BHP Billiton Worsley Alumina Pty Ltd Standard Specification

8.0
S-001-M-004 Mechanical
Version

Status
Equipment Installation Deployed

PURPOSE
The principal purpose of this standard specification is to detail the requirements for the accurate and correct
installation of new mechanical equipment at BHP Billiton Worsley Alumina Pty Ltd (BWAPL) Refinery, Mine
and Port sites. However, the content of this specification is always applicable to the existing equipment and
installations at these sites and should be used as a guide to determine whether or not a particular installation
complies with the current approved equipment and engineering practices for BWAPL's business, and to rectify if
required.

CONFIDENTIALITY

The information contained herein is the confidential property of BHP Billiton Worsley Alumina Pty Ltd (BWAPL)
and may not be used for any purpose other than a BWAPL project. It may not be disclosed to any other person
without the prior authorisation of BWAPL. Any such disclosure shall be limited to the purposes of performing your
obligations to BWAPL. Such disclosure shall be made only to parties who have been informed of, and who have
agreed to abide by, your obligation of secrecy. All copies or extracts are to be treated in the same manner and must
(unless otherwise agreed) be returned to BWAPL on request.

INTERIM AMENDMENTS
Please check BWAPL’s Document Management System (DMS) for the latest Interim Amendment/s (IA/s) that
may have been published for this standard. The previous IA/s incorporated into this version of the standard are as
follows:
Not Applicable.

APPROVAL CIRCULATION

Role Name Signature Date

Author
Reviewer
Principal Mechanical Engineer
Superintendent Maintenance
Engineering
Document Administrator

00115908 Owner Author Page

470207109.docx Maint Engineering Supt Park, Alex (WAPL) 1 of 23

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 TABLE OF CONTENTS

PAGE
1 SCOPE........................................................................................................................................... 3
2 APPLICABLE PUBLICATIONS........................................................................................................3
3 SAFETY REQUIREMENTS.............................................................................................................3
3.1 General............................................................................................................................... 3
3.2 Construction....................................................................................................................... 3
3.3 BHP Billiton Standards.......................................................................................................3
4 SITE CONDITIONS......................................................................................................................... 3
4.1 Meteorological and Load Conditions...................................................................................3
4.2 External Operating Conditions............................................................................................3
4.3 Design Philosophy..............................................................................................................3
5 SPECIFICATIONS.......................................................................................................................... 3
5.1 General Design Considerations..........................................................................................3
5.2 Materials, Services and Information Supplied.....................................................................3
5.3 Installation.......................................................................................................................... 3
5.4 Inspection and Testing........................................................................................................3
5.5 Information Required from Bidder/Vendor..........................................................................3
6 DEFINITIONS, TERMS AND ABBREVIATIONS...............................................................................3
7 REVISION EVENTS........................................................................................................................ 3

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1 SCOPE
This BWAPL Engineering Standard Specification (WESS – Worsley Engineering Standard Specification)
covers the general requirements for the accurate and correct installation of mechanical equipment, that has been
cleaned, inspected, tested and prepared for use at BWAPL’s alumina refinery near Collie, Western Australia,
the Bunbury Port, and the Boddington Bauxite Mine sites.
It includes but is not limited to the installation of pumps, gearboxes, conveyors, agitators, vacuum pumps, fans,
blowers, filters, cyclones, classifiers, crushers, mills, tanks, pressure vessels, heat exchangers, chutes, cranes,
dust collectors, hydraulic drives and rotary valves.
The contents of all sections and clauses within this document are mandatory, unless otherwise indicated within
the text or exempted in writing by the responsible BWAPL Principal Mechanical Engineer (WPME).

2 APPLICABLE PUBLICATIONS
All work covered by this Specification shall comply with applicable statutory requirements of Federal, State and
Local Authorities of Australia, whether referenced in this Specification or not, and shall comply with the
following nominated Australian Standards, WESS’s and Drawings. In the event of any discrepancy between
any Standard and this Specification, that discrepancy shall be referred in writing to BWAPL for resolution.
The latest version or revisions of the following documents shall apply:
Australian Standards
Non-destructive testing – Ultrasonic testing of carbon and low alloy
AS 1065
steel forgings
AS 1110 ISO metric hexagonal bolts and screws – Product grades A and B
AS 1111 ISO metric hexagonal bolts and screws – Product grade C
AS 1112 ISO metric hexagonal nuts
High strength steel bolts with associated nuts and washers for
AS/NZS 1252
structural engineering
AS 1275 Metric screw threads for fasteners
AS 1403 Design of rotating steel shafts
AS 1532 Short pitch transmission precision roller chains and chain wheels
AS 1654 ISO system of limits and fits
AS 1755 Conveyors – Safety requirements
Bolts, stud bolts and nuts for flange and other high and low
AS 2528
temperature applications
AS 2784 Endless wedge belt and V belt drives
AS 2938 Gears – Spur and helical – Guide to specifications and rating
AS/NZS 3000 Electrical installations (Australian/New Zealand Wiring Rules)
AS/NZS 3678 Structural steel – Hot rolled plates, floor plates and slabs
AS 3679.1 Structural Steel – Hot rolled bars and sections
AS 4100 Steel structures

International Standards
ANSI/ASME B18.21.1 Lock Washers

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BS 4235-1 Specification for metric keys and keyways – Parallel and taper keys

BWAPL Engineering
Standard Specifications
00113953 S-001-C-002 – Grouting
S-001-D-001 - Engineering Drawings
00115468 S-001-D-003 – Plant Equipment Numbering
00113958 S-001-D-004 – Manufacturer’s Data Report
S-001-E-002 - Electrical and Instrumentation Installation
S-001-E-010 - Approved Electrical and Instrumentation Equipment
00116029
Listing
01001141 S-001-M-003 – Centrifugal Process Pumps
00112614 S-001-M-007 - Enclosed Speed Reducers
00112389 S-001-M-008 - Mechanical Couplings
00112336 S-001-M-009 - Plummer Blocks and Bearings
00112095 S-001-M-010 - Safety Guards
00112338 S-001-M-011 - Roller chains and V-belt drives
00114219 S-001-M-101 - Mechanical Design Criteria
00117304 S-001-S-008 - Galvanizing of Structural Steelwork
00112236 S-001-S-101 - Structural Design Criteria

BWAPL Standard Drawings

D-001-C-10011 Cast in items and Anchor Bolts
D-001-E-10601 Motor Installation, Typical Details

BHPB Publications
GLD.008 Community
GLD.009 Environment
GLD.010 Fatal Risk Controls
GLD.011 Health

Other Publications
MSIA Mines Safety and Inspection Act 1994
MSIR Mines Safety and Inspection Regulations 1995
Construction Safety Acts and Regulations
Electricity Act and Regulations

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3 SAFETY REQUIREMENTS
3.1 General
For jobs requiring onsite works, the Implementation Contractor (IC) shall comply with all the safety
requirements of the relevant Standards and Acts listed in this document. In addition, the IC shall undertake to
implement the ‘safety by design’ concept, the objective of which is that risk shall be minimised by ensuring
safety is ‘built’ into the design, and then accurately replicated in the construction.
Safe conditions shall be ensured under all operating conditions, including: those conditions associated with
start-up and shutdown of plant and equipment; and in those conditions where swapping from one valid
operating configuration to another valid operating configuration produces an expected transient overload
situation.
The designer (and/or constructor) shall ensure that all operating and maintenance activities can be performed
safely and that convenient access is provided. To achieve this, all designs shall be reviewed for ‘safe
constructability’ and ‘safe operability’, including a review to identify environmental and design related hazards.
If the review identifies high risk hazards, then formal HAZOP and/or HAZAN studies shall be carried out.
In addition, risk reviews/workshops shall be conducted to ensure that the outcomes from the design/s will
minimise operation and personnel risk, and that clear and obvious endeavour has been pursued to comply with
BHP Billiton risk management requirements.

3.2 Construction
The safety of personnel carrying out construction and installation work shall be considered in the design
stage. The hazards that will be encountered during construction shall be identified and, as far as possible,
minimised by good design. Particular attention shall be paid, when choosing locations for equipment, to
providing safe access for construction workers, and ongoing (post project) plant maintenance personnel
workers.

3.3 BHP Billiton Standards

BHP Billiton standards documents prescribe the mandatory performance requirements for the establishment of
systems that support the aspiration of Zero Harm across BHP Billiton.
The BHP Billiton standards mandatorily apply to all sites and facilities that are owned or operated by BHP
Billiton, and to all BHP Billiton employees and contractors performing controlled activities.
The BHP Billiton standards that expressly apply to the performance of this Worsley site standard specification
are listed in, but not necessarily limited to, Section 2 - BHPB Publications.

4 SITE CONDITIONS
4.1 Meteorological and Load Conditions
With regard to designs that are carried out to meet the requirements of this WESS, the environmental and load
(wind, earthquake, earth pressure, etc) conditions, which those designs must cater for, are stipulated in S-001-S-
101 (Document No. 00112236).

4.2 External Operating Conditions

The external operating (process) environment that equipment must be designed to successfully endure
and operate in is characterised by the presence of the following conditions:
 Dust laden air;
 Salt laden air;
 Caustic derived gases and fumes;
 Caustic derived air-borne vapour/mist and ‘caustic rain’ in winter;
 Hydrochloric acid;
 Chemical fumes;

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  Direct sunlight;
 Ultraviolet radiation;
 Vermin;
 Vibration;
 Impact;
 Hazardous areas (explosive atmospheres - gas/vapours or dust);
 High temperatures;
 Damp/high humidity situations;
 Pressurised sprays/jets of liquid;
Specific values for each that is applicable will normally be specified in the Job Data Sheet.

4.3 Design Philosophy

The equipment design shall aim to produce cost effective, fit for purpose designs that achieve the
following objectives:
 To provide safety for personnel in construction, operation and maintenance;
 To effectively perform the designated function;
 To minimise whole of life costs;
 To comply with all relevant Regulations and Australian and BWAPL Standards;
 To facilitate future work;
 To maximise ease of maintenance;
 To minimise spares holding;
 To maintain compatibility with existing installations;
 To ensure reliability and continuity of supply;
 To provide simplicity of operation;

5 SPECIFICATIONS
5.1 General Design Considerations

5.1.1 Safety and Reliability

Design of the equipment and installation work shall be in accordance with the codes and standards defined in
this document. Maximum safety of operating/maintenance personnel and equipment, and continuity of service,
shall be given prime consideration.

5.1.2 Equipment
All equipment and materials specified for outdoor installation shall be suitable for use in the defined ambient
conditions. Aluminium or aluminium alloys, copper, zinc, tin and their alloys shall not be used unless formally
approved in writing by the WMPE.
All equipment and materials specified for indoor installation shall be suitable for a maximum ambient
temperature of 50°C, a minimum ambient temperature of 0°C and a maximum humidity of 100%.

5.1.3 Preferred Equipment

To facilitate procurement, maintenance and spare parts inventory, standardised equipment shall be selected
wherever practical. In general, the same function shall be performed by the same type and manufacture of
equipment in all plant areas.
Where such approval is not obtained, the equipment may be required to be removed and replaced with the
approved type.
All equipment and materials shall be selected to match the design life of the project (+25 years).
Equipment and materials nearing discontinuation by the manufacturer shall not be installed.

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5.1.4 Provision for Future Installation
Equipment shall be designed and installed to facilitate future additions without re-arranging the original
installation. It is not the intent to provide spare capacity beyond plant design requirement (that is, normal
operating equipment).

5.1.5 Non-documented Standards

There exists at BWAPL, long term, accepted plant standards and practices which have not necessarily been
captured in WESS documents or in standard drawings. Nevertheless, such standards shall still apply to any
design work performed under the jurisdiction of this WESS until unequivocally demonstrated to the Asset
Owners that the current standard/practice is not safe, will not work, or is incompatible with any new technology
that has been, or is proposed to be, introduced into the existing plant/process.

5.2 Materials, Services and Information Supplied

5.2.1 Materials
Aluminium, Copper, Tin, Zinc and their alloys shall not be used on any equipment where it can be directly
exposed to a caustic/acid environment.

5.2.2 Equipment
The equipment shall be pre-assembled by the manufacturer to a stage suitable for transportation and installation
onsite. This may consist of main assembly, sub-assemblies and other items that require final fitting at the site
during installation to complete the equipment.

5.2.3 Other Materials

Where materials are supplied by BWAPL or the equipment manufacturer, the contractor shall not substitute any
other materials without prior written approval from BWAPL.
Consumable items such as electrodes, filler wire, flame tips, flux, gas and rag, etc, and equipment such as cranes
and lifting gear, welding gear, compressors, scaffolding, aerial work platforms, and other installation equipment
shall be supplied by the contractor as required.
All spare parts required to test and commission the equipment will be supplied by the equipment manufacturer.
All valves, loose fittings (such as expansion joints), traps, strainers, blinds, spacer rings, bolts nuts and washers
(other than holding down bolts), etc, will be supplied by BWAPL unless otherwise stated in the contract
document.

5.2.4 Information
Where special installation procedures are required to be followed, instructions from the Equipment
manufacturer will be provided by BWAPL to the Contractor.
The provision of documentation including but not limited to equipment data sheets, installation, operating and
maintenance manuals, training manuals, circuit diagrams and functional descriptions is covered under the
relevant WESS for each specific item of equipment as detailed in section above.

5.2.5 Design Requirements

Detailed design work will not be required to be carried out by the contractor in relation to mechanical
installation work, unless so specified in the project scope of work. The contractor will be required to carry out
constructability reviews, risk assessments, hazard analysis, rigging and crane studies to enable handling of the
heavy items and safe placement of the equipment in accordance with Section 5.3.
The Contractor shall furnish an accurate line on the concrete base and an elevation control point for checking
centre lines and elevations shown on the drawings.

5.2.6 Approved Manufacturers and Suppliers

Anti Seize Compound - Devcon Stop-Seize or Maxwell Chemicals Surefilm Anti-Lock
Lubricants - Standard products; Shell Company or ETS Australia

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 Grout - Epirez or Parchem

5.3 Installation

5.3.1 General Requirements

All work shall be performed in accordance with the applicable WESS and drawings and applicable Australian
and International Codes and Standards referenced therein.
Installation of mechanical equipment, whilst not necessarily defined herein, includes activities that are subject to
the BHP Billiton Fatal Risk Controls. Isolation, working at heights and lifting are examples that have been
identified by BHP Billiton as key fatal risks. Particular attention to these FRC is required. Compliance with the
FRC is mandatory.

5.3.1.1 Survey of Site

Prior to attempting to install the equipment, a survey shall be conducted by the contractor to ensure the
following:
 Equipment concrete footings or steel supports are correctly installed in dimension and elevation;
 Anchor bolts and holes in steelwork are correct in location and anchor bolt type configuration and
projections are correct;
 Adequate clearance is available for the equipment during installation and for operation in its final
location;
 Interfaces with other equipment are correct;
 Any irregularities found shall be immediately reported to BWAPL;
 Survey checks and measurements shall be recorded and signed by the person responsible for the
survey and the records shall be made available to BWAPL;

5.3.1.2 Personnel

Assembly and installation of mechanical equipment shall be carried out by competent and experienced trades-
persons. All personnel shall be fully instructed and conversant with the installation procedure applicable to the
equipment prior to commencement of work.

5.3.1.3 Manufacturer’s Installation Instructions

Where equipment is supplied by BWAPL, or by a nominated sub-contractor, the supplier’s installation

instruction shall be obtained from BWAPL. If the supplier’s installation instructions are not available when the
contract is awarded, then the information shall be requested in writing from BWAPL. A method statement for
the installation of equipment shall then be submitted for approval by BWAPL before commencing installation
or erection.
All work shall be carried out according to the approved method statement. No departures shall be allowed
without specific written approval from BWAPL.
For specific and detailed requirements, the Equipment supplier’s installation instructions shall be followed. In
the event of conflict, the latter shall govern, without specific written approval from BWAPL.

5.3.1.4 Commissioning and Assistance to Others

Commissioning of the equipment shall be carried out by others.

The contractor is responsible for installation of commissioning spares on completion of the installation, their
replacement with operating spares after commissioning and preparation of the equipment for final inspection.
The equipment manufacturer will provide a list of all operation and commissioning spare parts concurrently
with the installation Instructions.
The contractor shall provide assistance, as required, to the equipment supplier’s field representatives, erection or
commissioning engineer for the installation, testing and setting of equipment. The assistance will be given
promptly to allow equipment setting and testing to be carried out in the minimum possible time.

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5.3.2 Installation Requrements

5.3.2.1 Preparation of Concrete Foundation Bases

All laitance shall be removed from the top of the concrete base and all loose material shall be removed by wire
brushing and/or wet scabbing, before mechanical equipment is placed on the concrete.
A flat area shall be prepared on each side of each holding down bolt by grinding or other approved means to
received packers and/or shims. This area shall extend over the full width of the mating flange of the structural
member and at least 10mm beyond the edge of the packing material.
Bending of anchor bolts to fit equipment base shall only be allowed within the tolerance set by the tolerance
tubes. If any greater action is required, the method of correcting the error shall be submitted for approval by
BWAPL.
Where anchor bolts are not provided with tubes and the anchor bolts are found incorrectly positioned, the
method of correcting the error shall be approved by BWAPL.
Anchor bolts shall not be altered by cutting or heating.

5.3.2.2 Preparation of Steelwork Supporting Mechanical Equipment

Where equipment is mounted on steelwork, the bearing surfaces areas shall be cleaned of all paint, rust and
scale prior to placing packers.
When equipment mounting is complete, the damaged surface protection on the areas around the equipment feet
shall be repaired in accordance with WESS S-001-S-008 (Document Number 00117304).

5.3.2.3 Position and Levelling

Equipment, base plates or motor slide rails shall be accurately set on steel packing pieces on prepared concrete
bases or structural steel members.
The centre lines and levels of equipment or base plates shall comply with those given on the drawings or in the
supplier’s installation instructions.
Equipment shall be levelled within 0.5mm/metre unless otherwise required by the Equipment manufacturer. In
the case of pumps and other flanged equipment for connection to piping, it shall be the flanges that are levelled
and plumbed.

5.3.2.4 Grouting and Permanent Fixing

The preparation and application of grouting shall be in accordance with WESS S-001-C-002 (Document
Number 00113953) with attention to the following:
 Grouting or permanent fixing shall not be commenced until the setting and alignment has been
approved by BWAPL;
 Grouting shall be carried out as soon as possible after approval has been granted by BWAPL;
 After thoroughly cleaning all load surfaces and tolerance tube pockets, the equipment shall be
grouted with an approved non-shrink, non-rust or epoxy grout mix and struck off square with the
sole, bed or base plate periphery;
 Secondary grouting and edging shall be with an approved non-shrink, non-rust grout mix;
 On pumps where the electric motor feet are elevated above the pump base plate and an enclosed
void exists between the motor feet and the pump/motor base frame, the void shall be filled with
grout or concrete to ensure process fluids do not pond;
 Grouting of this void shall only be completed after the motor feet have been securely bolted to the
pump/motor base frame;
 All equipment set on concrete foundations shall be properly grouted and in such a manner that no
voids are left under the equipment;
 Among the items requiring grouting are supports, column bases, pump base plates, tank supports,
process equipment, and all other equipment which requires firm, uniform bearing upon its
foundation;

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  Foundation drawings shall show the base line of the supported unit with allowance shown for
grouting. Contractor shall determine the grout required for best setting;
 When equipment to be grouted is set on a large pre-finished slab, drawings shall show the base
elevation of the unit at 25mm above the slab elevation to allow for grout and avoid the necessity of
special forming during the slab pour;
 A minimum grout allowance of 25mm facilitates placement of materials. Deeper grouting is
sometimes necessary where it is required to push the grout some distance under the item being
grouted;
 Concrete footings, bases and grouting must be allowed to cure before applying operating loads or
tightening the anchor bolts;
 After final set and curing of the grout all anchor bolts shall be loosened and then tightened to the
required torque;

5.3.2.5 Anchor Bolts

All anchor bolts shall conform to the requirements of the equipment supplier. Where the equipment is mounted
on a common base frame, the anchor bolts shall conform to that specified in the design drawing and shall be
accessible from the outside of the common base frame and separated from voids requiring bulk infill of grout or
concrete (ie common base frame channels shall be designed and constructed to ‘toe outwards’).
Heavy hexagonal nuts shall be used.
Heating or welding of anchor bolts will not be permitted.
Holding down cap screws shall be of proper length to prevent extending down into the grout.
All bolts used for mechanical equipment shall be covered with a suitable thread protection compound and
protected from damage during erection, and shall be protected afterwards.
Anchor bolts for securing electric motor feet to pump/motor base frames shall be supplied loose with a bolt, nut
and washer as required and not secured via tapped holes into the pump/motor base frame.
Access to the nut shall be available on the underside of the pump/motor base frame top face or flange.

5.3.2.6 Packing and Shimming

Where referred to in this section, packing shall refer to a combination of packers and shims. Packer shall refer to
steel plate, 6mm thickness and greater; and shim to final trim to level.
Equipment to be grouted on concrete foundations shall be levelled using packing. Packers shall be supported on
steel levelling plates (where specified by equipment manufacturer). Levelling plates shall be bedded on
foundations using Epirez or Parchem non-shrink grout or BWAPL approved equal.
Packers shall be ferritic or austenitic steel. Shims may be ferritic or austenitic steel. Use stainless steel for
permanent installation of equipment not subject to periodic replacement during future maintenance (eg base
plates).
Where equipment installed is maintainable, stainless steel shims shall be used. A minimum of 3mm packing
shall be used for all such equipment to facilitate any changes in tolerances to motor heights. All packing
(packers and shims) shall be new, flat and free from corrosion or kinks. Plastic, brass or aluminium stock is not
acceptable.
Shimming for centrifugal process pumps shall be in accordance with S-001-M-003 (Document Number
01001141).
Reciprocating equipment shall be levelled with packing unless provided with jack bolts, where such equipment
normally requires precise alignment. The packing shall extend completely across the bearing underside of the
surface being supported. Wedges shall not be used for levelling.
Equipment set on structural steel shall be levelled and loaded accurately and to the specified elevation by
packing as necessary. Allowable packing shall be 3 – 6mm unless otherwise specified on the equipment
manufacturer’s drawings.
The minimum number of packing pieces shall be used at each packing point. Where a number of assorted
packers and shims are installed, these will be regarded as temporary and shall be replaced with not more than

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 two packers and a minimum number of shims, prior to final inspection and bolting down. Five packers/shims
shall be the maximum that may be used at one packing point.
Tapered shims and shims less than 0.5mm thick shall be avoided where possible.
In wet and corrosive areas, a silicon based material shall be used to seal around the shims.

5.3.3 Allignment

5.3.3.1 General

All driver and driven equipment, whether pre-assembled or not, shall be properly aligned in accordance with
vender’s recommendations.
Field test records shall be completed and submitted to BWAPL for acceptance or rejection of alignment.
Any alignment rejected by BWAPL shall be repeated until the measurements are within the required tolerances.
The dowelling of equipment, where required, shall be carried out as soon as possible after acceptance of
alignment has been given by BWAPL.

5.3.3.2 Allignment of Couplings of Motors with Flexible Connections

Work shall be done in order of priority as follows:

 Install coupling halves;
 Install and align driven equipment;
 Install motor and align to driven equipment;
 Align auxiliary equipment to driven equipment;

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 NOTES:
1. Coupling Halves
- For special applications and where approved by BWAPL, the use of locking ring assembly nuts may be
used.
- Where cone ring couplings are installed, the pin half of the coupling shall be the driver half.
- The coupling half to be installed on the motor shall not be driven or pressed on the shaft. Appropriate
temperature modification or oil pressurisation methods shall be utilised where required.
2. Alignment of Coupling Halves
- Coupling halves shall be aligned using laser alignment equipment where practicable, or other approved
equipment, to measure peripheral and angular differences between the coupling flanges as the shafts
are rotated through 360o.
- The alignment equipment shall be set up to take peripheral and angular alignment readings at 0 o, 90o,
180o and 270o if using dial gauges. For laser alignment it should be a continuous sweep if the machine
is set up to permit it.
- Driver and driven halves shall be adjusted horizontally or vertically using adjusting screws and/or
packers and shims, until the coupling flanges are aligned within the tolerances specified below.
3. Tolerances
- Couplings shall be aligned such that the parallel and angular errors measures at the coupling periphery
do not exceed the equipment manufacturer’s recommendations.
- All readings shall be demonstrated to be repeatable. Misalignment shall be corrected with the use of
levelling shims. Where possible, electric motors shall be moved rather than driven equipment.
- Allowances shall be made for potential movements such as thermal expansion or contraction, hydraulic
loading, gears with rising pinions and motor rotors seeking a magnetic centre and the like during
alignment of driver and driven equipment.
4. Loading from Piping or Chute Connections
- Where pipe or chute flanges are connected to equipment which is driven via a drive coupling, a full set of
alignment measurements shall be made on the coupling, with the pipe or chute flange connecting bolts
loosened and another with the bolts torqued, to ensure that the coupling alignment is not altered by
tightening the pipe or chute flange connections.
- Any coupling alignment rejected by BWAPL shall be realigned until the readings are within the specified
tolerances.
5. Completion of Coupling Assembly
- When the electrical and direction check and no load run of the motor is complete and coupling
alignment field test records have been checked and accepted by BWAPL, the coupling shall be coupled
(and torque if appropriate) in accordance with the equipment manufacturer’s instructions.
- Where specified on drawings, after couplings have been bolted up, dowel holes shall be drilled, reamed
and dowels fitted, to fix the location of motors and coupled units on base plates.

5.3.3.3 Final Alignment

Final alignment shall be made at normal operating temperature where possible.

If the driven equipment is not at its normal operating temperature, compensation shall be made for thermal
expansion/contraction.
The tolerances achieved shall be equal to or within the following:
a) Total parallel run-out: 0.050mm maximum;
b) Total angular run-out: 0.076mm maximum;
c) Comply with the coupling manufacturer’s specification for total parallel run-out and total angular run-out
where manufacturer’s requirement are tighter than a) and/or b) above.

5.3.3.4 Fluid Couplings

When installed, each fluid coupling shall be filled with oil recommended by the Equipment manufacturer and
approved by BWAPL. Under no condition shall two or more brand or types of oils be mixed in the couplings.
For approved lubricant supplier, refer Section 5.2.6 of this Specification.

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 The amount of oil charged into the fluid coupling shall comply with the equipment manufacturer’s
specifications prior to start up and during commissioning. This process will ensure that the specified torque
values will be achieved.

5.3.3.5 V-Belt Drives

Alignment and tensioning of belt drives, whether supplied pre-assembled or not, shall be checked and corrected,
if necessary, and shall be inspected and accepted by Worsley prior to fitment of guards.
Motors shall be assembled, with pulley fitted, on motor slide rails and driver and driven pulleys shall be aligned
to tolerances recommended by the Equipment manufacturer.
Pulley grooves shall be thoroughly cleaned to remove all oil, grease, rust and burrs. Centre distances between
the pulleys shall be reduced before V-belts (or wedge) are placed by hand into their respective grooves. No
implements shall be used to force belts into pulley grooves.
Before tensioning multi-belt drives, belts shall be worked around pulley groves by hand so that the slack of all
belts is on the same side, ie either top or bottom.
Belts shall be tensioned using the method recommended in Appendix B of AS 2784.

5.3.4 Fasteners

5.3.4.1 Bolts

New corrosion resistant and commercial grade fasteners complying with all applicable standards including
AS 1111, AS 1112, AS 1275 and ANSI/ASME B18.21.1 shall be used.
Precision bolts and screws shall comply with AS 1110.
Mechanical fasteners (studs, nuts and bolts) must not be welded on the WAPL site. The application of a
suitable primer and thread locking compound (Loctite) is recommended to lock fasteners as required and
subject to suitability for the environmental conditions (temperature and presence of acids/alkali’s etc).
The minimum diameter bolt or screw thread shall be 12mm (unless specifically supplied by equipment
supplier). All bolts and studs when fully tensioned; shall protrude a minimum of three and a maximum of six
threads beyond the face of the nut.
Masonry anchor bolts shall be galvanised Dynabolts, Hilti or approved equivalent having a minimum thread
diameter of 12mm.

5.3.4.2 High Strength (HS) Bolts

High strength bolts with nuts and washers shall conform to AS/NZS 1252.
HS bolts and nuts shall be tightened in accordance with AS 4100. Where a torque control method of tightening
is used, the tightening device shall be kept calibrated in accordance with AS 4100.

5.3.4.3 Taper Washers

Taper washers shall be provided on bolted sections whenever required by the shape of the sections being
connected.

5.3.4.4 Bolt Holes

All bolt holes shall be drilled or punched. Gas burning of holes is not permitted.

5.3.4.5 Thread Locking and Lock Washers

For normal applications, a lock washer shall be provided under each nut. Where bolted connections are subject
to heavy vibrations, self locking metal nuts shall be used. Bolts or screws assembled into blind holes shall have
threads treated with an approved thread locking compound, Loctite or equivalent before assembly.

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5.3.4.6 Anti-Seize Compound

Non-structural fastenings of mechanical equipment shall have the fasteners coated with an anti-seize compound
as per Section 5.2.6 at final assembly.

5.3.4.7 Stud/Bolt Tensions and Torques

The torque values required for tightening high strength stud/bolts are shown in Table 5.3.4.7. The use of thread
lubricant shall be adopted to reduced stresses, reduce wear and tear on torque wrenches and equipment, and to
minimise the risk of injury to employees.
Table 5.3.4.7: General Stud/Bolt Tension/Torque Table
TORQUE REQUIRED
STUD/BOLT Thread Dry
STUD/BOLT DIA. NUT A/F
TENSION FORCE Lubricated (µ-0.2)
(µ-0.1)
In mm in mm Lbf kN lbf.ft Nm lbf.ft Nm
6 10 1349 6 3.7 5 6.6 9
8 13 2473 11 8.1 11 15.5 21
10 16 3822 17 17.0 23 31.7 43
12 19 5110 23 30 40 55 75
½ 7/8 6785 30 40 55 75 100
16 24 9760 43 70 95 135 185
5/8 1 1/16 10870 48 80 110 150 205
¾ 1¼ 16220 72 145 195 265 360
20 30 15880 71 145 195 270 365
7/8 1 7/16 22520 100 230 310 430 585
24 36 22870 102 250 340 470 635
1 1 5/8 29555 131 345 470 635 860
27 41 30140 134 365 495 685 930
1 1/8 1 38900 173 500 680 935 1270
13/16
30 46 36635 163 495 670 925 1255
1¼ 2 49560 220 700 950 1315 1785
33 50 45670 203 670 910 1260 1710
1 3/8 2 3/16 61530 274 945 1280 1785 2420
36 55 53580 238 860 1165 1610 2185
1½ 2 3/8 74760 333 1240 1680 2355 3195
39 60 64450 287 1120 1520 2105 2855
1 5/8 2 9/16 89250 397 1600 2170 3055 4140
42 65 74120 330 1390 1885 2605 3530
1¾ 2¾ 105000 467 2015 2730 3855 5225
45 70 86120 383 1715 2325 3230 4380

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 TORQUE REQUIRED
STUD/BOLT Thread Dry
STUD/BOLT DIA. NUT A/F
TENSION FORCE Lubricated (µ-0.2)
(µ-0.1)
In mm in mm Lbf kN lbf.ft Nm lbf.ft Nm
1 7/8 2 15/16 122325 544 2500 3390 4795 6500
48 75 97415 433 2075 2815 3895 5280
2 3 1/8 140700 626 3050 4135 5865 7955
52 80 116475 518 2665 3615 5025 6815
56 85 134825 600 3320 4500 6255 8480
2¼ 3½ 181125 806 4375 5930 8450 11460
60 90 157415 700 4125 5595 7800 10575
2½ 3 7/8 226800 1009 6045 8195 11710 15880
64 95 177885 791 4975 6745 9395 12740
68 100 204005 907 6025 8170 11410 15470
2¾ 4¼ 251760 1120 7335 9945 14250 19325
72 105 231635 1030 7200 9765 13675 18545
3 4 5/8 302100 1344 9555 12955 18605 25230
80 115 292246 1300 10005 13585 19095 25895
3¼ 5 357675 1591 12200 18545 23805 32280
Notes: 1. Bolt material ASTM 193 or BS4882 or AS2528, Grade B7 or similar.
2. Bolt material 8.8 or similar.
3. Heavy series nuts.
4. Bolt tension equates to a bolt stress of 50% of the minimum yield stress of the
material. Figures are based on minor thread diameter.
5. For M12 stud/bolts and larger torque figures are rounded to the nearest 5 lbf.ft/Nm.
6. Assumes defect free threads on both stud/bolt and nut.
7. Note these torques are for tightening up of fasteners. An additional 50% may be
required to undo nuts if anti-seize lubricant has not been applied on torque up.

5.3.5 Bearings and Housings

5.3.5.1 General

Each pair of bearings supporting a shaft shall have one fixed and one floating bearing. The fixed end shall be
clearly marked on the bearing housing by punching the word “fixed” into the housing base. All adjusting
screws shall be galvanised.
Bearing housing shall be set square on the shaft such that the radial gap measured between the labyrinth seals at
any two diametrically opposite points does not vary by more than 0.5mm.
When bearings are fitted to the non drive end of a shaft, a steel blanking plate shall be provided in the housing
to seal off the open end.
Plummer block bearing cap bolts shall be tightened to the torque recommended by the Equipment
manufacturer.
Spring washers shall be fitted under the mounting bolt nuts and plain washers under the bolt heads. Nuts shall
be installed so that they are readily accessible.

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 If, for clearance reasons, the nuts are located above the mounting foot, then a plain washer and a locknut shall
be used.
Grease points for bearing housings shall be manifolded together using 6mm stainless steel tubing to a point
outside the guard for ease of access for regreasing while machinery is operating.
When bearings are installed, the internal radial clearance shall be set in accordance with the Equipment
manufacturer’s recommendations.
Refer to WESS S-001-M-009 (Document Number 00112336) for further details.

5.3.5.2 Cleaning and Flushing

All sleeve bearings and Kingsbury type thrust bearings must be cleaned and inspected before units are placed in
service. In all new equipment being placed in service the Contractor shall install the proper lubrication as
recommended by the Equipment manufacturer and BWAPL.
The Contractor shall thoroughly flush all equipment with approved flushing oil in accordance with Equipment
manufacturer’s recommendations. The flushing procedure shall include where possible, the manual rotation of
equipment to ensure complete penetration. On completion of flushing, the flushing oil shall be completely
removed prior to filling with running oil. Flushing oil, once used shall not be re-used.
On all sleeve bearing motor installations, the equipment must be installed so as to ensure that the motor bearings
will not take any end thrust. This shall be done in accordance with the Equipment manufacturer’s
recommendations.

5.3.5.3 Lubrication

Each lubricating system shall be fitted with a lubricant recommended by the Equipment manufacturer and
approved by BWAPL. The approved lubricant shall be suitable for the particular duty and ambient temperature
conditions. Two or more brands or types of lubricants shall not be mixed.
All lubricants shall be from approved manufacturers/suppliers in Section 5.2.6.
The amount of oil used shall be adjusted in accordance with Equipment manufacturer’s instructions before and
during start-up, to ensure correct performance.
Lubrication systems which have not been cleaned and plugged shall be flushed through with flushing oil under
pressure as directed by BWAPL. Once cleaned, the system shall be closed off with plugs that are
conspicuously located or suitably tagged.
Equipment or machinery shall not be deemed ready to run until BWAPL has been advised in writing, and
verification of the type and quantity of oil or grease used in all mechanical components requiring lubrication has
been provided.

5.3.6 Guards
Safety guards shall be installed in accordance with WESS S-001-M-010 (Document Number 00112095).
Equipment Safeguarding has been identified by BHP Billiton as a key fatal risk. Particular attention to FRC 7
included in WESS S-001-M-010 is required. Compliance with the FRC is mandatory.

5.3.7 Coated Flanges and Rubber Gaskets

All rubber to rubber, rubber to epoxy and rubber to metal mating flanges are to be coated with Colloidal
Graphite or equivalent at final assembly.

5.3.8 Numbering Systems

A mandatory requirement for all BWAPL sites is that all facilities and equipment shall be assigned a
unique identifying number in accordance with the requirements of WESS S-001-D-003 (Document
Number 00115468).
For those cases where S-001-D-003 does not specifically cover the assignment of numbers to the
equipment, then the numbering shall be carried out after consultation with the WPME and the Master
Data Facilitator (MDF), (and the Senior Electrical Draftsperson for electrical/instrumentation, etc).

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5.3.9 Electrical and Instrumentation
The contractor shall install all the instruments supplied with the equipment. All electrical and instrumentation
shall comply with WESS S-001-E-002 and S-001-E-010 (Document Number 00116029). All wiring shall
comply with the wiring rules, AS/NZS 3000.

5.4 Inspection and Testing

Inspection and testing shall be in accordance with the relevant codes and standards referenced herein, together
with the additional requirements outlined below.

5.4.1 Inspection
The following checks shall be carried out by the contractor:
 All equipment shall be immediately inspected upon receipt on site. Internal spaces of equipment
shall be checked for foreign materials. All temporary shaft locking devices shall be removed and
shafts checked by hand only for free rotation in the appropriate direction(s). Any short supply,
damage or apparent misalignment or distortion shall be immediately reported to BWAPL.
Damaged equipment shall not be installed unless directed otherwise by BWAPL;
 The hold-down bolts have been correctly installed by the concrete contractor;
 The equipment on the concrete footing is in the correct orientation as per the drawings;
 The drive trains including motors, couplings, guards etc are correctly assembled in order to make
the equipment mechanically ready for safe operation;
 All equipment is correctly aligned on the footings.
 Shims are placed under the equipment bases, bases to be levelled and bolted down to the footings;
 The equipment bases are suitably grouted;
 The equipment is correctly filled with lubricants;
 Start up equipment and check rotation to conform to the rotational direction specified by the
equipment manufacturer after the electrical installation has been completed by others;

5.4.2 Testing
Final alignment of couplings shall be checked and total parallel run-out and angular run-out shall be recorded.

5.4.3 Performance Guarantee

The contractor shall provide a guarantee for all items supplied and all work carried out.
The equipment supplier’s performance guarantee will be subject to compliance with their installation
procedures. The contractor shall comply with the requirements of the equipment manufacturer to enable
BWAPL to obtain a full warranty of the equipment.

5.5 Information Required from Bidder/Vendor

5.5.1 Spares Compatibilities

BWAPL desires to standardise on the design of all possible items of equipment. Where practicable, identical
components shall be used, to allow interchangeability, minimise spare parts requirements, including
compatibility with those in the existing plant, and to aid standardisation of service and repairs. The vendor shall
specify parts known to be compatible with those in existing BWAPL plant.

5.5.2 Manufacurer’s Data Report (MDR)

The vendor shall provide a separate Manufacturer’s Data Report (MDR) for each individual item of equipment
(refer to S-001-D-004 (Document Number 00113958)). The following sections shall be provided in the MDR:
Section A Inspection Release Certificate/Inspection Waiver/Signed off Inspection Test Plan (ITP);
Section B Material Certificates and Test Reports;
Section C Certificate of Compliance;
Section D Welding Records;

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 Section E Welder and Welding Operator Records;
Section F Non Destructive Examination (NDE) Records;
Section G Heat Treatment Records;
Section H Dimensional Records;
Section I Non Conformance Reports and Concessions;
Section J Pressure Test Records;
Section K Painting and Coating;
Section L Mechanical and Performance Test Records;
Section M Electrical Certificates and Records;
Section N Instrumentation Certificates and Records;
Section O Drawings;
Section P Miscellaneous Certificates, Reports and Records;
Section Q List of Parts of Equipment/Material Requiring Statutory Documentation;
Section R Statutory Documents for Cranes, Hoists and Lifts;
Section S Documentation for Pressure Vessels, Heat Exchangers and Other;
Section T Installation, Maintenance and Operation Manuals;

5.5.3 As-Built Drawings

On completion of the work, BWAPL shall be supplied with as-built drawings.

6 DEFINITIONS, TERMS AND ABBREVIATIONS

Term Definition
AF Across Flats
ANSI American National Standards Institute
AS Australian Standards
ASME American Society of Mechanical Engineers
BS British Standards
BWAPL BHP Billiton Worsley Alumina Pty Ltd
DMS BWAPL Document Management System (Documentum)
FRC Fatal Risk Controls
GLD BHP Billiton Group Level Document
HAZAN Hazard Analysis
HAZOP Hazard and Operability Study is the primary methodology for hazard
identification in the detailed design stage of process plant.
HS High Strength
IA/s Interim Amendments

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 IC Implementation Contractor: the contractor engaged to execute a project
under the direction of an Owner’s Project Manager or Project
Management Team - typically from the start of the project definition
phase through to the completion of the project execution phase.
However, for the purposes of this document the term Implementation
Contractor applies to companies or individuals whose scope of services
include all or any combination of, project management, design,
engineering, procurement, construction management, construction,
pre-commissioning, commissioning and/or handover.
ISO International Standards Organisation
Informative/Normative The terms ‘informative’ and ‘normative’ are used to define the
application of the appendix to which they apply. An ‘informative’
appendix is only for information and guidance, whereas a ‘normative’
appendix is an integral (mandatory) part of the standard.
MDF Master Data Facilitator
MDR Manufacturers Data Report
NZS New Zealand Standards
WESS Worsley Engineering Standard Specification
WPME Worsley Principal Mechanical Engineer
Revisions to previous version are indicated by a bold line down the
right-hand margin thus:

7 REVISION EVENTS
Version Clause Changes Date
6 General Standard Specification reformatted. 16/4/2007
6 Section 2 Referenced standards updated including- 16/4/2007
AS 1968 (obsolete) replaced with ANSI/ASME B18.21.1
Reference to drawing 300-M-0003 removed
6 Section 3 1. Safety Requirements included; 16/4/2007
2. Fatal Risk Control Protocols added;
6 Section 4 1. Contractor to carry out rigging studies to enable handling of 16/4/2007
the heavy items added;
2. Anti-seize compound specified;

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6 Section 5 1. Reference Fatal Risk Control Protocols made; 16/4/2007
2. Anti-seize and torque specifications adopted;
3. Reference made to grouting in S-001-C-002;
4. Plastic packers and shims removed;
5. Requirement for laser alignment stated;
6. Filling oil of fluid couplings clarified;
7. Fasteners reference standards updated;
8. Stud-bolt torques and tension tables installed;
9. Reference made to S-001-M-009 Plummer Blocks and
Housings;
10. Clause on Safety Guards S-001-M-010 updated;
11. Requirements for electrical, instrumentation and wiring
stated;
12. Reference made to S-001-S-008 Galvanizing of Structural
Steelwork;
7.0 Whole 1. All instances of the words “Worsley” or “Worsley Alumina
Document Pty Ltd” replaced with “BWAPL”;
2. All instances of the words “Worsley Standard Specifications”
replaced with “WESS”;
3. Formatting revised to align with new WESS template;
7.0 Front 1. “INTERIM AMENDMENTS” section added;
Page 2. “APPROVAL CIRCULATION” section revised;

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7.0 Section 2 1. References to AS 1100.201, AS 1101.1, AS 1101.3 and AS
1418 removed;
2. Reference to AS 2528, Australian Standard for Bolts,
studbolts and nuts for flange and other high and low
temperature applications, added;
3. Reference to ANSI/ASME B18.21.1, American National
Standards Institute/American Society of Mechanical
Engineers Standard for Lock Washers, added;
4. Reference to BS 4235-1, British Standard Specification for
metric keys and keyways, added;
5. Document numbers added for WESS;
6. Reference to WESS S-001-D-001, Engineering Drawings,
added;
7. Reference to WESS S-001-D-003, Plant Equipment
Numbering, added;
8. Reference to WESS S-001-D-004, Manufacturer’s Data
Report, added;
9. Reference to WESS S-001-M-003, Centrifugal Process
Pumps, added;
10. Reference to WESS S-001-S-101, Structural Design Criteria,
added;
11. Reference to drawing D-001-E-10022 replaced with D-001-E-
10601, Motor Installation, Typical Details;
12. Reference to BHPB Publications added;
13. Reference to Industrial Ventilation publication removed;
14. Reference to FRCP publication removed and replaced with
GLD.010, Fatal Risk Controls;
15. References to Construction Safety Acts and Regulations and
Electricity Act and Regulations added;
7.0 3.1 Content revised.
7.0 3.3 Retitled to “ BHP Billiton Standards” and content revised.
7.0 Section 4 1. The previous title “MATERIALS, SERVICES AND
INFORMATION SUPPLIED” has been deleted and all its
associated clauses have been relocated to clause level under
newly-titled clause 5.2. The new title “SITE CONDITIONS”,
has been added as part of a strategy to standardise the Table of
Contents across all WESS;
2. “Meteorological and Load Conditions” clause 4.1 added under
the newly titled Section 4;
3. “External Operating Conditions” clause 4.2 added under the
newly-titled section 4;
4. “Design Philosophy” clause 4.3 added under the newly-titled
section 4;
7.0 4.1 Renumbered to clause 5.2.1.
7.0 4.2 Renumbered to clause 5.2.2.
7.0 4.3 Renumbered to clause 5.2.3.
7.0 4.4 Renumbered to clause 5.2.4.
7.0 4.5 Renumbered to clause 5.2.5.

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7.0 4.6 Renumbered to clause 5.2.6 and “Grout” materials included.
7.0 Section 5 Renumbered to clause 5.3. The new title “SPECIFICATIONS”,
has been added as part of a strategy to standardise the Table of
Contents across all WESS.
7.0 5.1 1. Renumbered to clause 5.3.1.;
2. New title “General Design Considerations” added;
3. “Safety and Reliability” clause 5.1.1 added;
4. “Equipment” clause 5.1.2 added;
5. “Preferred Equipment” clause 5.1.3 added;
6. “Provision for Future Installation” clause 5.1.4 added;
7. “Non-documented standards” clause 5.1.5 added;
7.0 5.2 Renumbered to clause 5.3.2.
7.0 5.2.4 Additional bullet points added for grouting of enclosed voids
between the motor feet and the pump/motor base frame.
7.0 5.3 1. Renumbered to clause 5.3.2.5;
2. Additional information added for:
 Access to anchor bolts from outside of the common base
frame;
 Separation from bulk infill of grout or concrete;
 Common base frame channels shall be designed and
constructed to ‘toe outwards’;
7.0 5.4 1. Renumbered to clause 5.3.2.6;
2. Reference to Embecon grouting products replaced with Epirez
or Parchem;
3. Plastic packers and shims not acceptable;
4. Reference to S-001-M-003 for shimming of Centrifugal
Process Pumps included;
5. Quantities of packers and shims revised;
7.0 5.5 1. Renumbered to clause 5.3.3;
2. Re-titled to “Information Required from Bidder/Vendor”;
3. Sub-clause 5.5.1 added titled “Spares Compatibilities”;
4. Sub-clause 5.5.2 added titled “Maunufacturer’s Data Report
(MDR)”;
7.0 5.6 Renumbered to clause 5.3.3.4.
7.0 5.7 Renumbered to clause 5.3.3.5.
7.0 5.8 Renumbered to clause 5.3.4.
7.0 5.9 1. Renumbered to clause 5.3.4.7;
2. Additional tension and torque data for M6, M8 and M10 studs
and bolts has been included in table 5.3.4.7.
7.0 5.10 1. The previous title “Bearings and Housing” has been deleted
and relocated to newly-titled clause 5.3.5;
2. The contents of clause 5.10 have been deleted and relocated to
newly-titled clause 5.3.5.1 titled “General”.
7.0 5.11 Renumbered to clause 5.3.5.2.
7.0 5.12 Renumbered to clause 5.3.5.3.

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7.0 5.13 Renumbered to clause 5.3.6.
7.0 5.14 Renumbered to clause 5.3.7.
7.0 5.15 Renumbered to clause 5.5.3.
7.0 5.16 Renumbered to clause 5.3.9.
7.0 Section 6 Renumbered to clause 5.4.
7.0 6.1 Renumbered to clause 5.4.1.
7.0 6.2 Renumbered to clause 5.4.2.
7.0 Section 7 Renumbered to clause 5.4.3.
7.0 Section 8 Renumbered to section 6.
7.0 Section 9 Renumbered to section 7.

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