.2 Secondary Guarantees

The Contractor shall nominate in their bid, guaranteed values for the following secondary guarantees:

• Plant start up times from idle or shutdown status, • Plant turndown capability.

8.5 COMMISSIONING

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

8.5.1 Off-Site Testing

Single component equipment shall be individually factory tested and certified by the manufacturers.




Multi component equipment shall be factory tested in the assembled or inter-connected state.

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

8.5.2 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 • Site Acceptance Testing • Handover to Client.




APPENDIX A: CONTRACTOR’S QUALITY SYSTEM

In the context of the quality system requirements detailed herein, the word ‘Contractor’ shall be taken to embrace Contractor, Subcontractor, Consultant, Sub consultant, Suppliers, 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 9001Clauses 4.4.6 to 4.4.9 X C AS/NZS ISO 9002 X 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 X Quality Procedures X Design Validation X Technical procedures X Quality Records X

ACCESS

The Contractor shall provide the Client, and its agents, 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 whose decision on the proposal shall be obtained in writing before the nonconforming material or work is covered up or incorporated into the Works, or is the subject of any other disposition.




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

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 the Client 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 with such originals, and the reasons for this are acceptable to the Client, 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 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. The ITP shall conform to the requirements of AS/NZS 3905.2: ‘Quality System Guidelines, Part 2: Guide to Quality System Standards AS/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 at least two weeks prior to the scheduled date of such audit. The Client 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 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 with all progress claims and periodic progress reports, and prior to completion of the service or dispatch or the equipment.

WITNESS AND HOLD POINTS

At least five days prior to reaching any Inspection and/or Test Point which has been designated by the Client in the ITP as a Witness or Hold Point, the Contractor shall notify the Client 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 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, 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 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 requirements 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




APPENDIX B: CONTRACTOR 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 General Arrangement-Solvent Extraction Plant

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 A2.11 Roads, Pads, Drainage &

Earthworks X

A2.12 Fencing X

A2.13 Concrete Details X X

A2.14 Reinforcement Schedules X

A2.15 Preliminary Load Data X A2.20 Structural Steel Drawings A2.21 Structural Steel

Arrangements 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

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

A2.54 Schematics X

A2.56






Document Required

After Award


award)


Remarks

A2.57

A2.58 Termination drawings X

A2.60 Instrumentation and Control Drawings

A2.61 Control System Block Diagrams or sequence tables

X

A2.62 Instrument loop diagrams X

A2.63 Instrument Layout Diagrams

X

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 Pipe Line Easements X

A2.76 Communications Systems X

A2.77 Fire Protection Systems

A2.80 Vendor Drawings 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 Solvent Extraction Plant Data Sheet

X X

B2.0 KEY DOCUMENTS B2.1 Mechanical Equipment List X X

B2.2 Electrical Equipment List X X

B2.3 Cable Schedule X

B2.4 Instrument List X

B2.5 Piping Line List X

B2.6 Valve Schedule X

B2.7 Electric Load & 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






Document Required

After Award


award)


Remarks

B3.0 ENGINEERING CALCULATIONS

B3.1 Process X

B3.2 Concrete

B3.3 Structural Steel

B3.4 Tankage and Plate work X

B3.5 Mechanical Equipment

B3.6 Vendor Equipment Sizing

B3.7 Pipework

B3.8 Electrical Equipment and Cable Sizing

B3.9 Power Supply B4.0 PLANT OPERATION

Control Logic and Operating Philosophy and functional description

X

Plant Installation, Operation and Maintenance Manuals

X

Distribution Control System Programme

X

B.5.0 SPECIFICATIONS Technical Specifications X Equipment Specifications X

B.6.0 STATUTORY APPROVALS

Crane Certification X Monorail Certification X Pressure Vessels X Power Supply System X

B.7.0 OTHER Contractor to nominate

CONTRACTOR DRAWINGS AND DATA REQUIREMENTS PART C – CONTRACT DOCUMENTATION

C CONTRACT DOCUMENTATION

C1.0 GENERAL

C1.1 Commercial and Technical Non-Conformances

X

C2.0 ESTIMATE DOCUMENTS

C2.1 Capital Cost Estimate X

C2.2 Operating Cost Estimate X

C3.0 REGISTERS

C3.1 Scope Change Register X






Document Required

After Award


award)


Remarks

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 X

C4.4 4 Week Look-Ahead Schedule

X

C4.5 Shutdown & Tie-in Schedules

X

C4.6 Manning Schedule X

C.5.0 REPORTS

C5.1 Monthly Project Reports X

C5.2 Man-hour Reports – Home Office and Site

X

C5.3 Design Status Report and Productivity

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

X

C5.10 Site Safety Reports X

C5.11 Site Goods Received Reports

X

C5.12 Commissioning Reports X

C5.13 Project Closeout Report X

C5.14 Manufacturer’s Data Reports (MDR)

X

C6.0 MEETINGS

C6.1 Project Meetings with Client’s Rep

C6.2 Site Construction Meetings

C7.0 INSURANCE

C7.1 Workers Compensation X

C7.2 Public Liability X

C7.3 Motor Vehicle X

C7.4 Professional Indemnity X

C7.5 Marine Transit Cover X






Document Required

After Award


award)


Remarks

C7.6 Other (Tenderer to Nominate)

C8.0. PROJECT IMPLEMENTATION

C8.1 Project Quality Plan X

C8.2 Project Procurement and Contracting Strategy

X

C8.3 Project Contracting Strategy

X

C8.4 Industrial Relations Strategy

X

C8.5 Project Risk Analysis X

C8.6 HAZAN/HAZOP Review and Recommendations

X

C8.7 Environmental Review and Recommendations

X

C8.8 Constructability Review and Recommendations

X

C8.9 Maintainability Review and Recommendations

X

C8.10 Occupational Health And Safety Review And Recommendations

X

C8.11 Statutory Regulations Review And Checklist

X

C8.12 Security Systems Review And Recommendations

X

C.9.0 INTERNAL AUDITS

C9.1 Process Audits X

C9.2 Design Audits X

C9.3 Cost Control/Forecast Audits

X

C9.4 Project Schedule Audits X

C9.5 Quality Assurance/Control Audits

X

CONTRACTOR DRAWINGS AND DATA REQUIREMENTS PART D – SITE RECORDS

D SITE RECORDS

D1.0 Daily Diaries X

D2.0 Inspection Records X

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

X

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

X






Document Required

After Award


award)


Remarks

D5.0 Calibration Certificates X

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 X 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 Check sheets, Direction of Rotation Checks, Electrical and Safety Device Checks, Equipment No-Load Runs, Group Starts, PCS Configuration Verification, System Upset Condition Checks, Facility or System Operational Verification, and Process Commissioning respectively.

X

E4.0 Performance Trial/Test Procedures

X

E5.0 Performance Trial/Test Data

X




APPENDIX C: DRAWINGS AND SPECIFICATIONS

DRAWING / DOCUMENT NO. DESCRIPTION 140316-4000-45ED-PK0001 Datasheet – Solvent Extraction Plant 140316-0000-45D1-0004 Mechanical General Process Plant – Area Key Plan 140316-0000-40EG-0001 Project Specification 140316-0000-45EG-0002 Specification for Corrosion Protection 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




APPENDIX D: RESPONSIBILITY MATRIX

DESCRIPTION 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 Solvent Extraction Plant X 2.2 Utilities Design X 2.3 Effluent Treatment Plant X 2.4 Civil & Structural Works 2.4.1 Design and specify all civil and structural works,

including buildings/control rooms X

2.4.2 Commission site survey X

2.4.3 Commission Geotechnical Survey X

2.4.4 Site preparation and Grading X 2.5 Electrical and Instrumentation 2.5.1 Design: Switchgear & MCCs; Substations;

Switchrooms X

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

X

2.5.3 Specify: 415V MCCs Transformers; Substations; Switch rooms; 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 their nominated installation Contractor

2.5.6 Provide and Program Local PLC X

2.6 Drawing Approvals X

2.6.1 Solvent Extraction Plant Design Drawing X Client’s Rep to review and comment

2.6.2 Supplier Drawings X 3.0 SPECIFICATIONS 3.1 Provide specific Engineering Standards where

available X Client’s Rep to

provide

3.2 Prepare Equipment Specifications X

3.3 Prepare General Specifications X





Comments

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

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 ‘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 to approve

7.1.3 Prepare commercial conditions X X Use Client Terms and Conditions

7.1.4 Prepare enquiry X

7.1.5 Issue enquiry X

7.1.6 Receive enquiry X





Comments

7.1.7 Evaluate tenders and negotiate with tenderers X

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 supplier documentation X

7.1.12 Resolve supplier technical queries X

7.1.13 Resolve supplier commercial queries X

7.2 Expediting

7.2.1 Expedite progress of contracts X

7.2.2 Expedite supplier documentation X In accordance with document data sheet

7.3 Shipping X

7.4 Approval and Payment of Supplier 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 Ind 3rd Party Client’s Rep to participate.

7.8.3 Environmental Integrity X By Ind 3rd Party

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

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





Comments

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

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

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

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

X X

12.6 First fill of lubricants X X





Comments

12.7 Provide raw materials for commissioning X X

12.8 Provide general consumables for commissioning X X 13.0 TRAINING 13.1 Co-ordinate suppliers to train client personnel X

13.2 Provide operators for training X 14.0 PERFORMANCE TESTING 14.1 Supervise performance test X Client to Witness

14.2 Provide operating personnel, supplies and services

X

14.3 Provide laboratory and field services X

Documents

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