TSR-5-SR-08500-QA-PLN-001 · A 1-Mar-19 TM SP 1-Mar-19 Issued for review Distribution of Copies Revision Issued to name Issued to company A Stephen Hosking Tellus Holdings Ltd A Shai

Reference: 12574 2250150:P:tpm February 2019

GR ENGINEERING SERVICES LIMITED ABN 12 121 542 738 Tel: +61 8 6272 6000 Fax: +61 8 6272 6001 Email: [email protected] Website: www.gres.com.au

PO Box 258, Belmont WA 6984 71 Daly Street, Ascot WA 6104

TELLUS HOLDINGS LTD

Sandy Ridge Project

Quality Management Plan

TSR-5-SR-08500-QA-PLN-001

Document History and Status

Revision Date issued Reviewed by Approved by Date approved Revision type

A 1-Mar-19 TM SP 1-Mar-19 Issued for review

Distribution of Copies

Revision Issued to name Issued to company

A Stephen Hosking Tellus Holdings Ltd

A Shai Shilo Tellus Holdings Ltd

Document Information

File name: 2250150_1

Report author: Tony Masella

Project manager: Stuart Peirce

Client document number: TSR-5-SR-08500-QA-PLN-001

Client name: Tellus Holdings Ltd

Project name: Sandy Ridge Project

Document title: Quality Management Plan

Revision: A

Project number: 12574

Copyright: The concepts and information contained in this document are the property of GR Engineering Services Limited. Use or copying of this document in whole or in part without the written permission of GR Engineering Services Limited constitutes an infringement of copyright.

Tellus Holdings Ltd Page 2 Sandy Ridge Project Quality Management Plan Reference: 12574 2250150:P:tpm Revision A

TABLE OF CONTENTS

1. INTRODUCTION ....................................................................................................................... 4

1.1 Purpose .................................................................................................................................... 4

1.2 Scope of this Plan ................................................................................................................... 4

1.3 Australian and International Regulation, Standards and Codes ......................................... 4

1.4 Applicable Procedures ........................................................................................................... 5

2. RESPONSIBILITIES, AUTHORITIES AND COMMUNICATION .............................................. 6

2.1 Authorities and Delegations ................................................................................................... 6

2.2 Project Team and Quality Responsibilities ........................................................................... 6

2.3 Communication ....................................................................................................................... 8

3. QUALITY ASSURANCE MODEL ............................................................................................. 9

3.1 Integrated Management System .......................................................................................... 10

3.2 Project Documentation Requirements ................................................................................ 11

4. PROJECT REVIEW AND QUALITY IMPROVEMENTS ......................................................... 12

4.1 Audits ..................................................................................................................................... 12

4.2 Corrective Actions ................................................................................................................ 13

4.3 Improvement .......................................................................................................................... 14

5. DOCUMENT, RECORDS AND DATA CONTROL ................................................................. 15

5.1 Verification Records ............................................................................................................. 15

5.2 Manufacturing Data Report .................................................................................................. 16

6. PLANT, EQUIPMENT AND FACILITIES ................................................................................ 18

6.1 Control of Monitoring and Measuring Devices ................................................................... 18

7. SUPPORT ............................................................................................................................... 20

7.1 Human Resources ................................................................................................................. 20

7.2 Competence, Awareness and Training ............................................................................... 20

7.3 Computer Systems and Information .................................................................................... 21

8. PROJECT OPERATION ......................................................................................................... 22

8.1 Review of Requirements ....................................................................................................... 22

8.2 Design Management ............................................................................................................. 22

8.3 Inspection and Test Plans .................................................................................................... 24

9. CLIENT PROPERTY AND APPROVAL ................................................................................. 26

9.1 Handling, Storage, Packaging, Preservation and Delivery ................................................ 26

10. SUBCONTRACTOR/SUPPLIER MANAGEMENT ................................................................. 27

10.1 Selection of Suppliers/Subcontractors ............................................................................... 27

10.2 Supplier’s Quality Plan ......................................................................................................... 27

10.3 Supplier’s Inspection and Test Plans .................................................................................. 28


10.4 Supplier Material Traceability .............................................................................................. 29

10.5 Supplier Non Conformances ................................................................................................ 30

10.6 Supplier’s Manufacturer’s Data Report (MDR).................................................................... 30

10.7 Installation, Operation and Maintenance Manuals ............................................................. 30

11. DEFINITIONS ......................................................................................................................... 32

PROJECT QUALITY OBJECTIVES

REFERENCE TABLE

DEFINITIONS

FIELD INSPECTION REPORT LIBRARY

SAMPLE MANUFACTURERE’S DATA REPORT


1. INTRODUCTION

1.1 Purpose

The purpose of this document is to describe the Quality management systems to be employed by

GR Engineering Services Limited (GRES) to deliver the Sandy Ridge Project, successfully in

accordance with the requirements of Tellus Holdings Ltd, (Tellus) and the agreed Project objectives.

The QMP sets out the framework of Quality management and the minimum standard requirements to

be met to achieve the objectives for the project, whilst complying with the relevant laws and

regulations in Western Australia having jurisdiction over the site and works, including:

AS/NZS ISO 9001.2015 Quality Management Systems;

AS/NZS ISO 31000.2009 Risk Management Systems;

GRES policies and procedures;

The client’s site policies and procedures.

1.2 Scope of this Plan

This Management Plan applies only to the design, construction and commissioning phases of this

project.

1.3 Australian and International Regulation, Standards and Codes

GRES will execute the project in accordance with the relevant standards and codes as determined by

the project capability statement and the legal and other requirements registers.

The Project Integrated Management System, which the HR/IR Management Plan is a part of, will be

developed in accordance with the following standards:

AS/NZS ISO 9001.2015 Quality Management Systems - requirements;

AS/NZS ISO 9000.2016 Quality Management Systems - fundamentals & vocabulary;

ISO18001.2007 Occupational Health & Safety Management Systems - requirements;

AS/NZS ISO 31000.2009 Risk Management Systems - principles and guidelines;

AS/NZS ISO 55001.2014 Asset Management - management systems-requirements;

AS/NZS ISO19011.2014 Guidelines for auditing management systems;

AS ISO 10006.2003 Guidelines for Quality Management in Projects.


1.4 Applicable Procedures

The following documents are applicable to this plan:

Document Reference Title

GR Engineering Services Limited

EN-P001 Project Document Management

EN-P003 Design Drafting

EN-P005 Procurement

EN-P006 Drawing Control

EN-P013 Design Document Management

IM-STD-001 Management System Development

PCO-STD-001 Project Cost Control (EN-P002)

PSM-STD-001 Change Management (EN-P004)

QM-STD-001 Audits

QM-STD-002 Corrective and Preventative Actions

QM-STD-003 Management Review

RM-STD-001 Risk Management

Tellus Holdings Ltd

None Supplied

Note: The above is only a preliminary list. There may be additional project specific documents developed and used during the course of the project.

Table 1 Summary of Procedures Applicable to this Project


2. RESPONSIBILITIES, AUTHORITIES AND COMMUNICATION

2.1 Authorities and Delegations

Reference Document Name

OS-STD-001 Delegations of Authority

Authorities for all the key personnel positions are defined in the Project Execution Plan (PEP).

2.2 Project Team and Quality Responsibilities

Each member of the project team has a responsibility to ensure that the project works are completed

in accordance with the GRES quality policy and the applicable GRES procedures. The key roles and

responsibilities for the implementation of quality management for the project are detailed in Table 2

below.

Role Key Responsibilities

Project Manager Management Representative;

Ensure the availability of, and compliance with, all standards, codes, plans,

procedures and instructions for the Project;

Ensure that evidence of compliance is collated and saved in accordance with

the standard project filing;

Ensure the quality of goods and services for the project is maintained as per

this plan.

Quality Systems

Manager

Supporting project personnel in the execution of project management plans;

Development and implementation of appropriate practices by individual

functions and operating divisions/companies;

Liaison with Senior Managers to ensure that appropriate resources are

allocated to this plan;

Undertake and appraise verification activities;

Management audit, review and improvement programs.

Project Engineer

Assist the Project Manager in developing measures to correct non-

compliances and implement preventive actions;

Assist the Site Project Engineer with tasks to ensure that Contractor QA

documents are in place prior to starting work at Site;

Working with relevant engineers and supervisors, ensure that all ITPs are

complete and approved for use;

Ensure Document control for deliverable documents is being properly

maintained;

Working with relevant engineers and supervisors, ensure that all Supplier

MDRs are approved;

Working with relevant engineers and supervisors, ensure that all Supplier

IOMs are compiled and approved;

Check that the MDR is complete (if applicable);

Provide quality reports and statistics to the Project Manager.



Engineering Manager Ensure all designs and engineering services comply with relevant standards,

codes and procedures;

Ensure appropriate checks and reviews have been executed;

Ensure all drawings, engineering documents and other data are appropriately

signed and released;

Appoint engineers to identify quality documentation (ITP, IOM, and MDR)

required from vendors follow through in concert with the Procurement and

Quality Control functions.

Construction Manager Ensure all construction activities comply with relevant standards, codes and

procedures;

Ensure appropriate checks and reviews have been executed;

Ensure all drawings, engineering documents and other data are appropriately

received and issued for construction activities;

Cross-check that Contractor QA documents are in place prior to starting work

at Site.

Site Project Engineer Assist the Construction Manager in developing measures to correct non-

compliances and implement preventive actions;

Ensure Contractor QA documents are in place prior to starting work at Site;

Ensure all Site ITPs and FIRs are carried out, witnessed and signed off as

required;

Ensure goods receiving inspections are carried out at Site as required;

Ensure the distribution of equipment, parts and materials to Site activities is

properly managed;

Ensure Site Document control is being properly maintained;

Ensure all inspection, measuring and test equipment used at Site are correctly

calibrated with certificates available and included in MDRs where required;

Ensure Client property is correctly managed according to procedures;

Monitor the quality of Contractor work at Site;

Compile the MDR;

Ensure As-built information is being sent to the Project Office;

Provide quality reports and statistics to the Project Office.

Commissioning Manager Develop commissioning plan and monitor;

Liaise with client;

Document and monitor MPG’s;

Commissioning report.

Expediting and Logistics Ensure goods are supplied in full and on time;

Assist the Project Engineer to ensure all IOM’s are compiled and approved

prior to issue to the client;

Arrange and coordinate Supplier inspections;

Carry out quality inspections on Suppliers as required;

Carry out pre-qualification on new Suppliers where required;

Ensure expediting of goods from overseas Suppliers is as directed.



Document Controller Ensure all records required for the project are maintained within the GRES

Record Management System

Assist the Project personnel in the compilation and validation of Quality

records

Table 2 Key Personnel Responsibilities

2.3 Communication


IC-STD-001 Internal Communications

Key members of the project team will meet weekly to review the work performed and communicate

internal requirements relating to the progress of the work and quality issues. Meetings will be chaired

by the Project Manager and minuted. Minutes will be distributed to all project team members for

action.

The management representative for quality on this project is the Project Manager. Project

communications protocols are further detailed in the Project Execution Plan.

Change management linkages are described within this plan, and other plans. All Project Plans shall

be read in conjunction with one another.


3. QUALITY ASSURANCE MODEL


HS-POL-001 Human Resources


ISO AS/NZS 9001 Quality Management Systems


The project employs an integrated management system (IMS) that is compliant to AS/NZS ISO

9001.2015 Quality Management Systems and meets the needs of the project risk profile. Figure 1

describes the Management System Model demonstrating validation and continuous improvement

protocols.

Figure 1 Integrated Management System Design Model

Project documentation is prepared and issued in accordance with the guidelines provided in

IM-STD-001 Management System Development.


3.1 Integrated Management System

GRES standard operational systems documentation is developed to convey the management systems

and practices of each of the principal functional departments and divisions as outlined in Figure 2.

System overviews and Company Standards are intended to define objectives and associated

implementation strategies, organisation structure and key roles and responsibilities for individual

functions/divisions and to provide a brief overview of the practices and systems employed.

Process and Procedures are developed as a means of defining the management processes and

systems employed by each function/division to operate in accordance with GRES policy.

Work instructions comprise specifications, standards, method statements, drawings etc. referenced in

a procedure, contract, operations plan or inspection and test plan which provide specific details of how

tasks are to be undertaken.

The range and detail of procedures and instructions developed to deploy management system

requirements shall be consistent with the complexity of the work the methods used and the skills and

training required by personnel carrying out the associated activity.

Figure 2 Hierarchy of Documents


3.2 Project Documentation Requirements

Documentation is to be developed, when appropriate, to supplement/modify standard system

documentation to meet specific project delivery requirements.

Supplementary Documents: Shall be prepared to define specific or more detailed practices than

those presented in the standard procedure/instruction, if such requirements cannot be effectively

conveyed through insertion of a clarification statement in the associated Management Plan Risk Plan.


4. PROJECT REVIEW AND QUALITY IMPROVEMENTS


CI-STD-003 Lessons Learnt

EN-P005 Procurement

QM-STD-001 Audits




The Project Manager will report on the performance of the Project in relation to the QMP to GRES and

client management during meetings (i.e. quality performance will be an agenda item).

The monthly report for the Project will also contain commentary and statistics for quality management

and performance. Review and reporting topics will be:

Audit outcomes;

Corrective Actions and Non-conformances;

Status of Project Management System;

Improvement opportunities;

ITP/FIR/MDR Documentation status;

Quality surveillance initiatives;

Calibrations and measurement issues.

4.1 Audits

Internal audits will be conducted as per the audit schedule and as outlined in the Company Standard:

QM-STD-001 Audits, to:

Monitor the effectiveness of the project quality system;

Measure compliance to approved project plans;

Ensure controls from the Project Risk register are effective.

Internal audits covering the project quality system will be conducted at the discretion of senior

management. Following each audit an audit report and associated corrective actions will be issued to

the Project Manager for action.

Type of Audit/ Inspection Frequency and Comments

Project Audits The Quality System Manager will conduct a Project Systems audit once full

deployment has occurred and at least 4 weeks before practical completion.

Tellus Audits Additional audits may be carried out by Tellus on a periodic basis.

Table 3 Audit and Frequency Table


4.1.1 Client’s Review Activities

Project personnel will cooperate with the Client’s Representative during review activities. The Project

Manager will ensure that all quality records, documentation, personnel (including subcontractors),

where practicable, are made available to the Client’s representative for review purposes.

4.1.2 Suppliers and Subcontractors

The project will ensure that the suppliers providing products and services for this project will be

reviewed against relevant supplier’s quality documentation such as:

Quality Management Plans;

Inspection and test Plans including attendance at hold/witness points.

The Project Manager will ensure that all quality records and documentation are submitted and

compiled as part of the project record management system.

4.2 Corrective Actions

Processes, actions, services or products that do not conform to project specifications and expectations

will be controlled through the corrective action system as detailed in the Company Standard: QM-STD-

002 Corrective and Preventative Actions.

A corrective action may be the result of:

Non Conformance Report (NCR): Major breach of the agreed approach which, where

possible, should be rectified immediately;

Area of Concern (AOC): If not rectified, can result in a major breach of the agreed

approach, where possible should be rectified within 30 days;

Opportunity for Improvement (OFI): Suggestions that can result in improvement to the

agreed approach as part of continual improvement, where possible should be addressed

within 6 months;

Customer Complaints - Where a customer has determined that the service provided by

GRES has not meant their expectations. Customer Complaints, should be addressed within

30 days of receipt;

Supplier Complaints - Where a supplier has been determined not to meet GRES

expectations. The supplier should attempt to rectify these issues within 30 days, where

possible.

Corrective Actions can be generated by all GRES staff and GRES subcontractors through the

corrective action report which will be used to record:

Details of issue;

Proposed remedial action;


Cause of non-conformance;

Corrective action;

Close out and completion authority.

The Project Coordinator/Engineer will maintain the register of all corrective actions.

Status of all open corrective actions will be included within the project monthly report.

4.3 Improvement

GRES actively promotes and participates in identifying and evaluating opportunities for improvement

within its own business and adding value to the Project. By promoting continual improvement,

employees have an opportunity to make recommendations and practical suggestions to improve the

processes and practices currently employed by GRES Employee Feedback Program.

With a culture of value add and continually improving our methods, employees are encouraged to

make their job better, hence making GRES better by way of improved systems and processes.

4.3.1 Innovation

The industries that GRES operates in are facing multiple challenges over the coming years to meet

production and financial targets.

GRES is committed to providing innovative solutions in areas such as:

Capital costs, regulation and competition;

The use of latest processing technology in its designs;

Optimisation of supplier chain and project schedules;

Investment market dynamics.

4.3.2 Continuous Improvement

The project is committed to implementing the Continuous Improvement Scheme and Lessons Learnt

process on the project in order to keeping an active and positive means of innovation and

enhancement. This falls into many categories including constructability processes, quality systems,

safety management and general practices onsite.

4.3.3 Lessons Learnt

Lessons Learnt workshops are utilised to capture observations by the Project team members of things

done well and that could be done better with intent of improving systems and processes through

actioning opportunities for improvement and new initiatives.


5. DOCUMENT, RECORDS AND DATA CONTROL


KM-STD-001 Document and Record Management


A filing system in accordance with KM-STD-001 Document and Record Management will be

established at the commencement of the project. This system will be common to the Head office and

site for all documentation that is generated for the project.

At the completion of the project, key site records (both hard copy and electronic) will be returned to the

main office and archived.

A drawing register will be used to control the distribution of project and vendor design and detailed

shop drawings.

Only drawings which have been checked and approved (AFC) will be released for construction.

Preliminary drawings may be issued for pricing/information only and will be clearly marked as such.

5.1 Verification Records1

The Project Engineer shall ensure the identification, compilation and maintenance of verification

records to demonstrate conformance to the management system and operations specified

requirements.

Verification records shall be legible and readily identifiable such that traceability to process, activity or

item is maintained.

Records shall be stored such that deterioration and damage is minimized and loss prevented.

Permissible storage methods shall minimize exposure to undue sunlight, weather, moisture, vermin,

dust and dirt. When appropriate, records shall be archived in accordance with Company Standard:

EN-P001 Project Document Management.

1 GRES maintains the Worksite/iManage Record Management System for the capture of all verification records to the IMS.


5.2 Manufacturing Data Report

A deliverable of the project is the Manufacturer’s Data Report (MDR) which encompasses all of the

design documents, calculations and quality control and assurance documentation generated for the

project. In addition to the design office documentation and drawings, the MDR will include the

following types of documentation:

Manufactured Mechanical and Electrical Items:

- Inspection and Test Plans (ITP);

- Inspection reports;

- FAT tests;

- MDR from individual suppliers;

Catalogue Equipment Items:

- MDR from individual suppliers

- Material certificates;

- Inspection reports;

Earthworks:

- Compaction test results and method specification for repeatability;

- ITP’s;

Concrete:

- ITP;

- Pour records;

- Compression test records;

- Dimensional checks Field Inspection Reports (FIR);

Fabricated Structural Steel and Piping:

- FIR’s;

- Test records;

- Installation check-lists;

- MDR from individual fabricators;

Electrical and Instrumentation;

- FIR’s;

- Test records;

- Installation check-lists.

All subcontractors engaged for the project will either adopt this Quality plan or align their systems to

ensure compliance with this plan. Contributions to the project MDR will be controlled and expedited by

the project team.


Copies of the as-built drawings and final MDR will be submitted to the client after practical completion.

A sample Manufacture’s Data Report can be found in Appendix E.


6. PLANT, EQUIPMENT AND FACILITIES

All plant and equipment used by the organisation will be inspected, maintained, serviced and

controlled in accordance with the Construction and Safety Management Plan.

Subcontractors will be required to submit evidence of their plant/equipment’s service details to the site

Safety Advisor.

6.1 Control of Monitoring and Measuring Devices


PQM-STD-003 Inspection, Measurement and Test Equipment

Measuring and testing equipment and reference standards used by GRES and/or by subcontractors to

determine compliance with specified requirements and/or satisfactory process control shall be

registered, used, stored and calibrated in accordance with procedures appropriate to their function and

accuracy as per the Company Standard: PQM-STD-003 Inspection, Measurement and Test

equipment.

Equipment shall be calibrated at intervals and to tolerances established on the basis of stability,

purpose and usage.

Calibration shall be carried out in accordance with written instructions by suitably trained personnel.

Reference standards used to facilitate calibration shall themselves be in a known state of calibration,

traceable to national/international standards.

Functionally simple and rugged equipment is to be inspected and/or proven periodically to ensure

fitness for purpose.

Calibrated/proven equipment shall, where practical, be labelled to indicate calibration due dates.

Where this is not practical an alternative method which ensures positive recall when calibration is due

may be adopted.

Should equipment be found to be out of calibration, steps should be initiated to verify and document

the validity of tests undertaken with the equipment since its last valid calibration.

Records shall be maintained to demonstrate the calibration status of equipment and the suitability and

effectiveness of the calibration systems.


Monitoring and measuring equipment used onsite is the responsibility of the Construction Manager

who shall delegate authority for the equipment maintenance, calibration and registration at their

discretion but typically:

Safety and environmental related equipment - Site Safety Advisor;

Electrical related equipment - Electrical Supervisor.


7. SUPPORT

7.1 Human Resources


HR-STD-008 Recruitment

HR-PRO-002 Recruiting and Mobilising a New site-based employee

GRES shall ensure that all personnel whose duties influence the safe execution of the work in

accordance with time, conformance or cost requirements are selected based on pre-requisite

qualifications and competencies with due regard being given to:

Skill levels and appropriate site experience;

Attitude toward and awareness of GRES Quality, Safety, Health and Environmental

protection requirements;

Ability to follow procedures and instructions;

Ability to work as a team member achieving common goals;

Initiative and capacity to recognize and accept responsibility;

Attitude toward adding value to the operations.

7.2 Competence, Awareness and Training


HR-STD-001 Training and Competency Management

Training requirements are to be identified and implemented by the relevant GRES Manager, to ensure

the required levels of safety, quality and personnel expertise are developed and maintained.

Personnel employed on the Project will be competent on the basis of appropriate education, training,

skills and experience for the assigned tasks. Competency will also be established on site by the ability

of the worker’s to undertake the assigned tasks and work observations made by the worker’s direct

supervisor to verify such.

Where specialist skills are required to complete assigned work (such as welding), the employee may

be required to successfully complete a test to prove his competence. Competency certificates and test

results will be kept on the worker’s personnel folder for future reference by the supervisors.

Training shall be carried out in the following areas:

Company/Site Induction Training;

Business Systems and/or Procedure Training;

Safety System and/or Hazard Awareness Training;

Training to special or task specific skills (as required).


7.2.1 Inductions

All new personnel will receive training and an induction to understand the requirements of the Project,

project organisation and responsibilities, quality plan, computer systems, safety and environmental

requirements.

All new employees will be made aware of all GRES policies regarding equal opportunity, workplace

behaviours, quality, culture, occupational health and safety systems, environmental management,

human rights and community awareness.

7.3 Computer Systems and Information


KM-STD-001 Knowledge and Data Management


Computer systems will be established and maintained to manage the following activities:

Document Management System (DMS)2;

Project Controls (Greentree);

Labour resourcing (Greentree);

Record and Correspondence Management (DMS);

Planning and scheduling (Microsoft Project).

2 Document Management System (DMS) may be a combination of iManage and/or Windows File Server


8. PROJECT OPERATION

8.1 Review of Requirements

Requirements shall be reviewed on the basis of a contract to ensure that adequate resources have

been allocated to meet the needs of the customer, statutory and contract requirements.

GRES Management shall co-ordinate resolution of any anomalies identified through the review with

the customer, and the review of any subsequent changes in contractual arrangements, allocation of

additional work scopes or work scope variations to ensure that:

Amended requirements are adequately defined and documented;

GRES has the capability to meet the amended requirements;

Time, technical and cost implications are reflected in the commercial arrangements;

Any differences are resolved prior to the commencement of associated works.

Effective forums shall be established for communicating and discussing contractual requirements with

the client.

8.2 Design Management



PSM-STD-001 Change Management

8.2.1 Design Control

Controls are established to ensure that the specified design requirements are correctly translated into

manufacturing and construction documentation. The methods of control practiced by GRES either,

directly or by control over subcontracted design activities should include, but should not be limited to:

Provision of design and development programs;

Use of a code of design practice, design procedures, established designs, review

procedures and non-conformance data feedback;

Evaluations of materials under appropriate environmental and operational conditions;

Control of physical and functional tolerances;

Control of safety, reliability and maintainability;

Consideration of life cycle costs and value engineering tasks.

8.2.2 Design and Development Planning

Design requirements shall be evaluated, and design programs developed to establish:

Work Packages, by the division of design development and review, verification and

validation activities into appropriate disciplinary and product function categories;


Work Assignment to appropriately qualified personnel;

Interfaces, both organisational and technical, including definition of communication methods

across interfaces and the documented transmittal of technical information;

Design Input Requirements;

Design Output Requirements;

Design Review/Verification/Validation Requirements.

8.2.3 Design Input

Design inputs are to be established from contract documentation and should encompass:

Performance and functional requirements;

Results of conceptual studies;

Safety, Health and Environmental conditions;

Regulatory requirements;

Applicable codes and standards;

Manufacturing/Construction Requirements;

Relevant historical data.

Incomplete ambiguous or conflicting input requirements are to be identified and any inadequacy

resolved with those responsible for generating those requirements.

8.2.4 Design Output

Preliminary designs should identify assumptions, alternatives, development concepts, and feasibility

and design acceptance criteria and to plan and establish design requirements, work assignments and

decisions needed for the detailed design.

The design practices followed shall ensure that the design outputs:

Are traceable to design inputs;

Are compliant with input requirements;

Incorporate or reference all acceptance criterions;

Are subject to adequate control;

Define characteristics that are crucial to the safe and proper functioning of the product.

The design management processes, the progress of the design and the design results/outputs shall

be progressively reviewed during the execution of the design.

8.2.5 Design Verification and Validation

Design verification and, when appropriate, validation is to be carried out to ensure that the design

output achieves the intent of the design input and that the completed product achieves specified

performance criteria.


Verification and validation requirements shall be defined in design plans and shall include:

The identification and description of verification/validation points including those for design

inputs, outputs techniques and procedures;

Verification and validation methods/techniques;

Participants in the verification/validation process such as independent functional

departments or consultants, clients or subcontractors;

Evidence of verification/validation records;

One or a combination of the following methods may achieve verification:

- Performing alternative calculations;

- Comparing the new design with a similar proven design, if available;

- Undertaking tests and demonstrations;

- Reviewing the design stage documents including all relevant calculations, reports

and drawings before release.

Validation of the final design shall normally be based on demonstrated achievement of the specified

performance criteria by the completed product. Typically, validation may be based on proof testing,

plant commissioning trials and/or operating performance.

Verification and validation records are to be reviewed prior to release to ensure that all nominated

activities have been completed and appropriate records have been completed.

8.2.6 Design Changes

Design changes may be required because of: client initiated variation, manufacturing/construction

process requirement, unforeseen site conditions, material availability or error.

Design work required to facilitate changes shall be undertaken and the resultant design output raised,

verified and distributed in the same manner and subject to the same authorities and configuration

controls as the original design.

8.3 Inspection and Test Plans

Based on the requirements, Inspection and Test Plans (ITP’s) shall be developed, detailing process

control and product inspection and test requirements, for each discipline and/or portion of the work,

identifying:

A list of key activities required to complete the work;

Relevant procedures, instructions, codes and specifications;

Inspection and testing requirements (including acceptance criteria);

A record of how the activity is checked and documented;

The person responsible for the activity;

Special or unusual requirements of contract specifications;


GRES, the customer and/or statutory verification requirements.

Subcontractors shall be responsible for the planning of controls, inspections, tests and verification

activities for their portion of the work and submitting them to GRES for review, approval and identifying

customer and GRES hold and witness points, prior to commencement of works.

Where changes or additions to the original work scope have been identified through ‘Application for a

Deviation or Waiver’ or Contract Change Proposals (CCP), a review shall be undertaken of the

applicable ITP and nominate revise verification points, as required.

Alternatively, a request may be made for resubmission of the ITP to reflect the revised changes and

associated inspection and test requirements.


9. CLIENT PROPERTY AND APPROVAL


EN-P005 Procurement

The receipt, storage and release of Client property (free issue items) will be carefully handled.

A record will be kept of all goods received from the Client using a delivery advice form or similar. Items

that are short-supplied, damaged, unsuitable or missing will be immediately notified to the Client.

The intent of this process is to ensure that items supplied by the Client are fully accounted for, not

damaged and not lost in transit.

9.1 Handling, Storage, Packaging, Preservation and Delivery

Material and systems shall be controlled in respect to handling, storage, packaging, preservation and

delivery to prevent damage, deterioration or loss, to maintain conformance to specified requirements

and to ensure that any associated personnel or environmental risks are effectively managed.

Procedures developed to control handling, storage, packaging, preservation and delivery shall take

due consideration of material types, dimensions, weight, shelf life, transportation modes and

identification and security requirements.

They shall also address any related safety/environmental controls and/or statutory requirements.

When appropriate, material specific instructions shall be raised to initiate special requirements.


10. SUBCONTRACTOR/SUPPLIER MANAGEMENT


EN-P005 Procurement


10.1 Selection of Suppliers/Subcontractors

Evaluation of service provider capabilities should be consistent with the complexity of the scope of

supply and should, as a minimum include:

Appraisal of documentation submitted e.g. Manuals, Proposed Quality/Safety Plans etc.;

Evidence of prerequisite system approvals;

Verification of the implementation of the documented practices;

Appraisals of previous supply history with regard to conformance and timely delivery.

Evaluation shall include nomination of the type and extent of control that GRES would apply to the

supplier’s activity for the applicable scope of supply.

10.2 Supplier’s Quality Plan

All Suppliers’ quality management systems shall demonstrate that work undertaken by them has been

provided to specified quality standards.

For major suppliers, the Supplier’s contract-specific Project Quality Plan shall be the principal quality

assurance document and shall include:

Description of the organisation, organisational chart, and explanation of which roles have

quality responsibilities;

Planned quality-related activities, such as training of personnel, internal audits, document

control and process improvement;

Reference to relevant quality procedures such as inspection and test procedures (inclusive

of a list of scope-associated ITPs), work instructions and statutory requirements;

Listing of which work or services are to be subcontracted and the quality systems to be

applied by the subcontractor. This shall include a statement and commitment of how the

Supplier will verify the subcontractor’s compliance with the specified requirements by one or

more of the following methods:

- Inspection and test by the subcontractor against an ITP approved by the Supplier

and Company;

- Inspection and test by the Supplier at the subcontractor’s facility and/or at the

construction site against an ITP developed by the Supplier;

- Surveillance and audit (monitoring) by the Supplier;

- Incoming inspection at the Suppliers works and/or construction site.


10.3 Supplier’s Inspection and Test Plans

10.3.1 General

All Supplier ITPs are to be reviewed and approved by GRES prior to commencement of the work

applicable to the ITP. The following shall be addressed when reviewing ITPs:

The Project Engineer shall determine the critical aspects of the manufacturing/

fabrication/assembly involved in the scope of work;

Hold and witness points must be included in the ITPs at the appropriate stages based on

the determination of critical processes in manufacture/fabrication/assembly;

The Suppliers ITPs shall be equivalent to Project standard requirements.

10.3.2 Hold Points

As a minimum, Hold Points shall be nominated for:

Final Inspection/Shop Testing - Hold points shall be nominated in the ITP for Final

Inspection or Shop testing prior to delivery of equipment.

10.3.3 Witness Points

As a minimum, Witness Points shall be nominated for:

Subassemblies - Witness point shall be allocated at the final inspection of each

subassembly;

Surface preparation and painting - All surface preparation (including blast profiles) should

be nominated as a Witness Point. Final painting surveillance (including paint records) shall

be nominated as a Witness Point.

10.3.4 Overseas Inspections

For required witness and inspection points GRES will ensure that all key inspections will be completed

to the project specifications by considering the following:

The Project Manager will engage a 3rd party subcontractor inspection services provider

with an office based in the region of the vendors fabrication workshop and whom are

qualified with suitable experience for the type of inspection and relevant equipment;

The Project Engineer will liaise with the vendor representative and inspection services

provider to identify suitable date to conduct inspection;

An information package will be provided to the inspection services provider inclusive of

relevant drawings, specifications and standards. A discussion on the upcoming inspections

with inspection provider will be held detailing key points of interest and specific target areas;

Inspection services provide completes inspection on mandated vendor workshop during

agreed time period;


The inspection services provider will complete a detailed report with comprehensive photos

showing scope of completed work, any defects/errors and any corrections to vendor

supplied status of the package;

GRES analyses reports for any schedule slippage or required repairs and implement any

requisite rectification measures with Vendor.

10.4 Supplier Material Traceability

Material Traceability levels will be in accordance with the requirements of the design standards for the

Project. The traceability level for activities identified in Site Test Packs shall be indicated on each ITP

as appropriate. The Project Engineer will ensure that Suppliers comply with the relevant traceability

requirements applied to items or services in their scope of work.

Documented manufacturing and quality history of all identifiable materials, components and welds via

test reports, material certifications etc. which have been nominated in the approved ITP and MDR list

of contents. These documents shall be reviewed by the Project Engineer and other qualified Project

Personnel.

These records shall be traceable to the relevant component or part on the finished product and shown

using marked-up as-built drawings or isometrics, and separate traceability sheets for welding and non-

destructive examination records.

Documented manufacturing and quality history of all identifiable materials, components and welds

shall include the following where applicable:

Inspection and Test Plan (ITP);

Inspection Authority Certificate of Compliance, where appropriate (pressure vessels,

cranes, etc.);

Technical Queries (TQ);

Non-conforming Product Reports (NCP);

Corrective Action Requests (CAR);

Non-conformance concession notifications;

Inspection Release Reports;

Material Certificates (e.g. Structural, Piping, Fittings, Valves);

Welding Procedure Specifications;

Welding Procedure Qualification Records;

Welder Qualification Records;

Welding Consumable Register and Certificates;

Weld/Material/NDE traceability sheets;

Non-Destructive Examination Records;

Heat Treatment Records;

Hydrostatic/Pneumatic Test Records;


Calibration Certificates;

Surface Preparation and Humidity Records;

Coating Inspection Records;

As-Built Drawings.

10.5 Supplier Non Conformances

Any Project personnel (including Client personnel) identifying a potential non-conformance to

standards, procedures and plans shall notify the relevant Manager or Project Engineer, who shall

investigate the issue and confirm a non-conformance or otherwise. Where a non-conformance is

confirmed, a supplier complaint shall be raised detailing the nature of the non-conformance.

The Supplier complaint shall be forwarded to the Project Engineer or nominee for registering and

issuing of a unique number and the electronic copy forwarded to the relevant Package Engineer,

Supervisor or Supplier. The Project Engineer is responsible for the review, approval and/or rejection of

the proposed remedial action and final close-out of the supplier complaint with the assistance of the

relevant Supervisor/Lead/Manager.

10.6 Supplier’s Manufacturer’s Data Report (MDR)

GRES shall be responsible for reviewing the suite of documentation provided by each Supplier which

verifies that all necessary inspections, checks and testing requirements have been met prior to

handover for all work in the Project scope.

This documentation shall be compiled and made available for inspection by the client at any time.

The Document Controller shall ensure that the Certification Records are maintained and compiled in a

professional manner with constant coordination with all Supplier activities in relation to the records.

Certification Records including computer updates shall be kept current throughout the execution of the

Project. The Document Controller shall ensure that all records are completed and checked, and that

all necessary approvals are obtained from the Client.

All documents included in the MDRs shall be written in English3, be clear and legible, and be free from

corrections made with correction fluid. Erroneous information shall be crossed-out and the correct

information inserted and initialled.

10.7 Installation, Operation and Maintenance Manuals

All submitted IOMs shall be specific to the equipment and shall contain all of the relevant, approved,

certified and as-built data.

3 Foreign language documents will be translated to English as required.


For off-the-shelf equipment and equipment containing third party proprietary items (such as pumps,

gear reducers, couplings, relays, contactors, circuit breakers, etc.) sections of the manual may be

generic. Where the generic manual covers a range of items, the specific item shall be clearly

identified. Generic manuals shall be submitted for review and approval prior to inclusion in the IOM.

All instructions shall be sufficiently detailed to allow complete installation, operation, and maintenance

of the equipment by competent personnel who may not necessarily be familiar with the specific

equipment.

It is encouraged for Vendor manuals to include procedures and instructions, which if not correctly

followed may result in personnel injury to be printed in RED and headed with the word ‘Warning’.

Procedures and instructions, which if not strictly observed may result in damage to equipment tol be

highlighted and headed with the word ‘Caution’.


11. DEFINITIONS

Term Definition

AOC Area of Concern

CAR Corrective Action Report

EMP Environmental Management Plan

FIR Field Inspection Report

IMS Integrated Management System

IOM Installation, Operation and Maintenance Manuals

ITP Inspection and Test Plan

MDR Manufacturers Data Report

NCP Non-Conforming Product

NCR Non Conformance Report

OFI Opportunity for Improvement

PEP Project Execution Plan

QA Quality Assurance

QC Quality Control

SMP Safety Management Plan

Tellus Holdings Ltd Page 1 Sandy Ridge Project Appendix A Quality Management Plan Reference: 12574 2250150:P:tpm Revision A

PROJECT QUALITY OBJECTIVES

There are a number of key quality objectives that will be targeted when executing the Project. These objectives

are summarised in Table 4 below:

Objective Target

Maintain AS/NZS ISO 9001.2015 Certification requirements:

Management Plans are updated and communicated to key

personnel;

Project Management System is maintained;

Ensure Audits performed as per agreed schedule;

Corrective Action system is maintained and used to drive

continual improvement.

Certification Maintained;

Management Plans are reviewed as required

based on project requirements;

Management System is up-to-date with current

practice;

Audits completed within 30 days of schedule;

Corrective actions are being registered for

improvement projects.

The completed works satisfy the design requirements with

regards to specification and performance:

Compliance with the applicable GRES internal procedures

for all aspects of the Project execution;

Minimal rework;

AFC drawings available in time;

Quality inspections are being performed.

Successful completion of commissioning and

post-construction performance tests;

Ensure Inspection and test Plans are maintained;

Field Inspection Reports are being maintained as

per the FIR Register.

Table 4 Summary of Key Objectives for this Project

These objectives will be communicated to project staff during the kick-off meeting, site inductions and project

meetings.

Tellus Holdings Ltd Page 1 Sandy Ridge Project Appendix B Quality Management Plan Reference: 12574 2250150:P:tpm Revision A

REFERENCE TABLE

There are a number of documents referenced within this plan that have been developed as part of the GRES

Integrated Management System. Where appropriate, these documents will customise to suit the project

requirements.


BD-STD-002 Customer Feedback

CE-STD-001 Purchasing and Capital Acquisitions

CI-STD-001 Change Management

CI-STD-002 Innovation

CI-STD-003 Lessons Learnt

EC-STD-001 External Communications

EN-P001 Project Document Development



EN-P005 Procurement

EN-P006 Drawing Control

EN-P013 Design Document Management

EV-PLN-001 Organisational Environmental Plan

FA-STD-001 Office Management

HR-PLN-001 Organisational Human Resources Plan

HR-POL-001 Human Resources Policy

HR-STD-001 Training & Competency

HR-STD-002 Equal Opportunity Policy

HR-STD-010 Performance Development

HS-PLN-001 Organisational Health & Safety Plan

HS-STD-003 Consultation and Participation

HS-STD-004 Hazard ID & Risk Assessment

IC-PLN-001 Crisis Management Plan

IC-STD-001 Internal Communications

IM-PLN-001 Capability Library

IM-REG-001 Integrated Management System Design


ISO AS/NZS 9001 Quality Management Systems

IT-STD-002 Software Management

KM-STD-001 Record & Data Management (Upgrade to EN-P001)

OS-STD-001 Delegation of Authority Guidelines

OS-STD-002 Organisational Structure

PCO-STD-001 Project Cost Control

PMO-STD-001 Project Mobilisation

PO-STD-001 Subcontractor Management

PO-STD-002 Procurement (EN-P005)

PQM-STD0-003 Inspection, Measurement and Test Equipment (IMTE)

PQM-STD-001 Inspection & Test Plans

Tellus Holdings Ltd Page 2 Sandy Ridge Project Appendix B Quality Management Plan Reference: 12574 2250150:P:tpm Revision A


PQM-STD-002 Identification and Traceability

PSM-STD-001 Change Management

QM-PLN-001 Organisational Quality Management Plan

QM-POL-001 Quality Policy

QM-STD-001 Audits

QM-STD-002 Corrective and Preventative Action


RM-PLN-001 Corporate Risk Register


Tellus Holdings Ltd Page 1 Sandy Ridge Project Appendix C Quality Management Plan Reference: 12574 2250150:P:tpm Revision A

DEFINITIONS

Term Definition

AOC Area of Concern

CAR Corrective Action Report

EMP Environmental Management Plan

FIR Field Inspection Report

GRES GR Engineering Services Limited

IMS Integrated Management System

IMTE Inspection, Measurement and Test Equipment (Calibrated Items)

IOM Installation, Operation and Maintenance Manuals

ITP Inspection and Test Plan

MDR Manufacturers Data Report

NCP Non-Conforming Product

NCR Non-Conformance Report

OFI Opportunity for Improvement

PEP Project Execution Plan

QA Quality Assurance

QC Quality Control

SMP Safety Management Plan

The Project Sandy Ridge Project

The Client Tellus Holdings Ltd

Tellus Holdings Ltd Page 1 Sandy Ridge Project Appendix D Quality Management Plan Reference: 12574 2250150:P:tpm Revision A

FIELD INSPECTION REPORT LIBRARY

Form Number Description

CIVIL

C01 Concrete Pour Sheet

C02 Earth Compaction Tests

C03 Foundation Packer Heights

C04 Soil Compaction Test

ELECTRICAL

E01 Earthing Test

E02 (A) Transformers

E02 (B) Small Distribution Transformers

E03 MCC & Distribution Test Report

E04 Ductor Test

E05 Power Control Cables

E06 Motors

E07 General Purpose Outlets RCD & Loop Impedance Test Sheet

E08 High Voltage Motor Test

E09 High Voltage Feeder Cables Test

E10 (A) Level Transmitters

E10 (B) Flotation Cell Level Transmitters

E11 (A) Magnetic Flowmeters

E11 (B) Thermal Mass Flowmeters

E12 (A) Solenoid Valves

E12 (B) Pneumatically Actuated Valves

E12 (C) Control Valves

E13 Ring Main Units

E14 Pressure Transmitter

E15 Nucleonic Density Gauge

E16 Communications Cables

E17 Temperature Transmitters

E18 HV Metal Enclosed Switchgear

E19 Temperature Switch

E20 Pressure Switch

E21 Level Switch

E22 Flow Switch

E23 Variable Speed Drives

E24 Analyser

E25 Miscellaneous Control Panels

MECHANICAL

M01 Align Mechanical Couplings

M02 Align Vee Belt Drive

M03 Brake Drum Coupling Runout Data Sheet

M04 Chain Coupling Angular & Parallel Alignment Data

M05 Gear Type Coupling Angular & Parallel Alignment Data



M06 Permissible Gear Type Coupling Misalignment

M07 Linear Screen 1

M08 Linear Screen 2

M09 Mechanical Equipment No Load Running

M10 Mechanical Pre-commissioning

M11 Packaged Equipment Pre-commissioning

M12 Primary Apron Feeder No Load Running

M13 Protective Coatings

M14 Pump Installation

M15 Pumps

M16 Rock Breaker No Load Running

M17 Anti Friction Bearing Housing Alignment

M18 Spherical Roller Bearings

M19 Steel Structure Erection Checks

M20 Thickener 1

M21 Thickener 2

M22 Thickener Mechanism No Load Running

M23 Vibrating Feeder No Load Running

M24 Vibrating Screen No Load Running

M25 Vibrating Screen Pre-Commissioning

M26 WHIMS General Inspection

M27 Wichita Clutch Run Out

M28 Trunnion Stud Torque Record

M29 Trunnion to Shell Alignment Record

M30 Record of Bolt Tensioning Torques

M31 Mill Drive Unit No Load Running

M32 Mill Pre-Commissioning Inspection

M33 Mill Trunnion & Bearing Centres

M34 Mill Trunnion Lubricating System

M35 Mill Trunnion Radial Runout Roller Bearing Type

M36 Open Gear Lubricating System

M37 Level Reading Trunnion

M38 Gear Alignment

M39 Gear Mounting Flange Axial Runout

M40 Gear Rim Axial Runout

M41 Gearing No Load Contact Pattern

M42 Gearset Contact and Backlash

M43 General Mill Lubricant

M44 Girth Gear Alignment 12 Stations

M45 Girth Gear Joint Clearance

M46 Crushing Cooling System Pre-Commissioning

M47 Crushing No Load Running

M48 Centrifugal Pump No Load Running

M49 Crane Certification Test



M50 Double Decker Screen

M51 Drum Scrubber

M52 Fan Installation

M53 Filter Press

M54 Filter Press Feed

M55 Bucket Elevator

M56 Grouting

M57 Hydraulic System No Load Running

M58 Hydraulic System Pre Commissioning

M59 Hydrostatic Pressure Testing of Vessels

M60 Kelsey Centrifugal Jig

M61 Kelsey Jig Commissioning

M62 Conveyor Belt Splice Inspection

M63 Conveyor Drive Pre-Commissioning

M64 Conveyor Drive Unit No Load Running

M65 Conveyor No Load Running Inspection

M66 Conveyor Pre-Commissioning

M67 Conveyors

M68 Trunnion Roller Bearing Housing Alignment

M69 Belt Weightometer

M70 Agitator Pre-Commissioning

M71 Dust Collector

M72 Chillers

M73 Gravity Concentrator Pre-Commissioning

M74 Mill Gearbox Pre-Commissioning

M75 Overhead Crane/Monorail Pre-Commissioning

M76 Chute & Platework Installation

M77 Tank Installation

M78 Rotor Stator Alignment

M79 Site Touch up painting

M80 General Mechanical Load Run

PIPING

P01 Pressure Testing of Buried (Underground) Piping

P02 Pressure Testing of Plant Piping

P03 PE-HD Butt Welding Report (DVS 2207-1 [08/95])

P04 PE 80 Butt Welding Report (UNI 10520 [01/97)

P05 PP Butt Welding Report (DVS 2207-11 [02/99])

P06 Piping Installation

Tellus Holdings Ltd Page 1 Sandy Ridge Project Appendix E Quality Management Plan Reference: 12574 2250150:P:tpm Revision A

SAMPLE MANUFACTURERE’S DATA REPORT

A... INSPECTION & TEST PLANS

A.1.. ITP's by Discipline/Area



B... DEVIATIONS & CONCESSIONS

B.1.. Technical Query Register

B.2.. Technical Queries

C... WELDING RECORDS (SITE)

C.1.. Welding Procedures

C.2.. Welder Qualifications

D... NON-CONFORMANCE REPORTS

D.1.. Non-Conformance Register

D.2.. Non-Conformance Reports

E... CONSTRUCTION QA/QC

E.1.. Field Inspection Reports

E.2.. Classified/Registered Plant Reports

E.2.a. Pressure Vessels

E.2.b. HV Switchboards

E.3.. Surveys

F... DRAWINGS

F.1.. Design Drawings

F.2.. Vendor Drawings

G... SOFTWARE (Not Used)

H... VENDOR DATA

H.1.. Vendor MDR's

GR ENGINEERING SERVICES LIMITED ABN 12 121 542 738

Tel: +61 8 6272 6000 Fax: +61 8 6272 6001 Email: [email protected] Website: www.gres.com.au PO Box 258, Belmont WA 6984 71 Daly Street, Ascot WA 6104

25 September 2019 Reference: 12574 2377537:P:sp Tellus Holdings Limited via Email: [email protected] Attention: Mr Ettienne Cronje

SANDY RIDGE PROJECT QUALITY ACCREDITATION

GR Engineering Services Limited (GRES) maintains an integrated management system certified to AS/NZS ISO 9001:2015 Quality Management Systems that is based on risk. (Certifying Body: Lloyds Registrar (LRQA); Licence Number: MEL6037923). The Quality Assurance (QA) methods used by GRES are a defined set of responsibilities, procedures and standards (Australian Standards, International Standards and internal technical standards; whichever are most applicable to the work) used to facilitate design and to control engineering and design documentation for the projects we undertake. Implementation of the GRES Quality program results in: Design that is safe and fit for purpose; Quality drawings, free of errors and authorised for construction; An efficient design process achieving schedule milestones; Increased client satisfaction; Enhanced reputation; Reduced project implementation schedule and cost; Validation of our processes to drive improvement and lessons learnt. The Quality Control (QC) aspects of the GRES quality system are the procedures and processes of checking work quality through calculation verification, independent checking of drawings, documentation sign off and authorisation for construction, peer review processes and physical quality measurement systems applied to construction materials, component supply, field inspection reports and defect rectification reporting. The feedback loop of the QC system results into QA system improvements has enabled GRES to consistently achieve ‘on time’ and ‘on budget’ EPC and EPCM project delivery to the benefit of our clients. GRES recently achieved Federal Safety Council (FSC) accreditation. Engineers accredited under FSC are able to provide services into projects which have been granted NAIF funding. More information on the Quality systems is provided within the GRES Quality Management Plan.

mailto:[email protected]

http://www.gres.com.au/

Inspection and Test Plans (ITP’S)

GR ENGINEERING SERVICES LIMITED

E01 FIELD INSPECTION REPORT EARTHING TEST

E01 Earthing Test Page 1 of 1 Revision: A Date: 21-Dec-2017 327232_4.docx

This document is UNCONTROLLED once printed

Client Project Job No.

Plant Area Inspected By Initial Date

Contractor Super/Engineer Initial Date

Attachments

Equipment No.

Description

Purpose of Earth

Electrode Length Method of Installing Electrodes

Electrode Type Hole Diameter

Cable Size Backfill Material

Cable Type Other

Method of Installing Cable

Test Equipment Used

Sketch layout of electrodes, showing electrode numbers and distance between electrodes

Test Results

Local Grid Only

Complete Grid

Soil Condition Soil Type

Remarks


E02 (B) FIELD INSPECTION REPORT SMALL DISTRIBUTION TRANSFORMERS

E02 Small Distribution Transformers Page 1 of 2 Revision: A Date: 22-Dec-2017 fir e02 (b) small dist

transformers This document is UNCONTROLLED once printed




Attachments

Equipment No.

Description

Make Rating kVA Voltage HV LV

Cooling % Impendence F/L Amps HV LV

Serial No. Vector Group

IR Tester Type Serial No.

IR Test Volts Duration Result Remarks

A+B+C to E Note 1 5kV

a+b+c+n to E Note 2 1kV

All following checks/test to be completed:

1. Transformer Main Earth Connected Yes No

2. Glandplate and all covers Earthed Yes No

3. Cables Bolted up and Checked for Tightness Yes No

4. Oil Level Satisfactory Yes No

5. Location of MEN (Switchboard/ Transformer)

6. Tap set on appropriate tap Yes No

Tap setting

Note 1: LV windings to be connected to earth during test

Note 2: HV winding to be connected to earth during test

Remarks

GR ENGINEERING SERVICES PTY LTD

Reference: S:\Quality\Forms\FIR E02:P:tad Page 2 of 2 Last update: 2/10/19


E02/1 FIELD INSPECTION REPORT TRANSFORMERS

E02 Transformers Page 1 of 2 Revision: A Date: 22-Dec-2017 2153075_1





Attachments

Equipment No.

Description

Make Rating kVA Voltage HV LV

Cooling % Impedance F/L Amps HV LV

Serial No. Vector Group


IR Test Volts Duration Result Remarks

A+B+C to E Note 1

a+b+c+n to E Note 2 Note 1: LV windings to be connected to earth during test

Note 2: HV windings to be connected to earth during test

Winding Temp. Device Make Model Type

N/A Alarm SP °C Trip SP °C

Oil Temp. Device Make Model Type

N/A Alarm SP °C Trip SP °C

Buchholz Make Model Serial

N/A Alarm Gas Op-Trip Surge Op. kg/cm2

Remarks


E02/2 FIELD INSPECTION REPORT TRANSFORMERS

E02 Transformers Page 2 of 2 Revision: A Date: 22-Dec-2017 2153075_1


Equipment No. Description

All following checks / tests to be completed:

1. Main Earth Connected Yes No

2. Frame Earth Connected Yes No

3. Gland Plates and All Covers Earthed Yes No

4. Cables Bolted Up and Checked for Tightness Yes No

5. Oil Level Satisfactory Yes No

6. Oil Valves in Correct Positions Yes No

7. Neutral Earth Fault CT Installed Yes No

8. MEN Location (Switchboard / Transformer / NA)

9. Tap Setting

Remarks


E03 ST1 FIELD INSPECTION REPORT MCC & DISTRIBUTION BOARD TEST REPORT

E03 MCC & Distribution Board Test Report Page 1 of 2 Revision: A Date: 22-Dec-2017 327235_5





Attachments

Equipment No.

Description

Test Instrument Make Serial No.

Note: All readings in Ohms

Insulation Resistance Readings

R-W R-B W-B R-E&N W-E&N B-E&N

Results


1. All earth cables connected Yes No

2. All equipment isolators to have correct labels Yes No

3. Board to be fastened down N/A Yes No

4. Board to be cleaned of all foreign materials Yes No

5. Check tightness of bolts on all completed cable terminations Yes No

6. All covers and doors to be replaced Yes No

7. MEN connected (if required) N/A Yes No

8. Protection set up on incoming CB N/A Yes No

9. All shrouds in place on Line Side terminals Yes No

10. All shrouds in place on outgoing modules N/A Yes No

Remarks


E03 ST2 FIELD INSPECTION REPORT MCC & DISTRIBUTION BOARD TEST REPORT

E03 MCC & Distribution Board Test Report Page 2 of 2 Revision: A Date: 22-Dec-2017 327235_5





Attachments

Equipment No.

Description


1. All holes to be sealed for ingress of dust/moisture Yes No

2. Cable numbers on all cables entering compartments Yes No



5. Voltmeter reading (MCC only) V

Remarks


E05 FIELD INSPECTION REPORT LV/ELV CABLES

E05 LV/ELV Cables Page 1 of 1 Revision: A Date: 22-Dec-2017 327237_5



Plant Area Attachments

Contractor

Cable Label From To Cable Description Labelled Point

to Point

Terminated Correctly Earth

Resistance

Insulation Resistance Initial Date

End 1 End 2 ph-E ph-ph

Remarks

Notes Place Ticks () in appropriate columns Cable Schedules may be modified to represent FIR-E05 for testing purposes and recording of results Where multiple Insulation Resistance test results are obtained due to multiphase installations record the lowest value obtained


E06 ST1 FIELD INSPECTION REPORT LV MOTORS

E06 LV Motors Page 1 of 2 Revision: B Date: 22-Dec-2017 327238_7




Contractor

Attachments

415 V Induction Motor 1. Equipment No.

2. Drive Designation

Installation Checks 3. Rating (kW) RPM Frame

Insulation Class Manufacturer Serial No.

Full Load Current Anti-Cond. Heater Resistance Ω

Connection (Star/Delta)

Insulation Resistance Readings (500V DC)

A to B B to C C to A ABC to E Heater to E

MΩ MΩ MΩ MΩ MΩ

Minimum acceptance insulation resistance: 2M Ohms

Remarks


E06 ST2 FIELD INSPECTION REPORT LV MOTORS

E06 LV Motors Page 2 of 2 Revision: B Date: 22-Dec-2017 327238_7




Contractor

Attachments

415 V Induction Motor 1. Equipment No.

2. Drive Designation

Commissioning Checks

Rotation Correct

Motor Runs OK

No Load Current

Overload Setting

Remarks


E09 FIELD INSPECTION REPORT HV CABLE TEST

E09 HV Cable Test Page 1 of 1 Revision: A Date: 22-Dec-2017 327241_3.docx





Attachments

Cable No.

Description

Cores Cross Sectional Area (mm2) Voltage Rating (kV)

Layup (e.g. Cu, XLPE Insulated, Individually Screened, steel wire Armoured, PVC Outer Sheathed.

Earth Conductor Details

Insulation Tester Type Serial No.

Insulation Test Volts (kV) Duration (minutes) Result Remarks

R to W

W to B

R to B

R+W+B to E Cable Point-to-Point Tested Yes No

Termination 1 Equipment Identification Type (e.g. Indoor Heat Shrink)

Location

Cable Screen/Earth Terminated Yes No

Cable Identification Label Correct and Fitted Yes No Termination 2 Equipment Identification Type (e.g. Indoor Heat Shrink)

Location

Cable Screen/Earth Terminated Yes No

Cable Identification Label Correct and Fitted Yes No

Remarks


E10 (A) ST1 FIELD INSPECTION REPORT LEVEL TRANSMITTERS

E10 (A) Level Transmitters Page 1 of 2 Revision: B Date: 02-Jan-2018 327243_8




Contractor

Attachments

Instrument Details Tag No. Sensor Type

Description Supply Voltage

Manufacturer Outputs

Sensor Model No. Display – Local/Remote

Sensor Serial No.

Installation Check Location is correct as per P&ID Instrument tag fitted and correct

Instrument and remote display (where applicable) are mounted correctly Terminations tight

Cable ID tags are correct Aiming correct

Wire ferrules correct Installation left secure

Remarks


E10 (A) ST2 FIELD INSPECTION REPORT LEVEL TRANSMITTERS

E10 (A) Level Transmitters Page 2 of 2 Revision: B Date: 02-Jan-2018 327243_8




Contractor

Attachments

Instrument Details Tag No.

Description

Setup Data Unit

Empty Distance Full Distance / Span Distance


Loop Tested

Remarks


E10 (C) ST1 FIELD INSPECTION REPORT HYDROSTATIC LEVEL TRANSMITTER

E10 (C) Hydrostatic Level Transmitter Page 1 of 2 Revision: B Date: 02-Jan-2018 1299018_9




Contractor

Attachments

Instrument Details Tag No. Transmitter Range

Description Process Connection

Manufacturer Supply Voltage

Model No. Outputs

Serial No. Measurement Type Gauge / Absolute / Differential


Instrument and remote display (where applicable) are mounted correctly

Isolation valve fitted

Terminations tight

Cable ID tags are correct

Wire ferrules correct

Remarks


E10 (C) ST2 FIELD INSPECTION REPORT HYDROSTATIC LEVEL TRANSMITTER

E10 (C) Hydrostatic Level Transmitter Page 2 of 2 Revision: B Date: 02-Jan-2018 1299018_9




Contractor

Attachments


Description

Setup Data Unit

Lower Range Value Upper Range Value


Loop Tested OK

Remarks


E11 (A) ST1 FIELD INSPECTION REPORT MAGNETIC FLOWMETERS

E11 (A) Magnetic Flowmeters Page 1 of 2 Revision: B Date: 02-Jan-2018 327245_8




Contractor

Attachments

Instrument Details Tag No. Line Size


Manufacturer Outputs Flowrate 4-20mA

Model No. Totaliser Pulse Source / Sink / Dry Contact

Serial No. Transmitter Integral / Remote


Mounting orientation (vertical / horizontal / incline) Cable ID tags are correct

Bolts secured Terminations tight

Display orientation correct Transmitter mounting ok


Earthed as per vendor specification

Remarks


E11 (A) ST2 FIELD INSPECTION REPORT MAGNETIC FLOWMETERS

E11 (A) Magnetic Flowmeters Page 2 of 2 Revision: B Date: 02-Jan-2018 327245_8




Contractor

Attachments


Description

Setup Data Flow Range Flow Unit

Totaliser Output 1 pulse /


Loop Tested OK

Remarks


E12 (A) ST1 FIELD INSPECTION REPORT SOLENOID VALVES

E12 (A) Solenoid Valves Page 1 of 2 Revision: B Date: 02-Jan-2018 327247_8




Contractor

Attachments

Instrument Details Tag No. Serial No.

Description Valve Type

Manufacturer Valve Size

Model No. Voltage


Instrument mounted correctly Terminations tight

Cable ID tags are correct Installation left secure


Remarks


E12 (A) ST2 FIELD INSPECTION REPORT SOLENOID VALVES

E12 (A) Solenoid Valves Page 2 of 2 Revision: B Date: 02-Jan-2018 327247_8




Contractor

Attachments


Description


Valve operates correctly OK

Fail position Open / Closed

Remarks


E12 (B) ST1 FIELD INSPECTION REPORT PNEUMATICALLY ACTUATED VALVES

E12 (B) Pneumatically Actuated Valves Page 1 of 2 Revision: B Date: 02-Jan-2018 327248_8




Contractor

Attachments

Instrument Details Tag No. Valve Type

Description Valve Size

Manufacturer Actuator Type

Model No. Single / Double Acting

Serial No. Voltage/Pressure

Limit Switches Yes / No


Valve mounted correctly Terminations tight

Cable ID tags are correct Instrument air tubing installation complete and secure


Remarks


E12 (B) ST2 FIELD INSPECTION REPORT PNEUMATICALLY ACTUATED VALVES

E12 (B) Pneumatically Actuated Valves Page 2 of 2 Revision: B Date: 02-Jan-2018 327248_8




Contractor

Attachments


Description


Valve operates correctly

Limit switches tested

Fail Position (loss of air) Open / Closed / Last

Fail Position (loss of power) Open / Closed / Last

Filter / regulator (kPA)

Remarks


E12 (C) ST1 FIELD INSPECTION REPORT CONTROL VALVES WITH POSITIONER

E12 (C) Control Valves with Positioner Page 1 of 2 Revision: B Date: 02-Jan-2018 327249_5




Contractor

Attachments

Instrument Details Tag No. Valve Type

Description Valve Size

Manufacturer Positioner Type

Model No. Single / Double Acting

Serial No. Signal


Valve mounted correctly Terminations tight

Cable ID tags are correct Instrument air tubing installation complete and secure


Remarks


E12 (C) ST2 FIELD INSPECTION REPORT CONTROL VALVES WITH POSITIONER

E12 (C) Control Valves with Positioner Page 2 of 2 Revision: B Date: 02-Jan-2018 327249_5




Contractor

Attachments


Description


Loop tested

Valve operates correctly

Fail Position (loss of air) Open / Closed / Last

Fail Position (loss of power) Open / Closed / Last

Filter / regulator (kPA)

Reference Signal Valve Position

0% 100%

Valve movement is continuous throughout the reference signal range

Remarks


E13/1 FIELD INSPECTION REPORT RING MAIN UNITS

E13 Ring Main Units Page 1 of 4 Revision: A Date: 02-Jan-2018 327250_4.doc





Attachments

Equipment No.

Description

Manufacturer Model Type

Rated Voltage kVac Rated Frequency Hz Extensible Yes No

No. Ring switches Current Rating A

No. Circuit Breakers Current Rating A

No. Fused switches Current Rating A


IR Test Volts Duration MΩ Remarks

R to W 10 kV 1 minute

W to B 10 kV 1 minute

R to B 10 kV 1 minute

R+W+B to E 10 kV 1 minute

Note: IR test to be done with all Switches and Circuit Breakers Closed, Fuses Installed and Earth Switches Open. The following checks to be completed:

1. RMU Main Earth Bar Connected Yes No

2. All Glandplates Earthed to Main Earth Bar Yes No

3. Oil Level / Gas Pressure Satisfactory Yes No

4. Correct Operating Tools / Levers located with Switchgear Yes No

5. All Operating Mechanisms and Interlocks Work Correctly Yes No

Remarks





Ring Main Unit Equipment No.

Ring Switch No. 1 Circuit Identification (e.g. Incomer from Overhead Line)

The following checks to be completed:

1. Cable Size: mm2 Cables Bolted up Yes No

2. Cable Screen/Earth Connected to RMU Main Earth Bar Yes No

3. Boots Fitted to all Phases Yes No

4. Phasing Correct (if applicable) Yes No

5. Circuit Identification Label Correct and Fitted Yes No

Ring Switch No. 2 Circuit Identification (e.g. Incomer from Overhead Line)












Tee-Off Circuit Breaker No. 1 Circuit Identification (e.g. Feeder to Overhead Line)







6. CT located in Cable Box Type (e.g. Earth Fault Torriod) Yes No

7. Circuit Protection Relay fitted (Overcurrent and Earth Fault) Yes No

Relay Setup Yes No

8. Phase CT Ratio

CT Ratio Link in correct Position (multiple ratio CTs) Yes No

9. Sensitive Earth Fault (Earth Leakage) Relay fitted Yes No

Relay Setup Yes No

Tee-Off Circuit Breaker No. 2 Circuit Identification (e.g. Feeder to Overhead Line)









Relay Setup Yes No

8. Phase CT Ratio

CT Ratio Link in correct Position (multiple ratio CTs) Yes No


Relay Setup Yes No






Tee-Off Fused-Switch Circuit Identification (e.g. Feeder South Vent Fan)








7. Shunt Trip Coil fitted Yes No


E14 ST1 FIELD INSPECTION REPORT PRESSURE TRANSMITTER

E14 Pressure Transmitter Page 1 of 2 Revision: B Date: 02-Jan-2018 327251_8




Contractor

Attachments

Instrument Details Tag No. Transmitter Range


Manufacturer Supply Voltage

Model No. Outputs

Serial No. Measurement Type Gauge / Absolute / Differential


Instrument and remote display (where applicable) are mounted correctly Isolation valve fitted

Cable ID tags are correct Terminations tight


Remarks


E14 ST2 FIELD INSPECTION REPORT PRESSURE TRANSMITTER

E14 Pressure Transmitter Page 2 of 2 Revision: B Date: 02-Jan-2018 327251_8




Contractor

Attachments


Description

Setup Data Unit

Lower Range Value Upper Range Value

Commissioning Check Loop Tested

Remarks


E16 FIELD INSPECTION REPORT COMMUNICATIONS CABLES

E16 Communications Cables Page 1 of 1 Revision: A Date: 03-Jan-2018 327253_6



Plant Area Attachments

Contractor

Cable Label From To Cable Description Length Labelled Correctly Pass/Fail Initial Date

Notes: Place Ticks () in appropriate columns Cable Schedules may be modified to represent FIR-E05 for testing purposes and recording of results

Remarks


E17 ST1 FIELD INSPECTION REPORT TEMPERATURE TRANSMITTERS

E17 Temperature Transmitters Page 1 of 2 Revision: B Date: 03-Jan-2018 327254_8




Contractor

Attachments

Temperature Element Details

Tag No. Serial No.

Description Sensor Type

Manufacturer Process Connection

Model No.

Transmitter Details Tag No. Supply Voltage

Manufacturer Outputs

Model No. Transmitter Range

Serial No. Display Local / Remote

Thermowell Details (if applicable) Manufacturer Process Connection

Model No.

Installation Check

Location is correct as per P&ID Instrument tag fitted and correct

Installation correct Terminations tight



Remarks


E17 ST2 FIELD INSPECTION REPORT TEMPERATURE TRANSMITTERS

E17 Temperature Transmitters Page 2 of 2 Revision: B Date: 03-Jan-2018 327254_8




Contractor

Attachments

Instrument Details

Tag No.

Description

Setup Data Output Range °C

Commissioning Checks Loop Tested

Remarks


E18/1 FIELD INSPECTION REPORT HIGH VOLTAGE METAL ENCLOSED SWITCHGEAR

E18 High Voltage Metal Enclosed Switchgear Page 1 of 2 Revision: A Date: 03-Jan-2018 327255_6





Attachments

Equipment No.

Description

Manufacturer Model Type

Rated Voltage kVac Rated Frequency

Busbar Current Rating A Busbar Fault Rating kA

Control Voltage VAC/VDC Number of Panels


IR Test Volts Duration MΩ Remarks

R to W 10 kV 1 minute

W to B 10 kV 1 minute

R to B 10 kV 1 minute

R+W+B to E 10 kV 1 minute

Note: IR test to be done with all Switches and Circuit Breakers Closed, Fuses Installed and Earth Switches Open.


1. Switchboard Main Earth Bar Connected Yes No

2. All Glandplates Earthed to Main Earth Bar Yes No

3. Oil Level / Gas Pressure Satisfactory Yes No

4. Correct Operating Tools / Levers located with Switchgear Yes No


6. Switchboard cleaned and all debris removed Yes No

Remarks


E18/2 FIELD INSPECTION REPORT HIGH VOLTAGE METAL ENCLOSED SWITCHGEAR

E18 High Voltage Metal Enclosed Switchgear Page 2 of 2 Revision: A Date: 03-Jan-2018 327255_6


Panel No.

Circuit ID (e.g. Incomer from Overhead Line)

Type (e.g. Circuit Breaker)

Manufacturer Type (e.g. Unifluorc R)

Current Rating A Fault Rating kA Serial Number



2. Cable Screen/Earth Connected to Main Earth Bar Yes No




6. CT(s) located in panel Type (e.g. Earth Fault Torroid) N/A Yes No


Relay Setup Yes No


Relay Setup Yes No


10. Earth Switch Fitted Yes No

Remarks


E19 ST1 FIELD INSPECTION REPORT TEMPERATURE SWITCHES

E19 Temperature Switches Page 1 of 2 Revision: A Date: 03-Jan-2018 327256_8




Contractor

Attachments

Instrument Details

Tag No. Serial No.


Manufacturer Max Temperature

Model No. Supply Voltage

Installation Check Location is correct as per P&ID Instrument tag fitted & correct




Remarks


E19 ST2 FIELD INSPECTION REPORT TEMPERATURE SWITCHES

E19 Temperature Switches Page 2 of 2 Revision: A Date: 03-Jan-2018 327256_8




Contractor

Attachments


Description


Output contact NO / NC

Switching point set

Operation tested

Switch setting

Remarks


E20 ST1 FIELD INSPECTION REPORT PRESSURE SWITCHES

E20 Pressure Switches Page 1 of 2 Revision: A Date: 03-Jan-2018 327257_6




Contractor

Attachments

Instrument Details

Tag No. Serial No.


Manufacturer Max Pressure






Remarks


E20 ST2 FIELD INSPECTION REPORT PRESSURE SWITCHES

E20 Pressure Switches Page 2 of 2 Revision: A Date: 03-Jan-2018 327257_6




Contractor

Attachments


Description



Switching point set

Operation tested

Switch setting

Remarks


E21 ST1 FIELD INSPECTION REPORT LEVEL SWITCHES

E21 Level Switches Page 1 of 2 Revision: A Date: 03-Jan-2018 327258_6




Contractor

Attachments

Instrument Details

Tag No. Serial No.


Manufacturer Switch Type






Remarks


E21 ST2 FIELD INSPECTION REPORT LEVEL SWITCHES

E21 Level Switches Page 2 of 2 Revision: A Date: 03-Jan-2018 327258_6




Contractor

Attachments


Description



Switching point set

Operation tested

Switch setting

Remarks


E22 ST1 FIELD INSPECTION REPORT FLOW SWITCHES

E22 Flow Switches Page 1 of 2 Revision: A Date: 03-Jan-2018 327259_6




Contractor

Attachments

Instrument Details

Tag No. Serial No.


Manufacturer Switch Type






Remarks


E22 ST2 FIELD INSPECTION REPORT FLOW SWITCHES

E22 Flow Switches Page 2 of 2 Revision: A Date: 03-Jan-2018 327259_6




Contractor

Attachments


Description



Switching point set

Operation tested

Remarks


E23 ST1 FIELD INSPECTION REPORT VARIABLE SPEED DRIVES

E23 Variable Speed Drives Page 1 of 2 Revision: B Date: 03-Jan-2018 327260_8




Contractor

Attachments

Variable Speed Drive Details

Equipment No.

Drive Designation

Variable Speed Drive Nameplate Details

Drive Current Voltage

Make Model

Installation Check Securely mounted OK

Labelled OK

Cables terminated OK

Shrouds / covers replaced OK

Remarks


E23 ST2 FIELD INSPECTION REPORT VARIABLE SPEED DRIVES

E23 Variable Speed Drives Page 2 of 2 Revision: B Date: 03-Jan-2018 327260_8




Contractor

Attachments

Variable Speed Drive Details

Equipment No.

Drive Designation

Motor Parameters Entered

Current kW

Frequency RPM

Power Factor Speed Range

Commissioning Checks Control Parameters Entered OK

Control I/O Checked OK

Thermistor I/O Checked OK

Remarks


E25 FIELD INSPECTION REPORT CONTROL PANEL/JUNCTION BOXES

E25 Control Panel/Junction Boxes Page 1 of 1 Revision: A Date: 03-Jan-2018 327262_8




Contractor

Attachments

Instrument Details Equipment No.

Description

Vendor


1. All earth cables connected Yes No

2. All Holes to be sealed for ingress of dust/moisture Yes No

3. Cable numbers on all cables entering compartments Yes No

4. All equipment isolators to have correct labels N/A Yes No

5. Board to be fastened down Yes No


7. Check tightness of bolts on all cable terminations Yes No


9. Vendor documents sighted N/A Yes No

10. Panel correctly sealed Yes No

11. Panel is labelled Yes No

Remarks


E26 FIELD INSPECTION REPORT EARTH RESISTIVITY TEST

E26 Earth Resistivity Test Page 1 of 1 Revision: A Date: 03-Jan-2018 937352_4.docx





Attachments

Soil Type e.g. sandy with clay particles

Soil Condition e.g. moist

Area Description e.g. natural ground prior to fill

Spacing a (m)

Reading Ohms Stake Locations From Test Point (m)

Test Equipment Used Orientation 1 Orientation 2

2 3 1 1 3 Make

4 6 2 2 6 Model

8 12 4 4 12 Serial No.

16 24 8 8 24

32 48 16 16 48 Sketch layout of test, showing location and orientations

Test Location


E27 ST1 FIELD INSPECTION REPORT MISCELLANEOUS

E27 Miscellaneous Page 1 of 2 Revision: B Date: 03-Jan-2018 1148614_8




Contractor

Attachments

Instrument Details

Tag No. Serial No.


Manufacturer Process Connection

Model No.





Remarks


E27 ST2 FIELD INSPECTION REPORT MISCELLANEOUS

E27 Miscellaneous Page 2 of 2 Revision: B Date: 03-Jan-2018 1148614_8




Contractor

Attachments


Description



Switching point set

Operation tested

Switch setting

Remarks


E28 ST1 FIELD INSPECTION REPORT CONVEYOR DEVICES

E28 Conveyor Devices Page 1 of 2 Revision: A Date: 03-Jan-2018 1299046_5



Plant Area Contractor

Attachments

Installation Checks Pull Wire Switches Manufacturer Model No.

Tag No. Contact NO / NC

Mounting Secure

Cable Labels OK

Wire Ferrules OK

Terminations Tight Inspected By Initial Date

Belt Drift Switches Manufacturer Model No.


Mounting Secure

Cable Labels OK

Wire Ferrules OK


Underspeed Switch Manufacturer Model No.


Mounting Secure

Cable Labels OK

Wire Ferrules OK


Belt Rip Switch Manufacturer Model No.


Mounting Secure

Cable Labels OK

Wire Ferrules OK


Remarks


E28 ST2 FIELD INSPECTION REPORT CONVEYOR DEVICES

E28 Conveyor Devices Page 2 of 2 Revision: A Date: 03-Jan-2018 1299046_5



Plant Area Contractor

Attachments

Commissioning Checks Pull Wire Switches

Tag No. Lanyard Rope Tensioned

Lanyard Rope Operates Freely

Switch Function Test OK Inspected By Initial Date

Belt Drift Switches

Tag No. Level Arm Set Correctly

Lever Arm Roller Moves Freely

Function Test OK Inspected By Initial Date

Underspeed Switch

Tag No. Switch Positioned Correctly

Function Test OK Inspected By Initial Date

Belt Rip Switch

Tag No. Lanyard Tensioned Function Test OK Inspected By Initial Date

Remarks


E34 FIELD INSPECTION REPORT PLANT LIGHTING

E34 Plant Lighting Page 1 of 1 Revision: A Date: 03-Jan-2018 2128928_3





Attachments


1. Average lux levels in work / maintenance areas is not less than 80 lumens Yes No

2. Average lux levels on general walkways is not less than 20 lumens Yes No

3. Emergency lighting luminaires are installed on stairways Yes No

4. Lux levels on stairways is not less than 1 lumen during emergency lighting test Yes No

5. Emergency luminaires discharge for minimum prescribed time of 90min during testing Yes No

6. Green emergency luminaires are installed on all safety showers Yes No

6. Lighting installation complies with Australian Standards Yes No

Test equipment used

Time of test

Reference standards:

AS/NZS1680.5-2012 Outdoor workplace lighting AS2293.1-2005 Emergency escape lighting and exit signs for buildings

Mines Safety and Inspection Regulations 1995

Remarks


M01 FIELD INSPECTION REPORT ALIGN MECHANICAL COUPLING

Date: 20-Feb-2019 Rev: A

Page 1 of 2 2262803


Project Name: Project Name Project Number: Project Number

Equipment Name: Equipment Number :

Coupling Description (input/output/other)

Inspection Comments/Action Required Compliant/Action Complete Initial Date

1. Coupling details recorded on this form.

2. Piping or other equipment connected and free of stress and equipment at ambient temperature.

3. Alignment checks complete, recorded on this form and within tolerance.

4. All coupling components installed including spacers, elements and retaining rings with assembly bolts tightened.

5. Guard’s reinstated and adequate clearance to all rotating components.

6. Threads exposed to water or weather and subject to future disassembly protected by denso tape or other suitable anti corrosion product.

Reading Orientation

0° 90° 180° 270°

Axial (mm)

Radial (mm) Drive and driven shafts are to be rotated together when readings are taken.


M01 FIELD INSPECTION REPORT ALIGN MECHANICAL COUPLING


Page 2 of 2 2262803


Inspection Result/Comment

1. Coupling details (when available)

2. Drive shaft size (mm)

3. Driven shaft size (mm)

4. Axial run out (mm)

(Max axial – min axial)

5. Allowable axial run out (mm)

Where manufacturers tolerances are unavailable calculate based on 1° angular misalignment

6. Radial run out (mm)

(Max radial – min radial)/2

7. Allowable radial run out.

Where manufacturers tolerances are unavailable use 0.3 mm parallel misalignment

8. Coupling face to face clearance (mm)

Comments

All Items inspected, complete and approved

Inspected By: Date:


M02 FIELD INSPECTION REPORT ALIGN VEE BELT DRIVE


Page 1 of 2 2261383



Equipment Name: Equipment Number :

Inspection Comments/Action Required Compliant/Action Complete Initial Date

1. Pulley, taper lock and belt details recorded on this form. Sizes as per project documentation.

2. Pulley grooves clean and free of sharp edges.

3. Belt tensioning complete and values recorded on this form.

4. Pulley alignments complete, and misalignment less than 2 mm per meter of centre distance.

5. Guard’s reinstated and adequate clearance to all rotating components.

6. Tensioning threads exposed to water or weather protected by denso tape or other suitable anti corrosion product.

Belt Section

Small Pulley Diameter (mm)

Setting Force (kg)

SPA, XPA & QXPA

80 to 100 2.8

106 to 140 3.9

150 to 200 4.6

over 200 5.1

SPB, XPB & QXPB

112 to 160 5.1

170 to 224 6.3

236 to 355 7.9

over 355 8.3

SPC & QXPC

224 to 250 8.9

265 to 355 12.0

Over 375 15.0

Note the above values are the 1.25x “one-shot” tensioning setting forces

For checking belts already operated under load use the reduced basic tensioning setting forces


M02 FIELD INSPECTION REPORT ALIGN VEE BELT DRIVE


Page 2 of 2 2261383


Inspection Result / Comment

1. Belt section type

2. Number of belts

3. Drive pulley size

4. Drive pulley taper lock/shaft size

5. Driven pulley size

6. Driven pulley taper lock/shaft size

7. Centre distance (mm)

8. Calculated deflection.

16 x centre distance/1000 (mm)

9. Required belt tension.

Refer table (kg)

10. Actual belt tension (kg) at calculated deflection.

11. Pulley misalignment (mm)

Comments

All Items inspected, complete and approved

Inspected By: Date:


M03 FIELD INSPECTION REPORT MECHANICAL EQUIPMENT PRE-COMMISSIONING

Date: 13-Feb-2019 Revision: A

Page 1 of 2 2255357



Equipment Name: Equipment Number:

Equipment Make/Model: Equipment Serial Number:

Inspection Comments/Action Required Compliant/Actions Complete

Initial Date

1. Equipment name plate fitted and equipment name and number correct.

2. Equipment make/model and serial number recorded on this form and correct as per project equipment list.

3. Civil works and/or steel erection completed and accepted for installation.

4. All pedestals scrabbled, bolt pockets clean/free from contaminants and packers set to correct elevation.

5. Packaging removed, equipment cleaned and inspected for damage prior to placement.

6. Equipment levelled and positioned as shown on general arrangement drawings to correct location, orientation and elevation.

7. Grouting complete.

8. Anchor / hold down bolts snug tight.

9. Prior to commencement of assembly, machined bearing surfaces cleaned, stripped of protective coatings and surfaces lubricated as necessary.

10. All shaft clamps and locking devices removed.

11. All equipment designed to move in any way moves freely and without unnatural interference

12. All alignment checks complete and in accordance with manufactures specifications.

13. Coupling disengaged / belts removed for direction testing (where required). Final coupling alignment to be completed following direction test.

14. All shafts rotate freely and smoothly by hand.

15. Guards fitted and all rotating components guarded. All rotating components clear of guards.


M03 FIELD INSPECTION REPORT MECHANICAL EQUIPMENT PRE-COMMISSIONING


Page 2 of 2 2255357



Initial Date

16. Assembly fasteners checked for tightness and to specific torques where nominated by manufacturer.

17. All other accessories supplied with equipment / package installed and ready for service.

18. Threads exposed to water or weather and subject to future disassembly for maintenance or replacement protected by denso tape or other suitable anti corrosion product.

19. First fill lubrication complete and the type and quantity of oil/grease recorded.

20. Gearbox breather fitted.

21. All temporary construction materials removed and equipment checked for debris.

22. Record of any site modifications made on master as-built records.

23. Manufacturer's specification for assembly checked and any additional inspections required completed and attached to this form.

Comments

All pre-commissioning inspections reviewed, complete and approved

Approved By: Date:


M04 FIELD INSPECTION REPORT MECHANICAL EQUIPMENT RUNNING

Date: 22-Mar-2019 Revision: A

Page 1 of 2 2281906




Operating Condition (load/no load/water/slurry):


Initial Date

1. Pre-commissioning inspections complete.

2. No unusual noises or vibrations during initial start-up or operation.

3. Moving components clear of all guards.

4. All operating inspections and adjustments completed.

5. 2 hour run complete and relevant readings such as temperature, speed, current recorded on this form in the blank sections provided.

6. Any additional manufacturer’s operating checks required completed and attached to this form.

Reading Time (minutes)

0 30 60 90 120

1.

2.

3.

4.

5.

6.


M04 FIELD INSPECTION REPORT MECHANICAL EQUIPMENT RUNNING


Page 2 of 2 2281906


Comments

All running inspections reviewed, complete and approved

Approved By: Date:


M11 FIELD INSPECTION REPORT AIR COMPRESSOR PRE-COMMISSIONING


Page 1 of 2 2255359



Equipment Name: Equipment Number: Equipment Make / Model: Equipment Serial Number:

Inspection Comments / Action Required Compliant / Actions Complete Initial Date



3. Civil works completed and accepted for installation.



6. Shims placed under the compressor for levelling. Note skid mounted units do not require anchoring or grouting.

7. Compressor located in an adequately ventilated area where hot air from the discharge duct will not recirculate to the air inlet.

8. Adequate clearance available around unit to open all enclosure doors

9. Piping connected to air outlet connection and independently support

10. Ancillary items including dryers and filters installed.


12. All transport bolts removed from flexible isolation mounts.

13. Coupling disengaged / belts removed for direction testing (where required). Final coupling alignment to be completed following direction test.

14. Air-end oil level checked. All other first fill lubrication completed and type /quantity recorded.

15. Air-end and motor rotate freely and smoothly by hand.


M11 FIELD INSPECTION REPORT AIR COMPRESSOR PRE-COMMISSIONING


Page 2 of 2 2255359



16. Guards fitted and all rotating components guarded. All rotating components clear of guards.

17. For compressors containing an internal air/oil separator (pressure vessel) with a hazard level A, B, C or D regulatory requirements for registered classified plant must be met and statutory inspections completed before use.

18. All doors fitted and closed on enclosure.



21. Manufacturer's specification for assembly followed and checks complete. Attach to this form where available.

Comments


Approved By: Date:


M12 FIELD INSPECTION REPORT AIR COMPRESSOR RUNNING


Page 1 of 2 2281925





Initial Date


2. No unusual noises or vibrations from air end or drive during initial start-up or operation.

3. Internals of compressor enclosure inspected for oil and air leaks.

4. Air end oil level re-checked.

5. Compressor load/unload pressures switch settings set.

6. Appropriate flow/pressure observed.

7. Internal ancillary items including filters, cooling fans and auto drains inspected and functioning correctly.

8. External ancillary items including dryers and filters inspected and functioning correctly.

9. Adequate ventilation for cooling air flow

10. Local control functions and remoted signals tested and operating correctly.

11. Where multiple compressors are installed operation tested in conjunction with other units and any lead/lag sequencing control tested.

12. Run completed and temperature readings taken after a minimum two hours of steady operation.

13. Manufacturer commissioning checks completed and attached to this form.


M12 FIELD INSPECTION REPORT AIR COMPRESSOR RUNNING


Page 2 of 2 2281925



0 30 60 90 120

1. Ambient temperature (°C):

2. Air end housing/delivery temperature (°C):

3. Air end motor DE temperature (°C):

4. Air end motor NDE temperature (°C):

5.

6.

7.

8. Comments


Approved By: Date:


M15 FIELD INSPECTION REPORT PRESSURE VESSEL PRE-COMMISSIONING


Page 1 of 2 2267639




Equipment Serial Number:


Initial Date


2. Equipment serial number recorded on this form.


4. All pedestals scrabbled, bolt pockets clean/free from contaminants and packers set to correct elevation (for installation on concrete).



7. Grouting complete (for installation on concrete).

8. Hold down bolts snug tight.

9. Piping correctly connected to inlet / outlet and supported.

10. Inspection hatches closed and sealed.

11. All accessories installed including pressure relief valves, pressure gauges, manual drain and auto drain.

12. All surface protection inspected and repaired as required.

13. All temporary construction materials removed and internals checked for debris.

14. For pressure vessel with a hazard level A, B, C or D statutory inspections complete.



M15 FIELD INSPECTION REPORT PRESSURE VESSEL PRE-COMMISSIONING


Page 2 of 2 2267639


Comments


Approved By: Date:

For pressure vessel with a hazard level A, B, C or D regulatory requirements for registered classified plant must be met and statutory inspections completed before use.


M16 FIELD INSPECTION REPORT PRESSURE VESSEL COMMISSIONING


Page 1 of 1 2284172





Initial Date


2. Vessel holds air/liquid with no leakage including around all inlet/outlet pipework, submersed doors, valves and instruments.

3. No unusual movement or deflection of vessel during filling and operation.

4. Leak testing of vessel completed at operating pressure. Liquid vessels to have visual inspections (hydrostatic). Air vessels to have soap solution inspection (pneumatic).

5. All accessories supplied with vessel including pressure relief valves, pressure gauges, manual drain and auto drain functioning correctly.

Comments


Approved By: Date:

Note: Pressure vessels with a hazard level A, B, C or D require statutory inspections prior to being put into service.


M19 FIELD INSPECTION REPORT CHUTE AND PLATEWORK INSTALLATION


Page 1 of 1 2255362





1. Civil works / steel erection completed and accepted for installation.



4. Assembly bolts checked for tightness.

5. Internal lining inspected and repaired as required. Wear liners checked against design drawing (where applicable).

6. External surface protection inspected and repaired as required.

7. All accessories including hatches, guards and instruments installed as per design drawings.

8. All temporary construction materials removed, and internals checked for debris.


Comments


Approved By: Date:


M24 FIELD INSPECTION REPORT CONVEYOR PRE-COMMISSIONING


Page 1 of 4 2267383



Conveyor Name: Conveyor Number:

Drive Make/Model: Drive Serial Number:


Initial Date

1. Drive equipment name plate fitted and equipment name and number correct.

2. Drive equipment make/model and serial number recorded on this form and correct as per project equipment list.

3. Civil works completed and accepted.


5. All structural members and trusses installed as per the marking plan.

6. All structure members aligned and trestles vertical.

7. All structural fasteners installed, correct length and fully tensioned. 1% of bolts used direct tension washers.

8. Grouting complete around all legs/trestles.

9. Anchor bolts snug tight.

10. All grating installed along complete length of conveyor and fixed down.

11. All handrails installed along complete length of conveyor and free of gaps and sharp edges.

12. Where sliding joints are nominated stainless slip plates and retaining clamps installed.

13. All damaged surface protection on steelwork repaired.

14. Packaging removed from all mechanical components, equipment cleaned and inspected for damage prior to placement.





Page 2 of 4 2267383



Initial Date

16. All idlers installed as per the conveyor arrangement drawing. Correct idler types installed in the correct idler locations (carry, impact, trainer, transition, return, return training and weigh idlers).

17. All idlers set square to the conveyor centreline. Where packing is nominated on the design drawings idlers packed to correct height. Refer to weightometer pre-commissioning FIR for specific weigh idler alignments.

18. Idler hold down bolts snug tight.

19. All pulleys installed with floating bearings on non-drive side. Pulleys installed in the correct locations noting any special allowances such as shaft extensions/tapped holes for encoders or flags for under speed switches (tail, head, bend and take up).

20. All pulleys set square to the conveyor centre line. All pulley housings set square to pulley shafts. Pulley housing sole plates on support structure flat and level between each other.

21. Pulley locking devices removed. All pulleys rotate freely by hand with no fouling between housing labyrinths.

22. Pulley hold down bolts snug tight. Jacking screws installed with lock nuts.

23. Skirts fully assembled including all plate work, internal liners, dust covers, rubber curtains, guards and skirt clamp assemblies (skirt rubber to be installed after belt).

24. Drive installed complete with motor, reducer, reducer breather, guards and reaction arms. Where shaft mounted gearboxes are fitted with tapered hubs, bushing screws torqued to the manufacturer’s specification.

25. Drive shaft clamps and locking devices removed. Drive rotates freely by hand. Where back stops are installed direction of break checked.

26. Drive coupling disengaged/belts removed for direction testing (where required). Final coupling alignment to be completed following direction test.

27. Belt installed and splicing complete. Belt matches specification on arrangement drawing (width, cover thickness and number of plies).




Page 3 of 4 2267383



Initial Date

28. Primary and secondary scrapers installed including brackets, shaft, blades, tensioning mechanism and covers for the head chute penetrations. Scraper alignment and contact on belt checked. Blades backed off for initial tracking of conveyor.

29. Return belt plough installed including brackets, shafts, blades and anchor chains. Blade tension adjusted to prevent chattering.

30. Skirt clamp assemblies installed including clamps bars, pins and skirt rubber. Skirt rubber adjusted to ensure only light contact with belt.

31. Where weightometers are installed relevant pre-commissioning FIRs completed.

32. Pull wires installed, accessible and cover all reachable locations over the complete length of the conveyor. All guards removable without removing pull wire.

33. Drift switches installed, positions adjusted and switch positions set.

34. Underspeed switch installed and correctly positioned relative to flag on tail pulley.

35. All guards installed as per arrangement drawing. All danger zones guarded including at tail pulleys, skirts, return idlers (where nip pint is less than 2.5 m off the ground), return belt ploughs, bend pulleys, base of take up tower, head chute lead in, head pulleys, snub pulleys and idlers at convex curves in the conveyor.

36. All guards secured in position with a bolt or devise requiring a tool to remove.

37. All guards include “Danger – isolate before removing” signs.

38. All remote grease lines completed to all inaccessible bearings.

39. Conveyor tensions set: For gravity take up - correct size counter weight/number of weight plates installed. Shedder plate with rubber strips installed. Take up frame released from temporary supports and able to move freely. No clashes visible for full range of take up movement. Where trolley mounted pulleys with wire tensioning arrangements are used all components installed and to sizes nominated on arrangement drawing including sheaves, shackles, thimbles, grips and wire diameter. For tail pulley take up - tension adjusted based on return belt sag. Threaded rods and tensioning arrangement move freely without unnatural interference.




Page 4 of 4 2267383



Initial Date

40. All grease lines and electrical cables to moving take up arrangements have sufficient length to allow for take up movement.

41. Entire length of belt checked to ensure no potential clashes between moving belt and static structure including any guards, piping/electrical brackets or sharp edges that can potentially damage the belt.

42. All other accessories supplied with conveyor installed and ready for service.


44. All remote grease lines primed and flushed.

45. First fill lubrication complete for all components and the type and quantity of oil/grease recorded.

46. All temporary construction materials removed and belt checked for debris.



Comments


Approved By: Date:


M25 FIELD INSPECTION REPORT CONVEYOR RUNNING

Date: 10-Apr-2019 Revision: A

Page 1 of 3 2292120




Operating Condition (load/no load):


Initial Date


2. No unusual noises or vibrations during initial start-up, operation or stopping.


4. Belt clears all stationary objects. No rubbing marks visible on belt.

5. All pulleys and idlers rotating freely.

6. Back stop and torque arm functioning correctly.

7. Belt speed as per design.

8. Conveyor tension suitable with no slippage on the drive pulley and acceptable belt lift on bends. For gravity take up – counter weight moves freely and maintains tension on belt. For tail pulley take up – suitable sag observed on belt return.

9. Tracking complete and belt running in centre of idlers and pulleys.

10. Product feeding centrally on belt and flowing freely through head chute/transfer chutes.

11. Scrappers adjusted and operating satisfactory on ore (blades to be backed off for initial tracking/no load run of conveyor).

12. Return plough adjusted and operating satisfactory.

13. Skirt rubbers adjusted for light contact on belt. Skirts operating satisfactory on ore with no spillage (Skirt rubber may be left off for initial tracking/no load run of conveyor).

14. All instrumentation including belt drift and underspeed sensors functioning correctly.




Page 2 of 3 2292120



Initial Date

15. 2 hour run complete and relevant readings such as temperature, throughput, and current recorded on this form in the blank sections provided.



0 30 60 90 120

1. Electric motor drive end temperature (°C):

2. Electric motor non-drive end temperature (°C):

3. Gearbox temperature (°C):

4. Head pulley drive side bearing temperature (°C):

5. Head pulley non-drive side bearing temperature (°C):

6. Tail pulley drive side bearing temperature (°C):

7. Tail pulley non-drive side bearing temperature (°C):

8. Gravity take-up pulley drive side bearing temperature (where applicable) (°C):

9. Gravity take-up pulley non-drive side bearing temperature (where applicable) (°C):

10. Bend pulley head end drive side bearing temperature (where applicable) (°C):

11. Bend pulley head end non-drive side bearing temperature (where applicable) (°C):

12. Bend pulley tail end drive side bearing temperature (where applicable) (°C):

13. Bend pulley tail end non-drive side bearing temperature (where applicable) (°C):

14.

15.




Page 3 of 3 2292120



0 30 60 90 120

16. Comments


Approved By: Date:


M27 FIELD INSPECTION REPORT CYCLONE RUNNING


Page 1 of 1 2292118




Operating Condition (water/slurry):


Initial Date


2. No leakage during operation including around joins in the distributor, cyclones, overflow launder, underflow launder and all instrument nozzles.

3. No unusual movement or deflection of plate work during operation including distributor, overflow launder and underflow launder.

4. Product flows freely through launders and product nozzles without spillage.

5. Appropriate flow, pressure and underflow/overflow split observed during operation.

6. All accessories supplied with cyclone including valves, pressure gauges and instruments functioning correctly.

Comments


Approved By: Date:


M28 FIELD INSPECTION REPORT DUST COLLECTOR PRE-COMMISSIONING


Page 1 of 2 2263814






Initial Date



3. Civil works/steel erection/platework completed and accepted for installation.


5. Filter body/bag house fully assembled and all joints sealed.



8. Inlet ducting connected.

9. Outlet ducting installed including any exhausts stacks, silencers, dampeners or rain hoods.

10. Product discharge chute/pipework installed.

11. Filter elements/bags/cartridges installed. Items sealed correctly to plenum plate.

12. Reverse pulsing system including air tank, solenoid valves, jet tubes/venturi and timer board installed.

13. Pneumatic piping connected to revers pulse system including filter regulator.

14. Differential pressure indicators installed (when supplied).

15. All inspection hatches closed and sealed.


M28 FIELD INSPECTION REPORT DUST COLLECTOR PRE-COMMISSIONING


Page 2 of 2 2263814



Initial Date


17. All other accessories supplied with equipment/package installed and ready for service. If dust collector includes an extraction fan or rotary valve complete relevant per-commissioning FIR separately.


19. All temporary construction materials removed and equipment internals checked for debris.



Comments


Approved By: Date:


M29 FIELD INSPECTION REPORT DUST COLLECTOR RUNNING


Page 1 of 1 2292113






Initial Date


2. Bag house/dust collector holds vacuum with no leaks including around all inlet/outlet ducting, inspection hatches, valves and instruments.

3. No unusual movement or deflection of bag house/dust collector during operation.

4. Where multiple suction points are used, dampeners adjusted to achieve equal suction across all points (when fitted).

5. Dust collector exhausts satisfactory clean.

6. Dust collector suction points satisfactorily entrain fumes/particles.

7. Reverse pulse system functioning correctly. Air pressure and pulse timers set.

8. Where ancillary equipment is supplied, such as rotary valves or fans equipment inspected and any relevant running inspections completed.


Comments


Approved By: Date:


M36 FIELD INSPECTION REPORT SCREW FEEDER PRE-COMMISSIONING


Page 1 of 2 2263811






Initial Date



3. Steel erection and/or platework completed and accepted for installation.



6. Motor, transmission (gearbox or vee-belts), screw, inlet section, intermediate tubular trough, outlet section and bearing housing assembled.


8. Equipment positioned as shown on general arrangement drawings to correct location, orientation and elevation.


10. Inlet/outlet chutes connected.

11. Access hatches closed and sealed.

12. Shaft seal installed and packing adjusted (when applicable).

13. Intermediate bearings installed (when applicable).


15. Internal screw, gearbox and motor rotate freely. Screw clears inner wall of tube.


M36 FIELD INSPECTION REPORT SCREW FEEDER PRE-COMMISSIONING


Page 2 of 2 2263811



Initial Date

16. Guards fitted and all rotating components guarded. No access possible to screw. All rotating components clear of guards.

17. All other accessories supplied with equipment/package including inlet isolation valves installed and ready for service.






Comments


Approved By: Date:


M37 FIELD INSPECTION REPORT SCREW FEEDER RUNNING


Page 1 of 2 2284174






Initial Date




4. Internal screw clears inner wall of tube. No rubbing sound or vibration during operation.

5. Mechanical/gland seal inspected/adjusted and functioning correctly.

6. No leakage from inspection hatches or inlet/outlet chutes.

7. Appropriate throughput observed through feeder.

8. 2 hour run complete and relevant readings such as temperature, speed, throughput recorded on this form in the blank sections provided.



0 30 60 90 120

1. Screw feeder drive end bearing temperature (°C):

2. Screw feeder non-drive end bearing temperature (°C):





M37 FIELD INSPECTION REPORT SCREW FEEDER RUNNING


Page 2 of 2 2284174



0 30 60 90 120

6.

7.

8. Comments


Approved By: Date:


M48 FIELD INSPECTION REPORT TANK AND HOPPER INSTALLATION


Page 1 of 1 2255363





Initial Date


2. All pedestals scrabbled for grouted base plates or concrete slabs cleaned of debris for flat bottom tanks.


4. Grout installed (for base plates) or interface joint sealed to concrete (for flat bottom tanks).

5. Anchor and assembly bolts checked for tightness.

6. All surface protection and internal lining inspected and repaired as required.

7. All temporary construction materials removed, suctions spools and tank checked for debris.


Comments


Approved By: Date:


M49 FIELD INSPECTION REPORT TANK AND HOPPER WET COMMISSIONING


Page 1 of 1 2281964





Initial Date


2. Vessel holds liquid with no leakage including around all submersed doors, valves and instruments.

3. No unusual movement or deflection of plate work during filling and operation. Comments


Approved By: Date:


M70 FIELD INSPECTION REPORT HORIZONTAL CENTRIFUGAL PUMP PRE-COMMISSIONING


Page 1 of 2 2255366



Equipment Name: Equipment Number: Equipment Make/Model: Equipment Serial Number:

Inspection Comments/Action Required Compliant/Actions Complete Initial Date









9. Piping connected and free of stress and does not impact coupling alignment.


11. Coupling disengaged/belts removed for direction testing (where required). Final coupling alignment to be completed following direction test.

12. Pump impeller and bearing assembly turns freely by hand.

13. Drive and coupling guards fitted and all rotating components clear of guards.

14. Threads exposed to water or weather and subject to future disassembly for maintenance or replacement protected by denso tape or other suitable anti corrosion product. (jacking and guard bolts to be left until after direction test and final coupling alignment).


M70 FIELD INSPECTION REPORT HORIZONTAL CENTRIFUGAL PUMP PRE-COMMISSIONING


Page 2 of 2 2255366



15. First fill lubrication complete and the type and quantity of oil/grease recorded for each item.





Comments


Approved By: Date:


M71 FIELD INSPECTION REPORT HORIZONTAL CENTRIFUGAL PUMP RUNNING


Page 1 of 2 2281981






Initial Date


2. No unusual noises or vibrations during operation.

3. Mechanical/gland seal inspected/adjusted and functioning correctly.

4. Rotating components clear of all guards.

5. Appropriate flow produced at end of line.

6. Where instrumentation is available other relevant readings such as pump speed (VSD only), current, pressure or flow recorded on this form on the blank sections provided.

7. Run complete and temperature readings recorded on this form.


0 30 60 90 120

1. Pump drive end bearing temperature (°C):

2. Pump non-drive end bearing temperature (°C):



5.

6.

7.


M71 FIELD INSPECTION REPORT HORIZONTAL CENTRIFUGAL PUMP RUNNING


Page 2 of 2 2281981


Comments


Approved By: Date:


M72 FIELD INSPECTION REPORT VERTICLE CENTRIFUGAL SUMP PUMP PRE-COMMISSIONING


Page 1 of 2 2255367



Equipment Name: Equipment Number: Equipment Make/Model: Equipment Serial Number:







6. Support frame levelled and grouted.


8. Mesh screen installed around sump

9. Strainer fitted to bottom of pump inlet.

10. Anchor bolts and support frame bolts snug tight.

11. Piping connected and free of stress.



14. Pump impeller and bearing assembly turns freely by hand.

15. Drive and coupling guards fitted and all rotating components clear of guards.


M72 FIELD INSPECTION REPORT VERTICLE CENTRIFUGAL SUMP PUMP PRE-COMMISSIONING


Page 2 of 2 2255367



16. Threads exposed to water or weather and subject to future disassembly for maintenance or replacement protected by denso tape or other suitable anti corrosion product. (jacking and guard bolts to be left until after direction test and final coupling alignment)

17. First fill lubrication complete and the type and quantity of oil/grease recorded for each item.


19. All temporary construction materials removed and sump cleared of debris.



Comments


Approved By: Date:


M73 FIELD INSPECTION REPORT VERTICAL CENTRIFUGAL SUMP PUMP RUNNING


Page 1 of 2 2281987






Initial Date






6. Any other relevant data where instrumentation is available recorded on this form in the blank sections provided.

7. Any other relevant manufacturer’s operating checks completed and attached to this form.


0 30 60 90 120

1. Pump drive end (upper) bearing temperature (°C):

2. Pump non-drive end (lower) bearing temperature (°C):



5.

6.


M73 FIELD INSPECTION REPORT VERTICAL CENTRIFUGAL SUMP PUMP RUNNING


Page 2 of 2 2281987


Comments


Approved By: Date:


M74 FIELD INSPECTION REPORT VERTICAL MULTI-STAGE PUMP PRE-COMMISSIONING


Page 1 of 2 2255369






Initial Date




4. All pedestals scrabbled, bolt pockets clean, free from contaminants and packers set to proper elevations (when directly mounted to concrete).

5. Pump sub-frame installed and grouted (when mounted on sub-frame).

6. Prior to placing equipment packaging removed and equipment cleaned.





11. Piping connected correctly to inlet/outlet connections for direction of flow.

12. Drive coupling connected, tight and guards fitted.





M74 FIELD INSPECTION REPORT VERTICAL MULTI-STAGE PUMP PRE-COMMISSIONING


Page 2 of 2 2255369



16. Manufacturer's specification for assembly followed and checks complete. Attach to this form where available.

Comments


Approved By: Date: Note: Most vertical multi-stage pumps cannot be run dry. Do not direction test or start the pump until it has been filled with liquid and vented. If the pump runs dry, the pump bearings and the shaft seal

may be damaged.


M75 FIELD INSPECTION REPORT VERTICAL MULTI-STAGE PUMP RUNNING


Page 1 of 2 2281992




Operating Condition (load/no load/water/solution):


Initial Date



3. Mechanical seal inspected and functioning correctly.




7. Where instrumentation is available other relevant readings such as pump speed (VSD only), current, pressure or flow recorded on this form on the blank sections provided.

8. Relevant manufacturer’s operating checks completed and attached to this form.


0 30 60 90 120



3. Mechanical seal temperature (°C):

4.

5.

6.


M75 FIELD INSPECTION REPORT VERTICAL MULTI-STAGE PUMP RUNNING


Page 2 of 2 2281992


Comments


Approved By: Date:

Note: Most vertical multi-stage pumps cannot be run dry. Do not run the pump until it has been filled with liquid and vented. If the pump runs dry, the pump bearings and the shaft seal may be damaged.


M78 FIELD INSPECTION REPORT DOSING PUMP PRE-COMMISSIONING

Date: 11-Jun-2019 Revision: A

Page 1 of 2 2322169






Initial Date




4. All pedestals scrabbled, bolt pockets clean, free from contaminants and packers set to proper elevations (when mounted to concrete).

5. Pump sub-frame installed and grouted (when mounted on sub-frame).



8. Anchor/hold down bolts snug tight.


10. Piping correctly plumbed to inlet/outlet nozzles for direction of flow and pump rotation.




14. All other accessories supplied with pump such as strainers, foot valves, PRVs and pulsation dampeners installed and ready for service.


M78 FIELD INSPECTION REPORT DOSING PUMP PRE-COMMISSIONING


Page 2 of 2 2322169



Initial Date



17. Gearbox breather fitted and activated.




Comments


Approved By: Date:


M79 FIELD INSPECTION REPORT DOSING PUMP RUNNING


Page 1 of 2 2322171




Operating Condition (water/solution):


Initial Date



3. Any mechanical seals/gland inspected and functioning correctly.


5. Appropriate flow/pressure produced at end of line.

6. 2 hour run complete and relevant readings such as temperature, speed, current recorded on this form in the blank sections provided.

7. Where the dosing pump has adjustable dosing rates and/or strokes, all operating adjustments made to suit the required dosing rate and flows recorded on this form.



0 30 60 90 120



3. External surface of wet end temperature (°C):

4.

5.


M79 FIELD INSPECTION REPORT DOSING PUMP RUNNING


Page 2 of 2 2322171


Reading Pump Speed Set Point

0% 25% 50% 75% 100%

1. Measured Flow (l/hr).

2. Stroke length/pump adjustment set point.

3. Comments


Approved By: Date:


M80 FIELD INSPECTION REPORT AIR OPERATED DIAPHRAGM PUMP PRE-COMMISSIONING


Page 1 of 2 2322177






Initial Date




4. All pedestals scrabbled, bolt pockets clean/free from contaminants and packers set to correct elevation (when mounted direct to concrete).

5. Pump sub-frame installed (when mounted on sub-frame).




9. Anchor/hold down bolts snug tight.


11. Piping correctly plumbed to inlet/outlet nozzles for direction of flow through pump.

12. Compressed air connected to the air valve body on the pump. Control (regulator) and isolation valves installed on the air supply line.

13. All accessories installed and ready for service including valves, instruments, exhaust mufflers and strainers (where applicable).



M80 FIELD INSPECTION REPORT AIR OPERATED DIAPHRAGM PUMP PRE-COMMISSIONING


Page 2 of 2 2322177



Initial Date






Comments


Approved By: Date:


M81 FIELD INSPECTION REPORT AIR OPERATED DIAPHRAGM PUMP RUNNING


Page 1 of 1 2322124




Operating Condition (water/solution):


Initial Date


2. Initially start pump slowly using the control valve on the air line. No excessive noises or vibrations during initial start-up. Note pump is expected to produce some movement with the diaphragm action.

3. Increase air pressure to pump to achieve desired flow. Appropriate flow produced at end of line.

4. No excessive noise or vibration from pump when operating at full flow. Note pump is expected to produce some movement with the diaphragm action.

5. No excessive pulsing in discharge line with diaphragm action. Sufficient supports and anchors on line.


Comments


Approved By: Date:


M88 FIELD INSPECTION REPORT ROTARY VALVES PRE-COMMISSIONING


Page 1 of 2 2263812






Initial Date



3. Platework completed and accepted for installation.



6. Motor, transmission (gearbox or vee-belts) and valve assembled.


8. Equipment positioned as shown on general arrangement drawings to correct location, orientation and elevation.

9. Inlet / outlet chutes connected.


11. Rotor, gearbox and motor rotate freely. Rotor clears inner wall of housing.

12. Guards fitted and all rotating components guarded. No access possible to rotor. All rotating components clear of guards.

13. Compressed air connected to any air purged seals or air purging ports (when fitted).

14. All other accessories supplied with equipment/package including inlet isolation valves installed and ready for service.


M88 FIELD INSPECTION REPORT ROTARY VALVES PRE-COMMISSIONING


Page 2 of 2 2263812



Initial Date






Comments


Approved By: Date:


M89 FIELD INSPECTION REPORT ROTARY VALVE RUNNING


Page 1 of 2 2284129






Initial Date




4. Internal rotor clears inner wall of housing. No rubbing sound or vibration during operation.

5. Shaft seals inspected, adjusted and functioning correctly.

6. Where air purged seals or air purging ports are fitted air supply pressure adjusted and functioning correctly.

7. No leakage from inlet / outlet chutes.

8. Appropriate throughput observed through valve.

9. 2 hour run complete and relevant readings such as temperature, speed, throughput recorded on this form in the blank sections provided.



0 30 60 90 120

1. Screw feeder drive end bearing temperature (°C):

2. Screw feeder non-drive end bearing temperature (°C):



M89 FIELD INSPECTION REPORT ROTARY VALVE RUNNING


Page 2 of 2 2284129



0 30 60 90 120



6.

7.

8. Comments


Approved By: Date:


P01 FIELD INSPECTION REPORT PIPING INSTALLATION


Page 1 of 2 2255356



Service System Description


1. Approved for construction design drawings available for system.

2. All lines complete and installed as per P&ID to correct size and material specification.

3. All valves and special piping items installed as per P&ID.

4. All pre-spooled lines installed as per isometric drawings.

5. Adequate supports and fixings installed for all lines and temporary construction supports removed.

6. All joint assembly bolts tight.

7. Correct bolts and gaskets installed on flange joints as nominated for the material specification.

9. All manually operated valves accessible for operation.

10. All lines identified with correct colour code and flow direction indicators.

11. Thermal insulation/personal protection complete for all lines (were specified).

12. All lines clear of moving and/or removable components and flanges/unions provided to allow maintenance of equipment.

13. All damaged surface protection repaired.

14. All temporary construction materials removed and lines checked for debris.



P01 FIELD INSPECTION REPORT PIPING INSTALLATION


Page 2 of 2 2255356


Comments


Approved By: Date:


P02 FIELD INSPECTION REPORT SERVICE TESTING OF PIPING


Page 1 of 1 2263069





Initial Date

1. Pre-commissioning inspections complete for lines to be tested.

2. Limits of test illustrated on P&ID and appended to this form.

3. Modifications to lines required for test purposes including temporary blinds and the removal of inline equipment, strainers and instruments noted on P&ID appended to this form.

4. Service test completed and details recorded below.

5. Leak testing of lines completed by visual (hydrostatic) or soap solution (pneumatic) inspections during pressure test. Any leaks found rectified.

6. Following completion of service test temporary blinds removed and equipment removed for test purposes reinstalled.

Reading Result/Comment

1. Test Type (hydrostatic/pneumatic)

2. Test Medium

3. Service Test Pressure (kPa)

Comments

All inspections reviewed, complete and approved

Approved By: Date:


P03 FIELD INSPECTION REPORT PRESSURE TESTING OF PIPING


Page 1 of 2 2263068





Initial Date

1. Pre-commissioning inspections complete for lines to be tested.

2. Limits of test illustrated on P&ID and appended to this form.

3. Modifications to lines required for test purposes including temporary blinds and the removal of inline equipment, strainers and instruments noted on P&ID appended to this form.

4. Service test completed and details recorded below.

5. Leak testing of lines completed by visual (hydrostatic) or soap solution (pneumatic) inspections during pressure test. Any leaks found rectified.

6. Following completion of service test temporary blinds removed and equipment removed for test purposes reinstalled.

Reading Result/Comment

1. Test type (hydrostatic/pneumatic)

2. Test medium

3. Test pressure (kPa)

4. Hold period (minutes)

5. Pressure after hold period (kPa)

6. Pressure gauge serial number

7. Pressure gauge calibration certificate number:


P03 FIELD INSPECTION REPORT PRESSURE TESTING OF PIPING


Page 2 of 2 2263068


Comments


Approved By: Date:


S02 FIELD INSPECTION REPORT STEEL STRUCTURE ERECTION CHECKS


Page 1 of 1 2255355



Area:


Initial Date

1. Civil works completed and accepted.

2. All pedestals scrabbled, bolt pockets clean and free from contaminants and packers set to correct elevations.

3. All structural members installed as per the marking plan.

4. All structure members aligned to grid lines and columns vertical.

5. All fasteners installed, correct length and fully tensioned. 1% of bolts to use direct tension washers.

6. All design, detailing and fabrication errors rectified.

7. All site welds/site modifications complete and surface protection repaired.

8. Grouting complete around all columns and all anchor bolts snug tight.

9. All grating installed and fixed down.

10. All grating penetrations banded and kick plate installed on open edges.

11. Abrasive nosing installed on all stair treads.

12. All handrails installed and free of sharp edges.

13. All damaged surface protection repaired.

14. All temporary construction materials removed.



Approved By: Date:


S03 FIELD INSPECTION REPORT GROUTING


Page 1 of 2 2255353



Equipment Number/Area:


Initial Date

1. Grout type Conbextra HF, approved equivalent or as noted on design drawings.

2. Grout in good condition and within expiry date.

3. All concrete surfaces in contact with grout scabbled, concrete laitance removed and a clean rough surface achieved.

4. Packers installed to correct levels.

5. Bolt pockets and inside of form clean and free of contaminants. Underside of equipment clean and free from oil.

6. Surface or foundation soaked with potable water for several hours prior to grouting. Immediately before grouting free water removed.

7. Ambient temperatures during pour within temperature limitations of grout (5°C to 35°C) or enclosures used to provide shade.

8. Potable water used for mixing.

9. Grout and water measured and mix proportions as per manufactures instructions.

10. Grout mixed for a minimum of three minutes into a homogenous uniform mixture.

11. Grout pour completed in a period no longer than 20 minutes from mixing.

12. Formwork free of leaks during pouring. Adequate clearances provided in form to allow grout placement.

13. Grout placed in a continuous manner to completely fill all voids, eliminated the entrapment of air and make complete contact with the area to be supported.

14. After initial set grout cut at 45° from the bottom edge of the base plate. Finish of grout smooth and neat.

15. Curing compound applied to all exposed areas.


S03 FIELD INSPECTION REPORT GROUTING


Page 2 of 2 2255353



Initial Date

16. Any scrabbled surfaces not covered by grout repaired with plaster.

Comments


Approved By: Date:


Prepared by: GR Engineering Services Limited Approved by: H – Inspection Hold Point M – Monitor Operations R – Review Documentation S - Surveillance W – Witness Point

PQM-TEM-003a Inspection and Test Plan Page 1 of 3 Revision: 0 Date: 16-Jun-2017 pqm-tem-003a - itp steel piping

- site fabrication and installation


FORM: PQM-TEM-003a INSPECTION AND TEST PLAN CLIENT: <Insert Client Name> PROJECT: <Insert Project Name> JOB NUMBER: XXXXX ITP NO.: <Insert ITP No.> CONTRACT NO: XXXXXX SCOPE: Site Fabrication and Installation REVISION 0 DATE: 16-Jun-2017 DESCRIPTION:

Item No. Inspection Description Procedure and/or Relevant

Standards Acceptance Criteria Verifying Document SURVEILLANCE

Remarks GRES Act Sign

1.0 Submission / Approval of Documentation 1.1 Quality Plan, NDT Procedure, NDE Operator Qualifications,

Fabrication Procedure & Surface Treatment Procedure Approved documents H/R

2.0 Materials 2.1 Inspect materials condition. Including welding consumables

for defects damage or contamination and verify that they are correct in accordance with Purchase Order, Delivery Docket and Material Certificates and “Free Issue” material register. Quantify and verify materials marking is in line with that specified on the drawings and identified.

ASME IX AS 4041

AS1554-SP AS 4041 ASME 1X

Delivery Dockets, Material Register & Certificates, Consumable Certificate

M

2.2 Check for imperfections in flanges such as gouges and or protrusions in the serrations of gasket seating faces.

AS 4041 AS 4041 FIR P06 Material Certificates

H/R

2.3 Material requirements – Check the correct materials are installed as specification and line class.

AS 4041 TS12

AS 4041 TS12

FIR P06 Material Certificates

H/R

2.4 Store materials and welding consumables to eliminate damage.

AS 4041 M

3.0 Pre Processing & Assembly 3.1 Material allocation.

Transfer & marking of heat numbers. Mark piping material to required length. Cut pipe sections to length in readiness for Preparation, bevelling.

Approved drawings AS 4041

M

3.2 Assembly of components prior to welding. Check: - Fit-up & alignment - Root Gap & Landing - Install pipe supports as per Drawing. - Dimensional check prior to welding

TS12 AS 4041 Approved drawing & qualified WPS

Approved drawings W

4.0 Welding (Field) 4.1 Ensure Internals are clean and dry before welding. TS12 TS12 10.2 FIR P06 M 4.2 Welding to be performed by qualified welder in accordance

with approved welding Procedure Specification TS12 AS 4041

AS/NZS 3992 AS/NZS 1554

Welder Qualification Welder Register

M

4.3 Carry out welding of joints, field welds, pipe supports & M









attachments. 4.4 Welding visual Inspection, check:

- Root pass/weld size/profile & finish - Welder, WPS consumables

TS12 AS 4037

AS 4041 AS/NZS 3992 AS/NZS 1554 AS 4037

FIR P06 Approved drawings

W

4.5 Weld repairs (if any) Remove defect and re-weld in accordance with qualified procedure

Weld Repair Sheet NDT report

H

5.0 Inspection & Testing 5.1 Dimensional check of piping assembly after welding “As Built” TS12 AS 4041 As Built drawings & FIR P06 H 5.2 100% Final visual inspection of all welds TS12 AS 4037 As Built drawings H 5.3 Non Destructive Examination: (If required) TS12 AS 4037 NDT Report H 6.0 Pipe Installation – Bolted / Victaulic / Screwed Joints 6.1 Inspect nozzle integrity on all static and rotating equipment to

which pipe spools are connected. TS12 TS12 FIR P06 W

6.2 Ensure Internals are clean and dry prior to assembly. TS12 TS12 FIR P06 M 6.3 Shim steelwork at pipe support location and check for correct

elevation. TS12 TS12 FIR P06 W Visual as required

6.4 Assembly – Install pipework Align mating flange joints to specified tolerances - To mechanical equipment - To static equipment - Pipe to pipe

TS12 TS12 FIR P06 & drawings H

6.5 Install in line piping components gaskets, nuts, bolts and Instrumentation

TS12 TS12 FIR P06 & drawings M

6.6 Check valves & instrumentation for identification tags & check orientation. Installation of valves & instrumentation.

TS12 TS12 FIR P06 & drawings W

6.7 Ensure correct bolts are installed & tensioned. TS12 TS12 FIR P06 & drawings M 7.0 Pressure Testing – (N/A for Tie in Points) 7.1 Develop Hydrostatic or Pneumatic Pressure Test Packs.

Check NDE & Calibrated Certificates prior to testing. TS12 AS 4041

AS 4037 TS12

FIR P02 NATA Calibration Report for pressure gauge

R

7.2 Flush clean piping system. W 7.3 Pressure test pipework ‘Witness Test for any leaks’ H 7.4 Verification of cleanliness & dryness W 8.0 Surface Treatment (Touch ups) 8.1 Touch ups TS15 SS-P118 FIR P06 W 9.0 Final Inspection & Completion 9.1 Carry out final inspection

Generate punch list Verification/clearance of punch list

TS12 TS12 Field Inspection FIR P06

H

10.0 Finalise Documentation









10.1 Progressively check all test reports are correct. AS 4041 AS 4041 Reviewed and Approved Report H 10.2 MDR to be progressively compiled and submitted to client for

final approval. TS12

TS12

MDR R

Reference Documentation: GR Field Inspection Report (FIR) GRES Specification FIR P06 Piping Installation TS15 Surface Treatment FIR P02 Pressure Test of Plant Piping TS12 Piping



PQM-TEM-003b Inspection and Test Plan Page 1 of 2 Revision: 0 Date: 16-Jun-2017 pqm-tem-003b - itp site touch

up painting This document is UNCONTROLLED once printed

FORM: PQM-TEM-003b INSPECTION AND TEST PLAN CLIENT: <Insert Client Name> PROJECT: <Insert Project Name> JOB NUMBER: XXXXX ITP NO.: <Insert ITP No.> CONTRACT NO: XXXXXX SCOPE: Site Touch Up Painting REVISION 0 DATE: 16-Jun-2017 DESCRIPTION:




1.0 Materials 1.1 Materials received as per delivery dockets and conforms

with condition requirements (expiry date) TS15 Approved paint coating product Delivery Dockets, material

certification. M

1.2 Materials stored as per manufacturers recommendations TS15 TS15 Material certification M 1.3 MSDS available TS15 MSDS onsite MSDS M 2.0 Surface Preparation 2.1 Wire brush area to be painted TS15 FIR M78 W 2.2 Wipe and clean down area to be painted TS15 Free of grease, dirt & loose

particles FIR M78 W

2.3 Protect areas not to be painted if applicable TS15 Area masked up where applicable FIR M78 S 2.4 Check ambient conditions TS15 Temperature 10-45C, Humidity less

than 75% FIR M78 S

3.0 Paint Application 3.1 Check paint mixed correctly TS15 Manufacturers Data Manufacturers Data M 3.2 Apply primer with brush and allow to dry TS15 Manufacturers Data FIR M78 M 3.3 Apply first coat with brush and check for correct application,

no runs and sags and allow to dry TS15 Manufacturers Data FIR M78 W

3.4 Check DFT TS15 TS15 Thickness measurement W 3.5 Apply second coat with brush and check for correct

application, no runs and sags and allow to dry TS15 Manufacturers Data FIR M78 W

3.6 Check DFT TS15 TS15 Thickness measurement W 4.0 Final Inspection & Completion 4.1 Carry out final inspection/ Generate punch

list/Verification/clearance of punch list TS15 , FIR M78 / Punchlist H

5.0 Finalise Documentation 5.1 Progressively check all documentation is correct. GRES Sign off Reviewed and Approved Report R 5.2 MDR to be progressively compiled and submitted to client

for final approval. GR MDR GRES Sign off MDR R



PQM-TEM-003b Inspection and Test Plan Page 2 of 2 Revision: 0 Date: 16-Jun-2017 pqm-tem-003b - itp site touch

up painting This document is UNCONTROLLED once printed

Reference Documentation: GR Field Inspection Report (FIR) GRES Specification FIR M78 Site Touch Up Painting TS15 Surface Treatment



PQM-TEM-003c Inspection and Test Plan Page 1 of 3 Revision: 0 Date: 16-Jun-2017 pqm-tem-003c - itp poly piping

– site fabrication and installation


FORM: PQM-TEM-003c INSPECTION AND TEST PLAN CLIENT: <Insert Client Name> PROJECT: <Insert Project Name> JOB NUMBER: XXXXX ITP NO.: <Insert ITP No.> CONTRACT NO: XXXXXX SCOPE: Poly Piping – Site Fabrication and Installation REVISION 0 DATE: 16-Jun-2017 DESCRIPTION:




1.0 Submission/Approval of Documentation 1.1 Welder Qualifications –Tickets AS 2033 TS12

AS 2033 Welder Qualification Record (WQP) PMBWELD301B & PMBWELD302B

H

2.0 Materials 2.1 Inspect materials condition, quantify and verify materials

marking is in line with that specified on the drawings and identified. Including welding consumables for defects damage or contamination and verify that they are correct in accordance with Purchase Order, Delivery Docket and Material Certificates..

AS 2033 Visual inspection Delivery Dockets, Material Register & Certificates, Consumable Certificate

M

2.2 Check for imperfections in stub flanges and backing rings. AS 2033 Visual inspection FIR P06 H/R 2.3 Material requirements – Check the correct materials are

installed as specification and line class. AS 4130 AS 2033

Visual inspection FIR P06 H/R

2.4 Store materials and welding consumables to eliminate damage.

AS 2033 Visual inspection M

3.0 Pre Processing & Assembly 3.1 Material allocation.

Mark piping material to required length. Cut pipe sections to length.

PIPA-POP001 & 003 Approved drawings AS/NZS 2033:2008

FIR P06 M

3.2 Assembly of components prior to welding, check: - Fit-up & alignment - Install pipe supports as per Drawing. - Dimensional check prior to welding

Approved drawing AS/NZS 2033:2008

Approved drawings FIR P06

W

4.0 Welding (Field) 4.1 Ensure Internals are clean and dry before welding. AS 2033 TS12 FIR P06 M 4.2 Welding to be performed by qualified welder in accordance

with approved welding Procedure Specification. AS 2033 PIPA-POP001 & 003

TS12 AS 2033 PIPA

Welder Qualification PMBWELD301B & PMBWELD302B FIR P003 Approved drawings

M

4.3 Carry out welding of joints, field welds, pipe supports & attachments.

M

4.4 Welding visual inspection, check: TS12 AS 2033 FIR P003 W









- Weld size/profile & finish AS/NZS 2033:2008









4.5 Weld repairs (if any). Remove defect and re-weld in accordance with qualified procedure

FIR P003 H

5.0 Inspection and Testing 5.1 Dimensional check of piping assembly after welding “As Built” AS 2033 AS 2033 Approved drawings & FIR P06 H 5.2 100% Final visual inspection of all welds. AS 2033 AS 2033 FIR P06 H 6.0 Pipe Installation – Bolted joints 6.1 Inspect nozzle integrity on all static and rotating equipment to

which pipe spools are connected. TS12 TS12 FIR P06 W

6.2 Ensure Internals are clean and dry prior to assembly. TS12 TS12 FIR P06 M 6.3 Shim steelwork at pipe support location and check for correct

elevation. TS12 TS12 FIR P06 W

6.4 Assembly – Install pipework Align mating flange joints to specified tolerances: - To mechanical equipment - To static equipment - Pipe to pipe

TS12 TS12 FIR P06 & drawings H

6.5 Install in line piping components gaskets, nuts, bolts and Instrumentation

TS12 TS12 FIR P06 & drawings M

6.6 Check valves & instrumentation for identification tags & check orientation. Installation of valves & instrumentations.

TS12 TS12 FIR P06 & drawings W

6.7 Ensure correct bolts are installed & tensioned. TS12 TS12 FIR P06 & drawings M 7.0 Pressure Testing – (N/A for Tie in Points) 7.1 Develop Hydrostatic or Pneumatic Pressure Test Packs.

Check NDE & Calibrated Certificates prior to testing. TS12 AS 2033

AS 4041 AS 4037 TS12 AS 2033

FIR P02 NATA Calibration Report for pressure gauge

R

7.2 Flush clean piping system. W 7.3 Pressure test pipework ‘Witness Test for any leaks’ H 7.4 Verification of cleanliness & dryness W 9.0 Final Inspection & Completion 9.1 Carry out final inspection


TS12 TS12 Field Inspection FIR P06

H

10.0 Finalise Documentation 10.1 Progressively check all test reports are correct. AS 4041 AS 4041 Reviewed and Approved Report H 10.2 MDR to be progressively compiled and submitted to client for

final approval. TS12

TS12

MDR R






Reference Documentation: GR Field Inspection Report (FIR) GRES Specification FIR P06 Piping Installation TS12 Piping FIR P02 Pressure Test of Plant Piping



PQM-TEM-003d Inspection and Test Plan Page 1 of 2 Revision: 0 Date: 16-Jun-2017 pqm-tem-003d - itp panels

installation This document is UNCONTROLLED once printed

FORM: PQM-TEM-003d INSPECTION AND TEST PLAN CLIENT: <Insert Client Name> PROJECT: <Insert Project Name> JOB NUMBER: XXXXX ITP NO.: <Insert ITP No.> CONTRACT NO: XXXXXX SCOPE: ITP Panels Installation REVISION 0 DATE: 16-Jun-2017 DESCRIPTION:




1.0 Submission/Approval of Documentation 1.1 Weld test documentation where welding required TS21 Visual inspection of documentation Weld test documentation R 2.0 Materials 2.1 Inspect materials for damage / defects, ensure correct

materials in accordance with design drawings TS21 Visual inspection Design drawings, MDR, IOM( if

applicable) M

3.0 Installation 3.1 Identify suitable location for panel – where possible outside of

bund, in a location where installation will not cause obstruction, minimum 600mm front access to panel

TS21, AS 3000 Visual inspection

Design drawings, general arrangement, TS21

H

3.2 Install bracketing - any holes drilled in structure to be touched up with paint. Refer to surface treatment ITP.

TS21

Visual inspection M

3.3 Where mounted on concrete install dyna bolts/chem-set bolts and mount stand. Base of stand to be grouted – refer to Grouting ITP. Ensure under side of panel is mounted above bund height.

TS21 Visual inspection & measurement M

3.4 Mount panel to bracket / stand – ensure rubber pad between dis-similar metals to prevent galvanic action. No fixing holes to be drilled in panel

TS21 Visual inspection FIR E25 M

3.5 Ensure All Outdoor Panel Penetrations are bottom entry only TS21 Visual inspection M 3.6 Ensure panel is equipotential bonded to earth TS21 Visual inspection W 4.0 Panel works 4.1 Ensure panel is isolated, lock out as per isolation procedures TS21 Isolations Permit / Procedures Isolations Permit / Procedures R 4.2 Remove redundant cables and wiring TS21 Visual inspection As-builts/design drawings, cable

schedule

M 4.3 Install new circuitry components TS21 Visual inspection M 4.4 Cut entry hole in panel for new cable, bring in cables TS21 Visual inspection M 4.5 Complete new wiring in panel TS21 Visual inspection M 5.0 Final Inspection & Completion 5.1 Carry out final inspection


TS21

Design Drawing, TS21 FIR E25

H



PQM-TEM-003d Inspection and Test Plan Page 2 of 2 Revision: 0 Date: 16-Jun-2017 pqm-tem-003d - itp panels





6.0 Finalise Documentation 6.1 Progressively check all documentation is correct. TS21 TS21 FIR E25 H 6.2 MDR to be progressively compiled and submitted to client for

final approval. TS21 TS21 FIR E25 R

Reference Documentation: GRES Field Inspection Report (FIR) FIR E25 – Miscellaneous panels

GRES Specification TS21 Electrical Installation



PQM-TEM-003e Inspection and Test Plan Page 1 of 2 Revision: 0 Date: 16-Jun-2017 pqm-tem-003e - itp lv power

cables installation This document is UNCONTROLLED once printed

FORM: PQM-TEM-003e INSPECTION AND TEST PLAN CLIENT: <Insert Client Name> PROJECT: <Insert Project Name> JOB NUMBER: XXXXX ITP NO.: <Insert ITP No.> CONTRACT NO: XXXXXX SCOPE: LV Power Cables Installation REVISION 0 DATE: 16-Jun-2017 DESCRIPTION:




1.0 Submission/Approval of Documentation 1.1 Electrical Worker Qualifications Visual inspection of

documentation Western Australia EW licence R

2.0 Materials 2.1 Inspect materials for damage / defects, ensure correct

materials in accordance with Purchase Order, cable schedule, design drawings

TS21AS 3000 Visual inspection Cable schedule, design drawings, purchase orders, Delivery Dockets

S

3.0 Installation of Cables 3.1 Verify correct cable size, number of cores. All cables to

be pulled to correct location as per cable schedule. Ensure all cables are adequately mechanically protected utilizing installed cable ladder and conduit.

TS21, AS 3000 Cable Manufacturer Datasheet, TS21

Visual inspection & refer to Power Cable Schedule, Design Drawings

Power Cable Schedule, Design Drawings

R

3.2 If using a winch, refer to Manufacturers maximum pulling tensions in cable datasheet. Adhere to cable manufacturer’s specification for pulling and installed bending radii. Avoid kinking cable during installation.

Visual Inspection Cable Manufacturer Specification,

Cable Manufacturer Specification,

M

3.3 After pulling, cable ends shall be sealed with adhesive insulating tape or shrink caps.

TS21 TS21 M

3.4 Install cable Labels. Ensure correct labelling is as per cable schedule and Termination drawings. Orientation of labels shall be top to bottom.

TS21 Visual inspection & refer to Power Cable Schedule, Design Drawings


R

4.0 Termination of LV Cables 4.1 Ensure correct isolation in place (if required) TS212 Isolations Permit /

Procedures Isolations Permit / Procedures R

4.2 Correctly terminate cable into decontactor, ensure bottom entry

TS21, AS 3000, Design Drawings

TS21, AS 3000 TS21, Design Drawings M

4.3 Correctly terminate flex cable into decontactor handle and motor

TS21, AS 3000, Design Drawings

TS21, AS 3000 TS21, Design Drawings M



PQM-TEM-003e Inspection and Test Plan Page 2 of 2 Revision: 0 Date: 16-Jun-2017 pqm-tem-003e - itp lv power

cables installation This document is UNCONTROLLED once printed




4.4 Correctly gland off cables into MCC. Cut cores to length and lug off, pull tails out of module, tape up ends and leave in tier until commissioning

TS21, AS3000, Design Drawings

SS-E101, AS3000 TS21, Design Drawings M

4.5 Where terminating varolex cable, gland off cable into EMC gland, ensuring all earths are bonded

TS21, AS3000, Design Drawings

SS-E101, AS3000 TS21, Design Drawings M

5.0 Installation Completion & Testing 5.1 Point to point test of cable TS21, AS/NZS 3017 TS21 FIR E05 R 5.2 Earth continuity test TS21, AS/NZS 3017 TS21 FIR E05 R 5.3 Cable insulation resistance test TS21, AS/NZS 3017 TS21 FIR E05 R 5.4 Carry out final inspection


TS21, AS/NZS 3017, SS-E101 TS21 FIR E05 H

6.0 Finalise Documentation 6.1 Progressively check all test reports are correct. TS21, AS/NZS 3000

TS21 FIR E05 H

6.2 MDR to be progressively compiled and submitted to client for final approval.

TS21, AS/NZS 3000

TS21 FIR E05 R

Reference Documentation: GRES Field Inspection Report (FIR) GRES Specification AS/NZS FIR E05 –Extra Low Voltage & Low Voltage Power Cables TS21 Electrical Installation AS 3000 Electrical Installation (Known As The Australian/New Zealand Wiring Rules) Mechanical Works AS 3017 Electrical Installation - Verification guidelines



PQM-TEM-003g Inspection and Test Plan Page 1 of 1 Revision: 0 Date: 16-Jun-2017 pqm-tem-003g - itp lighting


FORM: PQM-TEM-003g INSPECTION AND TEST PLAN CLIENT: <Insert Clients Name> PROJECT: <Insert Project Name> JOB NUMBER: XXXXX ITP NO.: ITP No. CONTRACT NO: XXXXXX SCOPE: Lighting Installation REVISION 0 DATE: 16-Jun-2017 DESCRIPTION:




1.0 Materials 1.1 Inspect materials for damage / defects, ensure correct in

accordance with purchase order, design drawings TS21 Visual inspection Purchase order, Lighting plan R

2.0 Install light poles / bulkheads 2.1 Identify locations of poles. Ensure proposed location does not

interfere with other services TS21 Visual inspection TS21, Lighting plan W

2.2 Assemble poles. Mount brackets, posi-box, spigots and luminaires

TS21 Visual inspection TS21 M

2.3 For column-mount assemblies, drill holes in column. Mount base to column and position swivel point to ensure clearance when pole is dropped. Check verticality of pole

TS21 Visual inspection SS-E101 M

2.4 For handrail-mount assemblies, mount pole on handrail. Position swivel point to ensure clearance when pole is dropped


2.5 Mount bulkheads in positions indicated on lighting plan TS21 Visual inspection Lighting plan M 3.0 Final inspection and completion 3.1 Carry out final inspection

Generate punchlist Verification / clearance of punchlist

TS21 TS21 Punchlist H

4.0 Finalise documentation 4.2 MDR to be progressively compiled and submitted to client for

final approval TS21 Visual inspection MDR, Lighting plan R

Reference Documentation: GR Field Inspection Report (FIR) GRES Specification TS21 Electrical Installation



PQM-TEM-003i INSPECTION AND TEST PLAN Page 1 of 2 Revision: 0 Date: 16-Jun-2017 pqm-tem-003i - itp installation

of sump pump This document is UNCONTROLLED once printed

FORM: PQM-TEM-003i INSPECTION AND TEST PLAN CLIENT: <Insert Client Name> PROJECT: <Insert Project Name> JOB NUMBER: XXXXX ITP NO.: <Insert ITP No.> CONTRACT NO: XXXXXX SCOPE: Installation of Sump Pump REVISION 0 DATE: 16-Jun-2017 DESCRIPTION: Item No. Inspection Description Procedure and/or Relevant



1.0 Material Receipt 1.1 Check supply of vendor equipment for completeness Visual inspection Vendor drawing, supply list and

Delivery docket M

2.0 Installation of Pump 2.1 Install mesh screen in sump TS09 Design Drawings FIR M14

H

2.2 Verify foundations & bolt locations. Foundations shall be free from oil or foreign matter and the entire grouting surface scabbled.

Vendor IOM & drawings TS10

Design Drawings FIR M14

H

2.3 Install frame and check for level Anchor bolts snug tightened.

TS10 Vendor IOM

FIR M14

H

2.4 Install sump pump on frame and tighten bolts. Verify flange position/level.

Vendor IOM & drawing TS11

Vendor IOM & drawing

FIR M14

H/R

2.5 Install grating and handrail TS09 Design Drawings FIR M14 H/R 2.6 Check alignment of drive/couplings/pulleys

Free rotation checked (locking tabs removed) Vendor IOM & drawing TS11


FIR M02 FIR M01

H/R

2.7 Ensure no stress on discharge and suction from piping connection

TS10 Vendor IOM & drawing

FIR M14 FIR M48

W

2.8 Check and verify grouting is acceptable See grouting ITP

TS10 Visual Inspection Grouting ITP H

2.9 Final tensioning of anchor bolts after grouting. TS10 Vendor IOM & drawing

FIR M14

H

2.10 Direction test (bump) checked TS11 Vendor IOM & drawing

FIR E06 H

2.11 V-belt installed and alignment checked Vendor IOM TS11


FIRM02 FIR M14

H

2.12 Safety guard installed and checked Vendor IOM TS11


FIRM02 FIR M14

H


FORM: PQM-TEM-003i INSPECTION AND TEST PLAN CONT.


PQM-TEM-003i INSPECTION AND TEST PLAN Page 2 of 2 Revision: 0 Date: 16-Jun-2017 pqm-tem-003i - itp installation

of sump pump This document is UNCONTROLLED once printed




3.0 Final Inspection on Completion 3.1 Walkdown Scope of Works, TS11 Vendor IOM Punchlist W 3.2 Construction Verification – All inspections complete, all

rectification complete and verifying documents available and authorised


Visual inspection

FIR M02, FIR M14, FIR M48, Punchlist

H

3.3 All relevant documentation to be progressively compiled in to the MDR and submitted to client for final approval..

Contract Requirements MDR R

Reference Documentation: GR Field Inspection Report (FIR) GRES Specification FIR M02 Align Vee Belt Drive TS11 Mechanical Installations FIR M14 Pump Installation FIR M48 Centrifugal Pump No Load Running FIR E06 Motors Stage 1

TS10 Grouting TS09 Steel Erection



PQM-TEM-003j INSPECTION AND TEST PLAN Page 1 of 2 Revision: 0 Date: 16-Jun-2017 pqm-tem-003j - itp installation

of pump This document is UNCONTROLLED once printed

FORM: PQM-TEM-003j INSPECTION AND TEST PLAN CLIENT: <Insert Client Name> PROJECT: <Insert Project Name> JOB NUMBER: XXXXX ITP NO.: <Insert ITP No.> CONTRACT NO: XXXXXX SCOPE: Installation of Pump REVISION 0 DATE: 16-Jun-2017 DESCRIPTION:





Delivery docket M

2.0 Installation of Pump 2.1 Verify foundations & bolt locations. Foundations shall be

free from oil or foreign matter and the entire grouting surface scabbled.



H

2.2 Check that the levels and alignments are set out within tolerance. Foundation bolt, nut & washers to be set and surveyed prior to landing of pumps. Anchor bolts snug tighten.


Vendor IOM

FIR M14

H

2.3 Check and verify grouting is acceptable

TS10 Visual inspection Grouting ITP H

2.4 Final tensioning of anchor bolts after grouting prior to alignment

TS11 Vendor IOM & drawing

FIR M14

H

2.5 Check alignment of drive/couplings/pulleys Free rotation checked (locking tabs removed)



FIR M02 FIR M01

H/R

2.6 Verifying pump impeller setting/spacing in accordance with Vendor IOM

Vendor IOM


FIR M14 H


TS11 Visual inspection FIR M14 FIR M48

W

2.8 Direction test (bump) and rotation checked Vendor IOM TS11


FIR M01 H See Electrical ITP

2.9 Coupling Bolted, torqued and checked Vendor IOM TS11


FIR M01 H

2.10 V-belt, chain drive installed and checked Safety guard installed and checked

Vendor IOM TS11


FIRM02 FIR M14

H


FORM: PQM-TEM-003j INSPECTION AND TEST PLAN CONT.


PQM-TEM-003j INSPECTION AND TEST PLAN Page 2 of 2 Revision: 0 Date: 16-Jun-2017 pqm-tem-003j - itp installation

of pump This document is UNCONTROLLED once printed




3.0 Final Inspection on Completion 3.1 Walkdown Scope of Works, TS11 Vendor IOM Punchlist W 3.2 Construction Verification – All inspections complete, all


Vendor IOM & drawings

Visual inspection

FIR M01, FIR M02, FIR M14, FIR M15, FIR M48, Punchlist

H

3.3 All relevant documentation to be progressively compiled in to the MDR and submitted to client for final approval.

Contract requirements MDR R

Reference Documentation: GR Field Inspection Report (FIR) GRES Specification FIR M01 Align Mechanical Couplings FIR M14 Pump Installation TS11 Mechanical Installations FIR M02 Align Vee Belt Drive FIR M48 Centrifugal Pump No Load Running TS10 Grouting



PQM-TEM-003k INSPECTION AND TEST PLAN Page 1 of 2 Revision: 0 Date: 8 August 2016 pqm-tem-003k - itp installation

of pump without cast-in bolt This document is UNCONTROLLED once printed

FORM: PQM-TEM-003k INSPECTION AND TEST PLAN CLIENT: <Insert Client Name> PROJECT: <Insert Project Name> JOB NUMBER: XXXXX ITP NO.: <Insert ITP No.> CONTRACT NO: XXXXXX SCOPE: Installation of Pump without cast-in bolt REVISION 0 DATE: 16-Jun-2017 DESCRIPTION:





Delivery docket M

2.0 Installation of Pump 2.1 Foundations shall be free from oil or foreign matter and the

entire grouting surface scabbled. Vendor IOM & drawings TS10


H

2.2 Set temporary packs to design RL. Vendor IOM & drawings TS11

Vendor IOM TS11

FIR M14

H

2.3 Place pump in position Vendor IOM & drawings TS11

Vendor IOM TS11

M

2.4 Installation of suction & discharge pipework Installation of Steel Pipe/Poly Pipe ITP

H

2.5 Adjust pump position to suit suction and discharge spools. TS11 TS11 FIR M14

H


TS11 Vendor IOM & drawing TS11

FIR M14 FIR M48

W

2.7 Grout hold down bolts Vendor IOM & drawing TS11


FIR M56 Grouting ITP

H

2.8 Remove pump & temporary packers Vendor IOM TS11


FIR M56 M

2.9 Scabble pump skid grouting area TS10 FIR M14 M 2.10 Glue 50x50mm poly form strip underneath the pump base Vendor IOM

TS11 Vendor IOM & drawing TS11

H

2.11 Foundation bolt, nut & washers to be set and surveyed prior to landing of pumps.

Vendor IOM TS11


FIR M14 Survey report

H

2.12 Land pumps and snug tighten anchor bolts. Vendor IOM TS11


FIR M14

H

2.13 Grout pump base Vendor IOM TS11


FIR M56 Grouting ITP

H

2.14 Direction test (bump) and rotation checked. Vendor IOM TS11


FIR M01 Electrical ITP

H

2.15 Coupling Bolted, torqued and checked Vendor IOM TS11


FIR M01 H


FORM: PQM-TEM-003k INSPECTION AND TEST PLAN CONT.


PQM-TEM-003k INSPECTION AND TEST PLAN Page 2 of 2 Revision: 0 Date: 8 August 2016 pqm-tem-003k - itp installation

of pump without cast-in bolt This document is UNCONTROLLED once printed




2.16 V-belt, chain drive installed and checked Safety guard installed and checked

Vendor IOM TS11


FIRM02 FIR M14

H

3.0 Final Inspection on Completion 3.1 Walkdown Scope of Works, Vendor IOM Punchlist W 3.2 Construction Verification – All inspections complete, all



Visual inspection TS11

FIR M01, FIR M02, FIR M14, FIR M15, FIR M48, Punchlist

H

3.3 All relevant documentation to be progressively compiled in to the MDR and submitted to client for final approval..

MDR R

Reference Documentation: GR Field Inspection Report (FIR) GRES Specification FIR M01 Align Mechanical Couplings FIR M14 Pump Installation TS11 Mechanical Installations FIR M02 Align Vee Belt Drive FIR M56 Grouting

FIR M48 Centrifugal Pump No Load Running TS10 Grouting



PQM-TEM-003m INSPECTION AND TEST PlAN Page 1 of 2 Revision: 0 Date:16-Jun-2017 pqm-tem-003m - itp installation

of mechanical equipment This document is UNCONTROLLED once printed

FORM: PQM-TEM-003m INSPECTION AND TEST PLAN

CLIENT: <Insert Client Name> PROJECT: <Insert Project Name> JOB NUMBER: XXXXX ITP NO.: <Insert ITP No.> CONTRACT NO: XXXXXX SCOPE: Installation of Mechanical Equipment REVISION 0 DATE: 16-Jun-2017 DESCRIPTION:

Item No. Inspection Description Procedure and/or Relevant Standards Type of Check Acceptance Criteria Verifying Document

SURVEILLANCE Remarks GRES

Act Sign 1.0 Materials 1.1 Receive on site GRES Standard Procedure ENP002 Visual No Damage Bill of Materials 1.2 Compliance GRES Standard Procedure ENP002 Visual Identification Markings Purchase Order,

Supplier Data

2.0 Site Preparation 2.1 Survey for Correct Levels GRES Technical Specification TS11 Visual Drawing Visual Check 3.0 Installation Method 3.1 Source Manufacturer’s Installation Instructions GRES Technical Specification TS11 Visual As per specification Vendor - IOM 3.2 Qualification of work crew GRES Technical Specification TS11 Visual Trade certificates & licenses Qualifications 4.0 Installation of Equipment < 5 tonnes 4.1 Level steel packers GRES Technical Specification TS11 Visual Within 0.42 mm/metre FIR 4.2 Ensure correct elevation and alignment GRES Technical Specification TS11 Visual Drawings FIR 4.3 Grouting GRES Technical Specification TS10 Visual As per specification FIR 5.0 Installation of Equipment > 5 tonnes 5.1 Prepare concrete base GRES Technical Specification TS11 Visual As per specification FIR 5.2 Position Plates GRES Technical Specification TS11 Visual As per specification FIR 5.3 Ensure correct elevation and alignment GRES Technical Specification TS11 Visual As per specification FIR 5.4 Level GRES Technical Specification TS11 Visual Within 0.42 mm/metre FIR 5.5 Grouting GRES Technical Specification TS10 Visual As per specification FIR 6.0 Bolts 6.1 High strength Friction Grip Bolts GRES Technical Specification TS11 Visual AS 1511 FIR 7.0 Handover Handover to Client Contract document As per specification MDR Reference Documentation: GR Field Inspection Report (FIR) GRES Specification FIR M11 Packaged Equipment Precommissioning TS11 Mechanical Installation


FORM: QA001 INSPECTION AND TEST PLAN CONT.


Reference: 12204 1301267:P:gt Revision 0 Page 2 of 2 Last update: 2/10/19

FIR M56 Grouting TS10 Grouting



PQM-TEMP-003n INSPECTION AND TEST PLAN Page 1 of 1 Revision: 0 Date: 16-Jun-2017 pqm-tem-003n - itp installation

of instrumentation This document is UNCONTROLLED once printed

FORM: PQM-TEMP-003n INSPECTION AND TEST PLAN CLIENT: <Insert Client Name> PROJECT: <Insert Project Name> JOB NUMBER: XXXXX ITP NO.: <Insert ITP No.> CONTRACT NO: XXXXXX SCOPE: Installation of Instrumentation REVISION 0 DATE: 16-Jun-2017 DESCRIPTION:





Delivery docket M

2.0 Installation of Instrument 2.1 Verify instrumentation installed as per Manufacturers

recommendations TS11 Approved Drawings

Vendor IOM ITP – Installation of Instrumentation H

3.0 Final Inspection on Completion 3.1 Walkdown (Part of System Walkdown) Part of System Punchlist 3.2 Construction Verification – All inspections complete, all



TS11 Punchlist H


MDR R

Reference Documentation: GRES Field Inspection Report (FIR) GRES Specification TS11 Mechanical Installation



PQM-TEMP-003p INSPECTION AND TEST PLAN Page 1 of 2 Revision: 0 Date: 16-Jun-2017 pqm-tem-003p - itp installation

of air receiver This document is UNCONTROLLED once printed

FORM: PQM-TEMP-003p INSPECTION AND TEST PLAN

CLIENT: <Insert Client Name> PROJECT: <Insert Project Name> JOB NUMBER: XXXXX ITP NO.: <Insert ITP No.> CONTRACT NO: XXXXXX SCOPE: Installation of Air Receiver REVISION 0 DATE: 16-Jun-2017 DESCRIPTION:




1.0 Submission/Approval of Documentation 1.1 Check supply of vendor equipment for completeness

including MDR, IOM’s, Arrangement Drawings, Piping & Instrumentation Diagrams.

TS11 Visual inspection Vendor drawing, supply list and Delivery docket IOM, Approved Drawings

H

1.2 Check registration and conformance certification TS11 Visual inspection Certification IOM, Approved Drawings

H

2.0 Materials 2.1 Confirm availability of all main unit assemblies and

associated ancillaries TS11 Approved Drawings

Vendor IOM FIR M11 H

2.2 Check for any damage that may have occurred during transportation and report any manufacturing defects via NCR form.

TS11 Approved Drawings Vendor IOM

FIR M11 H

3.0 Installation 3.1 Verify location, survey and set packers TS11 TS11

Approved drawings FIR M11 Survey report

H

3.2 Verify equipment installed as per Manufacturers recommendations

TS11 TS11 Vendor IOM & drawings

FIR M11 H

3.3 Verify ancillary pressure relief, auto drains and gauges installed as required

TS11 TS11 Vendor IOM & drawings

FIR M11 H

3.4 Ensure hold down bolts are snug tightened TS11 TS11 FIR M11 H 3.5 Grouting (refer Grouting ITP) TS10 TS10 FIR M56 H Refer Grouting ITP 3.6 Final tension of hold down bolts TS11 TS11 FIR M11 H 4.0 Final Inspection on Completion 4.1 Walkdown TS11 TS11 Punchlist W 4.2 Construction Verification – All inspections complete, all



TS11 FIR M11, Punchlist H


MDR R


FORM: PQM-TEMP-003p INSPECTION AND TEST PLAN CONT.


PQM-TEMP-003p INSPECTION AND TEST PLAN Page 2 of 2 Revision: 0 Date: 16-Jun-2017 pqm-tem-003p - itp installation

of air receiver This document is UNCONTROLLED once printed

Reference Documentation: GR Field Inspection Report (FIR) GRES Specification FIR M11 Packaged Equipment Precommissioning

TS11 Mechanical Installation

FIR M56 Grouting TS10 Grouting



PQM-TEM-003q INSPECTION AND TEST PLAN Page 1 of 2 Revision: 0 Date: 16-Jun-2017 pqm-tem-003q - itp hv cable


FORM: PQM-TEM-003q INSPECTION AND TEST PLAN CLIENT: <Insert Client Name> PROJECT: <Insert Project Name> JOB NUMBER: XXXXX ITP NO.: <Insert ITP No.> CONTRACT NO: XXXXXX SCOPE: HV Cable Installation REVISION 0 DATE: 16-Jun-2017 DESCRIPTION:




1.0 Submission of Documentation 1.1 HV Cable jointer qualifications Visual inspection of documentation HV cable jointer qualification R 2.0 Materials 2.1 Inspect HV cable for damage / defects, ensure correct cable

in accordance with cable schedule, design drawings TS21 Visual inspection Cable schedule, design

drawings S

3.0 Installation of Cable 3.1 Pull cable from substation to motors. Adhere to cable

manufacturer’s specification for pulling and installed bending radii. Avoid kinking cable during installation

TS21, AS 3000 Visual inspection Cable manufacturer recommendations

M

3.2 If using a winch, refer to Manufacturers maximum pulling tensions in cable datasheet

TS21 Visual inspection Cable manufacturer recommendations

M

3.3 After pulling, cut cable to length. Cable ends to be sealed with shrink caps. Ensure cable ends are left in safe location where likelihood of damage is minimal


4.0 Cable Glanding 4.1 Ensure correct isolation in place. Obtain any HV vicinity

permits that may be required for working on HV switchgear. Identify vents / arc flash chute / any other potentially hazardous areas. Establish exclusion zone where required

TS21 Isolations, Permit / Procedures Isolations, Permit / Procedures R

4.2 Penetrate switchgear and motor glandplates. Work on top of switchgear is to be done from ladders or scaffold only


4.3 Point to point test cables TS21 TS21 FIR E09 R 4.4 Measure off cable and strip insulation back. Cut steel wire

armouring using hacksaw, gland off cable into Steel Wire Armoured gland


4.5 Ensure appropriate tails length left in switchgear and motor terminal housing, seal ends with heatshrink cap


5.0 Terminations 5.1 Ensure correct isolation is in place TS21 Isolations, Permit / Procedures Isolations, Permit / Procedures R 5.2 HV cable jointer terminates cables TS21 Visual inspection FIR E09 M



PQM-TEM-003q INSPECTION AND TEST PLAN Page 2 of 2 Revision: 0 Date: 16-Jun-2017 pqm-tem-003q - itp hv cable


FORM: PQM-TEM-003q INSPECTION AND TEST PLAN CONT.

6.0 Testing 6.1 Ensure correct isolation in place TS21 Isolations, Permit / Procedures Isolations, Permit / Procedures R 6.2 Point to point test cables TS21 TS21 FIR E09 R 6.3 Insulation resistance test as per FIR E09 – electrician

stationed at both ends during IR testing TS21 TS21 FIR E09 R

6.4 Carry out other cable tests as per FIR E09 TS21, AS 1931 TS21 FIR E09 R 6.5 Torque lugged connections to manufacturer specifications TS21 TS21 FIR E09 M 6.6 Ductor test as per FIR E04 TS21 TS21 FIR E04 M 6.7 Carry out final inspection


TS21, AS/NZS 3000, SS-E101 TS21 FIR E09 FIR E04

H

7.0 Finalise documentation 7.1 Progressively check all test reports are correct TS21, AS/NZS 3000

TS21 FIR E09

FIR E04 H

7.2 MDR to be progressively compiled and submitted to client for final approval

TS21, AS/NZS 3000

TS21 FIR E09 FIR E04

R

Reference Documentation: GR Field Inspection Report (FIR) GRES Specification AS/NZS FIR E04 – Ductor Test FIR E09 – High Voltage Feeder Cables Test

TS21 Electrical Installations

AS 3000 Electrical Installation Mechanical Works (Wiring Rules) AS 1931 High Voltage Testing Techniques



PQM-TEM-003s INSPECTION AND TEST PLAN Page 1 of 2 Revision: 0 Date: 16-Jun-2017 pqm-tem-003s - itp installation

of optical fibre equipment This document is UNCONTROLLED once printed

FORM: PQM-TEM-003s INSPECTION AND TEST PLAN CLIENT: PROJECT: JOB NUMBER: ITP NO.: CONTRACT NO: SCOPE: Installation of Optical Fibre Equipment REVISION 0 DATE: DESCRIPTION:




1.0 Materials 1.1 Inspect materials for damage / defects, ensure correct in

accordance with Purchase Order, design drawings TS21 Visual inspection Cable schedule, Purchase Order M

2.0 Installation of fibre cable 2.1 Pull fibre from sub to remote IO panels. Manufacturer

recommendations concerning minimum bend radius to be adhered to

TS21 Visual inspection, manufacturer recommendations

Manufacturer recommendation M

2.2 Coil up extra length and leave in a secure location where likelihood of damage is minimised until cable is brought in to cabinets. Allow a minimum of 10m spare cable from point of entry in cabinet


2.3 Penetrate cabinets and gland off fibre into nylon gland, coil up spare fibre loosely in cabinet


3.0 Installation of hardware 3.1 Install FOBOTs / ethernet switches in comms cabinet. Special

care to be taken to ensure no disturbance to existing equipment

TS21 Visual inspection Design drawings M

4.0 Termination and Test 4.1 Termination and testing work to be completed by qualified

fibre terminator. Equipment used to be certified as calibrated TS21 Inspection of accreditations,

calibration certificate Accreditations, calibration certificate

R

4.2 Terminate fibre and test TS21 TS21 FIR E16 (including Termination Inspection Checklist)

R

4.3 Ensure all cables and components are correctly labelled TS21 Visual inspection FIR E16 M 4.4 Carry out final inspection


TS21 TS21 FIR E16 H

5.0 Finalise documentation 5.1 Progressively check all test reports are correct TS21 TS21 FIR E16 H 5.2 MDR to be progressively compiled and submitted to client for

final approval TS21 TS21 FIR E16 R



PQM-TEM-003s INSPECTION AND TEST PLAN Page 2 of 2 Revision: 0 Date: 16-Jun-2017 pqm-tem-003s - itp installation

of optical fibre equipment This document is UNCONTROLLED once printed

FORM: PQM-TEM-003s INSPECTION AND TEST PLAN CONT. Reference Documentation: GR Field Inspection Report (FIR) FIR E16 – Communication Cables

GRES Specification TS21 – Electrical Installations



PQM-TEM-003t INSPECTION AND TEST PLAN Page 1 of 2 Revision: 0 Date: 16-Jun-2017 pqm-tem-003t - itp extra low

voltage cable installation This document is UNCONTROLLED once printed

FORM: PQM-TEM-003t INSPECTION AND TEST PLAN

CLIENT: <Insert Client Name> PROJECT: <Insert Project Name> JOB NUMBER: XXXXX ITP NO.: <Insert ITP No.> CONTRACT NO: XXXXXX SCOPE: Extra Low Voltage Cable Installation REVISION 0 DATE: 16-Jun-2017 DESCRIPTION:




1.0 Submission/Approval of Documentation 1.1 Electrical Worker Qualifications Visual inspection of

documentation Western Australia EW licence R

2.0 Materials 2.1 Inspect materials for damage / defects, ensure correct

materials in accordance with Purchase Order, cable schedule, design drawings

SS-E159, AS 3000 Visual inspection Cable schedule, design drawings, purchase orders, Delivery Dockets

S

3.0 Installation of Equipment 3.1 Verify correct cable size, number of cores. All cables to

be pulled to correct location as per cable schedule. Ensure all cables are adequately mechanically protected utilizing installed cable ladder and conduit.

Iron Ore Electrical SWP (RTIO-HSE-0049669), TS21, AS 3000 Cable Manufacturer Datasheet, TS21

Visual inspection & refer to Power Cable Schedule, Design Drawings


R

3.2 If using a winch, refer to Manufacturers maximum pulling tensions in cable datasheet. Adhere to cable manufacturer’s specification for pulling and installed bending radii. Avoid kinking cable during installation.

Visual Inspection Cable Manufacturer Specification,

Cable Manufacturer Specification,

M

3.3 After pulling, cable ends shall be sealed with adhesive insulating tape or shrink caps.

TS21 TS21 M

3.4 Install cable Labels. Ensure correct labelling is as per cable schedule and Termination drawings. Orientation of labels shall be top to bottom.

TS21 Visual inspection & refer to Power Cable Schedule, Design Drawings


R

4.0 Termination of Instrumentation Cables 4.1 Ensure correct isolation in place (if required), TS21, Iron Ore (WA) Isolation

Regulations v3.2 Isolations Permit / Procedures

Isolations Permit / Procedures R

4.2 Correct termination of cables TS21, AS3000, Design Drawings

TS21, AS3000 M


FORM: PQM-TEM-003t INSPECTION AND TEST PLAN CONT.


PQM-TEM-003t INSPECTION AND TEST PLAN Page 2 of 2 Revision: 0 Date: 16-Jun-2017 pqm-tem-003t - itp extra low

voltage cable installation This document is UNCONTROLLED once printed




5.0 Installation Completion & Testing 5.1 Point to point test of cable TS21, AS/NZS 3017 TS21

FIR E05 R

5.2 Carry out final inspection Generate punch list Verification/clearance of punch list

TS21, AS/NZS 3000 TS21 FIR E05 H

6.0 Finalise Documentation 6.1 Progressively check all test reports are correct. TS21, AS/NZS 3000 TS21 FIR E05 H 6.2 MDR to be progressively compiled and submitted to

client for final approval. TS21, AS/NZS 3000 TS21 FIR E05 R

Reference Documentation: GR Field Inspection Report (FIR) GRES Specification AS/NZS FIR E05 –Extra Low Voltage & Low Voltage Power Cables TS21 Electrical Equipment Installation AS 3000 Electrical Installation (Known As The Australian/New Zealand Wiring Rules) Mechanical Works



PQM-TEM-003u INSPECTION AND TEST PLAN Page 1 of 2 Revision: 0 Date: 16-Jun-2017 pqm-tem-003u - itp conveyor

idler installation This document is UNCONTROLLED once printed

FORM: PQM-TEM-003u INSPECTION AND TEST PLAN CLIENT: <Insert Client Name> PROJECT: <Insert Project Name> JOB NUMBER: XXXXX ITP NO.: <Insert ITP No.> CONTRACT NO: XXXXXX SCOPE: Conveyor Idler Installation REVISION 0 DATE: 16-Jun-2017 DESCRIPTION:




1.0 Submission/Approval of Documentation 1.1 Confirm availability/receipt of supplier MDR’s, IOM’s, Bill of

Materials, Arrangement Drawings SS-D001 Approved Documents. R

2.0 Materials 2.1 Confirm availability of all Conveyor Idler components,

fasteners and sundry items. Vendor Packing Slips and Order

detail. Order documents, packing slips and assembly drawings

S

2.2 Check for any damage that may have occurred during transit and handling

Visual Inspection by trades and Supervisor

Field Inspection Report M10 & Photo record as req’d

W

2.3 Check to ensure materials of construction are correct and in accordance with relevant RTIO Standard and Drawings

Vendor Drawings, Supplier MDR’s and IOM.

Field Inspection Report M10 W

3.0 Installation of Idler Frames 3.1 Mark out and drill all frame bolt hole centres TS11 Approved Design Drawings,

Vendor Drawings Field Inspection report M10 H

3.2 Plug weld holes AS 4041 Visual Inspection by Supervisor Site Welding ITP H 3.3 Touch Up paint affected areas Visual Inspection by Supervisor Site Touch Up ITP S 3.4 Place Idler Frames and secure (snug tight) with fasteners

supplied TS11 Visual Inspection by

Supervisor/Design & Vendor Drawings

Field Inspection report M10 S

3.5 Check all rotating parts for free movement TS11 Visual Inspection by Supervisor/Design & Vendor Drawings

Field Inspection report M65 M

4.0 Adjustment and alignment of Idlers 4.1 Check and Align all frames within specified tolerance TS11 Visual Inspection by

Supervisor/Design & Vendor Drawings

Field Inspection report M10 W

4.2 Secure & check all bolts for tightness TS11 Visual Inspection by Supervisor/Design & Vendor Drawings

Field Inspection report M65 S

4.3 Confirm all Guarding installed TS11 Visual Inspection by Supervisor/Design & Vendor Drawings

Field Inspection report M65 H



PQM-TEM-003u INSPECTION AND TEST PLAN Page 2 of 2 Revision: 0 Date: 16-Jun-2017 pqm-tem-003u - itp conveyor

idler installation This document is UNCONTROLLED once printed




5.0 Test run 5.1 Confirm Belt is free of all foreign debris. Visual Field Inspection report M10 H 5.2 Carry Out Test Run on Conveyor/Check tracking TS11 Visual Inspection Field Inspection FIR M65 &

Supervisor check. S

6.0 Final Inspection & Completion 6.1 Walk Down TS11 Approved Drawings. Field Inspection

Field Inspection report M10, Punch List

H

6.2 Construction Verification- All inspections complete, all rectification complete and verifying documents available and authorised.

TS11 Visual Inspection. Field Inspection report M10 H

6.3 All relevant documentation to be progressively compiled in to the MDR and submitted to client for final approval

Reviewed and Approved Reports

R

Reference Documentation: GR Field Inspection Report (FIR) GRES Specification FIR –M10 Mechanical Pre-commissioning TS11 Mechanical Installation FIR –M65 Conveyor No Load running Inspection



PQM-TEM-003v INSPECTION AND TEST PLAN Page 1 of 2 Revision: 0 Date: 16-Jun-2017 pqm-tem-003v - itp cable

ladder and conduit installation This document is UNCONTROLLED once printed

FORM: PQM-TEM-003v INSPECTION AND TEST PLAN CLIENT: <Insert Client Name> PROJECT: <Insert Project Name> JOB NUMBER: XXXXX ITP NO.: <Insert ITP No.> CONTRACT NO: XXXXXX SCOPE: Cable Ladder and Conduit Installation REVISION 0 DATE: 16-Jun-2017 DESCRIPTION: Item No. Inspection Description Procedure and/or Relevant



1.0 Materials 1.1 Inspect materials for damage/defects, ensure cable ladder

and conduit is correct size, material (galv steel or stainless) TS21 Visual inspection Purchase order, design drawings R

2.0 Installation of cable ladder / conduits 2.1 Install brackets, ensuring no more than 6m span between

supports, or according to cable ladder loading calculations TS21, Cable Manufacturer Specification, Cable Ladder Weight Calculations, if applicable

Visual inspection Cable Manufacturer Specification, Cable Ladder Weight Calculations, if applicable

W

2.2 Where stainless steel cable ladder is installed, ensure rubber pad used to prevent galvanic action between dis-similar materials

TS21 Visual inspection TS21 W

2.3 Ladder to be electrically continuous via earth strap over splice plates

TS21, AS 3000 Visual inspection TS21 W

2.4 120mm2 earth to be installed in ladder tier with 120mm2 earth tap bonded to the ladder at 18m intervals


2.5 Suncover installed on ladder where necessary, peak cover on horizontal runs and flat cover on verticals. Suncover generally installed when all cables have been run

TS21, AS 3000 Visual inspection TS21 W

2.6 Install barrier strip where required. Barrier strip generally installed when all cables have been run


2.7 Conduit supports shall be provided at spacings not exceeding 1.5m, and shall be of approved Unistrut clamp or Caddy type

TS21 TQ 56

Visual inspection TS21 W

2.8 Install conduit, ensuring a neat and workman-like finish. Ensure conduit is continuous with no start-stop sections


3.0 Final inspection and completion 3.1 Walkdown


TS21 Visual inspection Punchlist H

4.0 Finalise documentation 4.1 MDR to be progressively compiled and submitted for final

approval TS21, AS 3000 Visual inspection MDR R

Reference Documentation: GRES Specification AS/NZS



PQM-TEM-003v INSPECTION AND TEST PLAN Page 2 of 2 Revision: 0 Date: 16-Jun-2017 pqm-tem-003v - itp cable

ladder and conduit installation This document is UNCONTROLLED once printed

TS21 Electrical Installation AS 3000 Electrical Installation (known as the Australian/New Zealand Wiring Rules) Mechanical Works