ENGINEERING SPECIFICATION

DOCUMENTATION SPEC 00-G-02

REV A 0 1

DATE 28/02/92 23/11/92 18/02/03

DESCRIPTION OF REVIEW Issued for comment Issued for use Section 2.3 revised.

BY BL JB JB

APPROVED A Popp

Specification No. 00-G-02 Revision 1

TABLE OF CONTENTS

1.0 2.0

SCOPE OF SPECIFICATION........................................................................................ 1 TECHNICAL REQUIREMENTS..................................................................................... 1

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1.0

SCOPE OF SPECIFICATION This specification covers the requirements for the documentation of engineering works within KCGM. The standard and quantity of drawings and data is given in the specification.

2.0

TECHNICAL REQUIREMENTS 2.1 2.2 All drawings and data shall be submitted to the address nominated by KCGM. All drawings shall be submitted with a covering numbered transmittal note which shall show the Contract number and list all documents included in the submission, the revision numbers of the issue where appropriate, and the number of copies submitted. All drawings shall be prepared as per Specifications 00-G-06 & 00-G-07. General arrangement drawings shall be in sufficient detail to show layout of equipment, access for maintenance and operation and for necessary design by others of foundations, supports and other interfaces. The Contractor shall submit marking plans and elevations at the same time as or before any detailed shop drawings are submitted. Drawings submitted for approval shall be signed by the Contractor; drawn, checked, designed, design checked. As Built drawings shall be submitted and to show all changes made during manufacture, erection and commissioning. As built drawings shall be provided for at least the following: 2.8 Arrangement Drawings Cabling wiring and termination diagrams Drawing list Electrical drawings Loop diagrams P&ID drawings Underground services

2.3 2.4

2.5 2.6 2.7

The Contractor shall provide at least the following design calculations: Conveyor calculations Detailed building structure design Motor support pedestal Process calculations/equipment sizing Pump/piping calculations Structural calculations Structural steel design

2.9

Detailed engineering documentation shall be provided to detail the following (but not limited to): Electrical/instrumentation specifications

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2.10

Electrical/instrumentation data sheets Equipment data Equipment specifications Lubricants/chemical requirements Motor lists Painting/insulation specifications PLC logic flow charts PLC logic printouts and associated Process data sheets Process operations manuals Program manuals Protection co-ordination calculations and graphs Screen graphics Utilities requirements

Detailed drawings shall be prepared for (but not limited to) the following: All as-built drawings and records All construction drawings Cable schedules

2.11

Welding Procedure Requirements The Contractor shall submit to KCGM detailed procedures for all welding including: The name of sub-contractor, if any The names and experience of the welders The proposed joint preparation Full details of the welding procedure and weld consumables Details of grinding

2.12

Test Reports and Certificates The Contractor shall submit test reports and test certificates in respect of motors, couplings, exciter units in accordance with the requirements defined in the relevant specification.

2.13

Operating Manuals Manual format shall be A4 size on the filing side which shall be vertical with a 20mm margin for filing. Pages shall be punched with holes, centrally, inner holes 48mm centres, outer holes 89mm centres. The operating manuals shall include but not necessarily be limited to the following: Full description and details of design capacity and design criteria for each item of equipment and each product. Detailed description and function of all operator controls. Detailed description of all alarms, indications and protective devices. Operating instructions, these must also cover the different modes of operating including start up, normal operation, shut-down and abnormal

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operation, procedures to set up for operations and sequence of machine operation. Relevant reduced drawings general arrangements, assemblies, electrical schematics, etc. Procedures in case of faults.

Operating manuals shall be submitted in three stages: 2.14 Preliminary for KCGMs approval reflecting the theoretical, design operation. Final approved, including all requirements. As commissioned incorporating all changes made during the commissioning phase and the as built condition.

Maintenance Manuals Manual format shall be A4 size on the filing side which shall be vertical with a 20mm margin for filing. Pages shall be punched with holes, centrally, inner holes 48mm centres, outer holes 89mm centres. The manuals shall include but not necessarily be limited to at least the following: Technical description of all components, both mechanical and electrical. Maintenance instructions (including proprietary items). Repair, overhaul and installation procedures. These must be specific and nominate all necessary tolerances, fits, tensions, etc. Change out procedures must also be included. Recommended inspection and frequencies. Schedules for running maintenance, shut-down maintenance and lubrication. Electrical data and drawings. Spare parts lists detailing the item, the number of units installed and the recommended quantity of spares to be held. Ladder listings of all PLC programs, with mnemonic labels, cross references for all contracts, descriptions of all less than obvious instructions and comments. Input and Output Allocation tables with PLC I/O address mnemonic label for each Input and Output.

Maintenance manuals shall be submitted in three stages: 2.15 Preliminary for KCGMs approval reflecting the theoretical, designed operation. Final approved, including all requirements. As commissioned incorporating all changes made during the commissioning phase and the as built condition.

Parts Lists and Recommended Spares Parts lists and a list of priced spares recommended for one years operation and as insurance spares shall be submitted to KCGM. Information regarding major spares shall be provided in sufficient time for manufacture to be carried

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out concurrent with the items required to be supplied under the scope of the Contract. The information for all spares shall be submitted by the Contractor in sufficient time for selection, order, manufacture, and delivery to be completed before commissioning and start-up. 2.16 All drawings must be legible, suitable for microfilming and be prepared in accordance with the following Australian Standards: 2.17 AS1100 AS1101 AS1102 AS1103 AS1104 All Parts All Parts All Parts All Parts

All calculations and documentation shall conform to all applicable KCGM specifications. All calculations and documentation shall conform to the requirements of the current applicable Australian Standard and relevant Statutory Authorities having jurisdiction in Western Australia. Alternatively where no Australian Standard exists, work shall conform to the most current and applicable British Standard. All calculations shall show sufficient explanatory detail to enable independent checking.