SCOPE OF WORK Document Number: XXXX DN100 Powerstation Fuel Feed Line Upgrade Project Page 1 of 34 Revision: 0 Date: 31 October 2016 SCOPE OF WORK DN100 POWERSTATION FUEL FEED LINE UPGRADE PROJECT SERVICES (INCLUDING SPECIFICATIONS) 1. INTRODUCTION 1.1 Purpose This Scope of Work details the Company’s requirements and standards for the Works to be performed by the Contractor under the Contract. 1.2 Background The Lorim Point Fuel Farm transfers diesel fuel from tanks 11 and 12 to the day tanks at Humbug Powerstation via a DN100 carbon steel pipeline. A section of the DN100 pipeline is currently installed underground. Figure 1 below illustrates the DN100 diesel line pipe route from the Fuel Farm to the Humburg Powerstation Day Tanks. Figure 1: DN100 Diesel Fuel Line route The Company wishes to replace and re-route a section of the DN100 Diesel Fuel Line aboveground wherever possible and through culverts wherever required to run below ground, e.g. at road crossings. Figure 2 below illustrates a section of approximately 300m of the DN100 diesel line pipe route which is to be re-routed.
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SCOPE OF WORK Document Number: XXXX
DN100 Powerstation Fuel Feed Line Upgrade Project Page 1 of 34
Revision: 0 Date: 31 October 2016
SCOPE OF WORK
DN100 POWERSTATION FUEL FEED LINE UPGRADE
PROJECT
SERVICES
(INCLUDING SPECIFICATIONS)
1. INTRODUCTION
1.1 Purpose
This Scope of Work details the Company’s requirements and standards for the Works to be
performed by the Contractor under the Contract.
1.2 Background
The Lorim Point Fuel Farm transfers diesel fuel from tanks 11 and 12 to the day tanks at Humbug
Powerstation via a DN100 carbon steel pipeline. A section of the DN100 pipeline is currently
installed underground.
Figure 1 below illustrates the DN100 diesel line pipe route from the Fuel Farm to the Humburg
Powerstation Day Tanks.
Figure 1: DN100 Diesel Fuel Line route
The Company wishes to replace and re-route a section of the DN100 Diesel Fuel Line
aboveground wherever possible and through culverts wherever required to run below ground,
e.g. at road crossings.
Figure 2 below illustrates a section of approximately 300m of the DN100 diesel line pipe route
which is to be re-routed.
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Figure 2: Illustration of DN100 fuel line to be re-routed.
1.3 Applicable Documents and Standards
The Contractor must ensure that the Services and any Associated Goods, equipment, and
vehicles, must as a minimum, comply with all Company Specifications, Standards and Contract
Drawing documents as set out in Table A1 of this Scope of Work document.
Table A1 - Company Specifications, Standards and Contract Drawings
Document Number Revision Title
CSTL-0150-15 Rio Tinto ASME Pressure Piping Specification
CSSW 449 1 Standard Specification for Piping Materials and
Valves
CSSW-C385 0 Standard Specification for Preparation and Coating
of Steel Surfaces
521 20001 A Diesel Line Upgrade
Road Culvert Crossings
Northern Culvert
521 20002 A Diesel Line Upgrade
Road Culvert Crossings
Southern Culvert
521 20003 A Diesel Line Upgrade
Road Regrading Details
521 30004 A Diesel Line Upgrade
Access Platform Modifications
Sheet 1
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521 80012 A Diesel Line Upgrade
General Arrangement
521 80013 A Diesel Line Upgrade
Arrangement
Sheet 1
521 80014 A Diesel Line Upgrade
Arrangement
Sheet 2
521 80015 A Diesel Line Upgrade
Arrangement
Sheet 3
521 80016 A Diesel Line Upgrade
Arrangement
Sheet 4
521 80017 A Diesel Line Upgrade
Arrangement
Sheet 5
521 80018 A Diesel Line Upgrade
Arrangement
Sheet 6
521 80019 A Diesel Line Upgrade
Pipe Support Details
Sheet 1
521 80020 A Diesel Line Upgrade
Pipe Support Details
Sheet 2
521 80021 A Diesel Line Upgrade
Pipe Details
Sheet 1
Prior to commencing the Services, the Contractor must:
(a) obtain a copy of all relevant Company policies and standards from the Company
Representative (if it does not already hold a copy); and
(b) ensure it and its Personnel have read and understood the contents of all documents.
(c) The Contractor acknowledges and agrees that the Company, as originator of any
Documentation contained in Table A1, reserves the right to alter, amend or discard any
of these documents or create new documents.
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(d) The Contractor acknowledges that, when the Company changes any of the applicable
documentation contained in Table A1 as per Paragraph 1.3(c) above, a copy of the
most recent document will be made available to the Contractor, which will then take
precedence.
1.4 Australian and International Standards
The Contractor must ensure that the Services meet any applicable laws or Government Agency
requirements (both State and Federal), including but not limited to relevant standards published
by the Standards Australia, and the American Society of Mechanical Engineers Standards
(ASME Standards) or, if there are no such standards, then relevant International Standards.
Australian and International standards relevant to this project include, but are not limited to, those
set out in Table A1 of this Scope of Work document.
Table A2 – Australian and International Standards
Document Number Year Title
AS4041 2006 Pressure Piping
AS4037 1999 Pressure equipment – Examination and testing
AS1345 1995 Identification of the contents of pipes, conduits and
ducts
ASTM A105 Standard Specification for Carbon Steel Forgings for
Piping Applications
ASTM A106 Standard Specification for Seamless Carbon Steel
Pipe for High-Temperature Service
1.5 Precedence of Documents in Scope of Services
This Scope of Work document may contain references to various documents and in the event of
any inconsistency between this Scope of Work document and a document referenced within this
document, unless otherwise provided, the documents will rank in order of precedence in the order
in which they are listed below:
(a) this Scope of Work document;
(b) the Company’s Specifications, Standards and Contract Drawings, as listed in Table A1;
(c) relevant Australian and International Standards, as listed in Table A2; and
(d) any other documents listed in this Scope of Work document.
1.6 Acknowledgement of Process Materials
The Contractor acknowledges that there is a fully operational bauxite processing plant at the Site
and any equipment (including motor vehicles) brought onto the Site by the Contractor or its
Personnel may be exposed to process materials and agrees to bear the risk in this regard. The
Contractor acknowledges that the Company will not be liable for any damage to or loss of such
equipment caused by exposure to or contact with process materials.
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2. GENERAL REQUIREMENTS
2.1 General
In completing the Services, the Contractor must:
(a) provide a single point of contact (project manager) who will be fully responsible for the
execution of the Services and all Site safety;
(b) complete a detailed constructability review and risk assessment for the project;
(c) ensure that the works that it performs meet the requirements as set out in drawings,
specifications, and standards identified in the Contract;
(d) provide all Personnel required to successfully complete the Services, including Site
trained and qualified permit recipients;
(e) ensure that all its Personnel comply with all Company policies and standards, including,
but not limited to:
(i) holding current Site-specific medical certification;
(ii) successfully complete all Site and area inductions;
(iii) have and maintain any relevant Site Competent to Operate (CTO) to operate
machinery and equipment;
(iv) have and maintain statutory licences, such as electrical, demolition or plumbing
licences; and
(v) Job Hazard Analysis (JHA) preparation.
(f) ensure that all Personnel wear appropriate safety equipment at all times;
(g) supply all tools and equipment required to complete the Services, including, but not
limited to:
(i) scaffolding;
(ii) mobile equipment;
(iii) pipe draining, pipe cleaning (pigging) and hydrotesting equipment;
(iv) cranes; and,
(v) temporary power supplies, including extension leads.
(h) ensure that all fixed and mobile plant, tools or equipment are approved for use on Site;
(i) prepare and submit for approval by the Company Representative, inspection and test
plans (ITPs);
(j) provide qualified work procedures for the Services;
(k) complete visual inspections with the Company Representative or appointed delegate
prior to sign off;
(l) provide a complete manufacturer’s data report (MDR);
(m) compile a daily shift log and site diary of work, progress and delays to be countersigned
by the Company’s Project Representative on a daily basis;
(n) within 2 weeks of completion of hydrotesting, provide all red-lined marked-up drawings
in hard copy and electronic formats; and,
(o) maintain a clean work area and complete a final clean-up of the area to the satisfaction
of the Company.
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2.2 Procurement
The Contractor must complete all procurement activities required to successfully complete the
Services to the stated quality and schedule objectives.
2.3 Transportation to Site
The Contractor is responsible for loading, transport, delivery and offloading of all equipment and
materials to Site. A laydown area will be provided by the Company.
2.4 Access
The Contractor is responsible for the provision of all access services required to complete the
Services. If scaffolding is required as an access method:
(a) scaffolding locations must be approved by the Company Representative; and
(b) scaffolding must be in accordance with the Company’s standard.
2.5 Workshop Inspection
(a) The Company reserves the right to conduct workshop inspections of the Services at the
Contractor’s premises as and when required.
(b) Inspections will be of a general nature only to monitor progress and performance and
the Contractor acknowledges and agrees that no fabrication errors will be deemed as
accepted by the Company as a result of these inspections.
2.6 Civil Works
The Contractor must complete all procurement and installation of all culverts, pipe support
footings and other civil materials and equipment required for this scope of Services in accordance
with Company standards.
2.7 Electrical Works
The Contractor must complete all modifications to existing electrical equipment as required for
this scope of Services in accordance with Company standards.
2.8 Structural Works
The Contractor must complete all procurement, fabrication, blasting and painting and installation
of all new piping structural supports, and modification to existing steelwork structures where
required, for this scope of Services in accordance with Company standards.
2.9 Piping Works
The Contractor must complete all procurement, fabrication, blasting and painting, installation and
hydrotesting of all piping materials. The following must be completed by the Contractor:
(a) transport to Site and prepare all materials;
(b) install pipe sections between nominated tie-in points, including structural and pipe
supports as per Section 5;
(c) obtain isolations as required;
(d) complete installation at tie-in points during planned shutdown, including drainage of
existing pipeline and local removal and disposal in the Company’s scrap metal bins of
minor sections of redundant pipe and pipe supports, plus any make-safe activities for
the redundant pipe remaining underground;
(e) complete all non-destructive testing (NDT), post weld heat treatment (PWHT) and stress
relieving activities in accordance with the Company’s standards and specifications;
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(f) successfully complete hydrotesting;
(g) return isolation;
(h) complete ‘As-Built’ survey of final pipe route and provide the Company with survey files
in .dwg electronic format;
(i) complete red-line marked-up drawings in .pdf format; and,
(j) clean-up and general housekeeping to Company’s satisfaction.
2.10 Hydrotesting
The Contractor must provide hydrotesting at the site.
The hydrotesting must include a detailed inspection by the Contractor of the equipment to assess
its condition and ability to operate to the desired efficiency.
The Contractor must provide the appropriate consumables and spares required for hydrotesting.
The Contractor must advise the Company of the services, facilities and Company Personnel
required to perform the hydrotesting.
Upon successfully completing the hydrotesting the Contractor shall include the hydrotest report
as part of the MDR submission.
2.11 Other Work Groups
The Contractor acknowledges that there may be other work groups in the work area at the time
of the Services. The Contractor must take care not to impinge upon their works and clearly
demarcate their worksite.
2.12 Isolations
The Contractor must provide a minimum of 48 hours’ notice to the Company Representative
ahead of any required isolation. The isolation request must include:
(a) the equipment required to be isolated;
(b) date and time required to be isolated; and
(c) duration of the isolation.
2.13 Underground services
The Contractor acknowledges that some underground services may not be identified on
Company As-Built drawings. The Contractor shall be responsible to obtain site dig permits, shall
use ‘Hydrovac’ trucks to expose all buried services and shall complete all excavation works in
accordance with Company standards and procedures.
The Contractor shall stop work immediately and contact the Company Project Representative if
any underground services are struck.
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3. QUALITY
3.1 General
The Contractor must have a Quality Management System which has been certified by a
certification body acceptable to the Company. The certification must include design and
development activities if these activities are required under the Contract.
If requested to do, so the Contractor must supply to the Company a quality plan which must:
(a) document how the requirements of the Contract will be met and what documents will be
used to assure compliance, including Sub-contractors’ and suppliers’ work;
(b) identify and trace the components of the Contract in accordance with Contract
requirements;
(c) provide separate inspection and test plans (Inspection and Test Plans) for each
requirement for each separable component of the Contract, with hold or witness points
for inspection, testing and verification as required under the Contract;
(d) identify any non-conforming components. The Contractor must advise the Company of
any non-conforming component and submit for approval, a proposal on addressing the
non-conformance by either:
(i) waiver;
(ii) rework;
(iii) repair; or
(iv) replacement; and
(v) record the approved disposition of the non-conformance; and,
(e) upon completion of inspections and tests, be updated with documents as necessary to
verify that the components conform to the Contract requirements.
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4. WELDING SCOPE
4.1 Welding Standards
On Site welding will be required as part of the Services and the welding must be completed in
accordance with this Scope of Work document, technical specifications, Company standards and
the latest versions of the Australian and International Standards relevant to this project.
4.2 Welding Package
The Contractor must prepare and submit a welding package to the Company project
representative prior to the start of welding. The package must include:
(a) Project drawings;
(b) ITPs;
(c) welding procedure specifications (WPS) and procedure qualifications records (PQRs);
(d) welder qualification register and records of applicable welders; and,
(e) nominated welding supervisor’s certification.
The ITP must identify the above items as steps of review by the Company Project
Representative. The Company Project Representative will then sign the applicable items as
reviewed and may add additional requirements and inspection hold points for ITP revision.
The Contractor must provide and nominate a person to carry out the role of welding supervisor.
This person must visit the job site on a 1-2 week basis and will be accountable to the Company
for the Contractor’s in-process welding inspection and welding quality assurance.
The Contractor’s welding supervisor must hold and maintain:
(a) WTIA AS1796 Certified Welding Supervisor or equivalent; for all Pressure Piping
activities; and
(b) WTIA AS2214 Welding Supervisor for Structural welding activities.
4.3 Welding NDT
All welding must be 100% visually inspected by a welding supervisor or certified welding
inspector representing the Contractor. The welding supervisor must sign the ITP at all necessary
points. All welding NDT must be completed by a National Association of Testing Authorities
(NATA) certified contractor approved by the Company and must be independent from the welding
contractor. Unless authorised by the Company Project Representative, all non-destructive
examinations (NDE) technicians must be NATA registered and certified and all reports must have
the NATA endorsement logo displayed. A minimum 10% of all welds are to be NDT inspected.
4.4 Company’s Welding Inspections
Company’s welding inspection activities as per the approved ITP will be carried out by the
Company Project Representative, or delegated representative. The Contractor must give the
Company Project Representative, or delegated representative, at least 24 hours’ notice of
readiness for inspections.
4.5 Welding Requirements
After the completion of the welding operation the welder must record beside each weld using
paint pen or other permanent marker the following details:
(a) date;
(b) WPS number;
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(c) welder ID number; and
(d) W/S sign off (must be completed by Contractor’s welding supervisor).
4.6 Post Weld Heat Treatment
Where required, post weld heat treatment must be completed as per Company Specifications
and Australian Standards.
4.7 Manufacturer’s Data Report
The Contractor must provide a complete draft MDR within one (1) week and final MDR within
three (3) weeks after completion of the Services in pdf. format and completely legible, including:
(a) the ITP signed on every line by responsible Personnel and signed by the Company
welding advisor at the required review/hold/witness points;
(b) PQRs;
(c) WPSs;
(d) welder qualification register and qualification records;
(e) material register and mill certificates;
(f) consumable register and certificates;
(g) weld maps and weld traceability;
(h) post weld heat treatment request, reports and charts NDT request and reports;
(i) hydrotest reports;
(j) visual inspection certificate approved and signed by certified welding
supervisor/inspector;
(k) painting quality assurance check sheets and reports (if applicable); and
(l) Non-conformance reports (NCRs) and concessions (if applicable).
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5. WORK SCOPE
5.1 Battery Limits
The Contractor acknowledges and agrees that the following are the battery limits for the Scope
of Work:
(a) DN100 pipe at ‘Fuel Farm’ side tie-in location as illustrated in contract drawings and
Figures 3 and 4 below.
Figure 3: Battery limit at 'Fuel Farm' side tie-in location: DN100 pipe
Figure 4: Battery limit at 'Fuel Farm' side tie-in location: DN100 pipe
(b) DN100 valve flange face at ‘Powerstation’ side tie-in location, as illustrated in Figures 5
and 6 below.
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Figure 5: Battery limit at 'Powerstation' side tie-in location: DN100 valve flange
Figure 6: Battery limit at 'Powerstation' side tie-in location: DN100 valve flange
(c) Underside new pipe support footings.
(d) Underside new and existing pipe supports where pipework supports are to be connected
to existing structures, including but not limited to: overhead walkways, cable tray support
structures, concrete walls.
5.2 Tie-In Works
The Contractor must follow the design for tie-in works as per supplied Company drawings.
The Contractor must provide the Company with a tie-in work shutdown schedule for review and
approval.
The Contractor shall drain and flush pipelines and execute any other works deemed required to
safely tie into the existing fuel line, as part of the Contractor’s Scope of Work.
Figures 3, 4, 5 and 6 identify the tie-in work locations for this project which are:
(a) ‘Fuel Farm’ side tie-in (DN100 pipe – to be cut into at location nominated on Contract
drawings); and,
(b) ‘Powerstation’ side tie-in (DN100 isolation valve).
5.3 Pipe Installation Details
The Contractor shall install the new DN100 pipework and associated materials in accordance to
the documentation listed in Section 1.3 of this scope of works document.
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The scope of works includes, but is not limited to, the following:
(a) ‘Fuel Farm’ side and ‘Powerstation’ side tie-ins;
(b) DN100 pipe to include drain point near ‘Fuel Farm’ side tie-in location as illustrated in
Figure 7 and as per Company drawings. Contractor to confirm no clash with existing
column member or existing pipework.
Figure 7: DN100 drain poing to be installed
(c) DN100 pipe to be routed from tie-in location to Polishing Dam wall as illustrated in Figure
8. Pipe supports and drain point to be installed as per Company drawings.
Figure 8: DN100 pipe to run from tie-in location to alongside Polishing Dam wall.
(d) DN100 pipe to be installed alongside Polishing Dam wall as illustrated in Figure 9. (pipe
to be protected by Armco barricading). Pipe to be supported via pipe supports as per
Company drawings.
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Figure 9: DN100 fuel line to be installed alongside Polishing Dam wall.
(e) Diesel line to be routed behind stairway and ladder, illustrated in Figures 10, 11 and 12.
Stairway to be modified to eliminate clash and allow pipe installation, in accordance with
Contract drawings. Existing pipework to be re-routed.
Figure 10: New DN100 line to be routed behind stairway and ladder.
Figure 11: DN100 pipe to be routed behind stairway. Stairway to be modified and existing
polyethylene pipe to be re-routed.
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Figure 12: DN100 pipe to be routed behind ladder.
(f) Safety bollard and Armco barricading to be installed in accordance with Company
drawings, to protect new DN100 diesel line, as illustrated in Figure 13.
Figure 13: Safety bollard and Armco barricading to be installed to protect new DN100 pipeline.
(g) New DN100 pipe to be routed along top of dam bunded wall, as illustrated in Figure 14.
Pipe supports to be fixed to dam wall as per Company drawings. Pipework and supports
to be installed clear of existing services and infrastructure. Where clashes occur,
existing pipework to be modified to allow installation of new DN100 pipework, as
illustrated in Figure 15.
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Figure 14: Pipework to be installed along top of bunded wall.
Figure 15: Existing pipework to be modifed to allow installation of new DN100 pipework.
(h) New DN100 pipe to be routed under existing stairway, on top of bunded wall, as
illustrated in Figure 16 and 17. Pipe supports to be installed as required.
Figure 16: New DN100 pipework to run along dam wall and underneath stairway.
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Figure 17: New DN100 pipework to be installed underneath existing stairway.
(i) DN100 pipe to be routed across underside of pedestrian walkway, above S8 and S9
ship loading conveyors, as illustrated in Figures 18 - 22. Existing pipework to be
modified if clash occurs.
Figure 18: DN100 line to travel along top of bund wall, up onto overhead walkway and across
ship loading conveyors S8 and S9.
Figure 19: Pipework to be supported underside of walkway steel beam members.
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Figure 20: DN100 pipework to travel over cable trays and provide adequate clearance at tunnel
access roadway.
Figure 21: Existing pipework to be modified if clash occurs.
Figure 22: DN100 pipe to be diverted to ‘fence side’ of cable tray rack.
(j) DN100 pipe to be routed on southern side of cable tray support structure, mounted on
new pipe supports which are to be connected to the cable tray support posts. Refer
Figures 23, 24 and 25
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Figure 23: DN100 pipework to be supported from cable tray posts, southern / fence side.
Figure 24: DN100 pipework to travel along fence side of cable tray racks, supported off new
pipe support brackets.
Figure 25: DN100 pipe to run along fence side of cable tray rack, towards MCC building.
(k) Diesel line to run around fence line, behind MCC building and transformer as
illustrated in Figures 26 and 27. Pipe supports and Armco barricading to be installed
as per Company drawings.
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Figure 26: DN100 fuel line to be routed around back of MCC building, along fence line.
Figure 27: New fuel line to travel around back of transformer, along fence line.
(l) Diesel line to be routed around fence line and through new culvert, across the road
shown in Figures 28, 29 and 30. Gate to be relocated as per Figure 29.
Figure 28: DN100 pipe to travel along fence line and through underground road culvert.
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Figure 29: Existing gate to be relocated to eliminate trip hazard.
Figure 30: New DN100 line to run inside culvert across roadway.
(m) DN100 line to be routed along fence line, on pipe supports as per Company drawings
and as illustrated in Figures 31 and 32. Drain point to be installed.
Figure 31: DN100 pipework to travel along fence line.
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Figure 32: DN100 pipeline to follow fence line before being routed through new underground
culvert, across roadway.
(n) DN100 diesel line to run through new underground culvert, across Admin Road, in
accordance with Company drawings. Refer images 33 and 34. Drain point and sump