Specification Standard Engineering Specification Water Ponds Engineering June 2017 100-SP-HY-0008 2G vw Fortescue The New Force non OreStandard Engineering Specification Water Ponds 100-SP-HY-0008 Disclaimer: Page 2 of 45 This document is protected by copyright, no part of this document may be reproduced or adapted without the consent of the originator/company owner, all rights are reserved. This document is “uncontrolled when printed’, refer to electronic copy for up to date version. ee aa 19/06/2017 Status IFU - ISSUED FOR USE (UL, _ Ae & Yes Confidentiality FORTESCUE STAFF & Publish on Extranet fom sy | No Review Date 19/06/2017 Revision History (to be completed for each version retained by Document Control) Autor Checker appro Rev | statue |tsund Oto STRETCH 8 Glogston Teoh A [wR | sewaon Fortescue heTABLE OF CONTENTS 1. SCOPE.. 1.1 Terminal Limits /Battery Limits for this specification 1.2 General 2. DEFINITIONS... 3. REFERENCE DOCUMENTS. 3.1 Standards and Codes 3.2 Applicable Project Documents 4. GENERAL REQUIREMENTS .. 4.1 Design and Design Changes 4.2 Risk Assessment and Risk Control 4.2.1 Design/HAZOP style risk assessment ... 4.2.2 Construction Risk Assessment / CRAW. 4.3 Noise 44 Guards 5. POND SIZING AND PROCESS REQUIREMENTS. 5.1 Flow Rates and Pressures. 5.2 Water Storage Volume 5.3. Solids Settling Rates and Calculations .. 5.4 Solids Storage Volume 5.5 Solids migration Weirs 5.6 Solids Clean out Arrangements for Speci 5.7 Spillway Weirs. 6. POND CIVIL REQUIREMENTS ... 6.1 Setting Out of the Works 6.2 Pond Batters... 6.3 Clearing and Grubbing 6.4 — Topsoil Removal .. 6.5 Site-Foundation Preparation... 6.6 — Excavation nl 1 12 14 14 17 Ww Fortescue Mm67 6.8 Pond Construction. 681 General 19 682 Compaction 19 6.9 Burial of Pipe through pond wall: 20 6.10 Spillway: 20 6.11 Conveyor Belt at High Wear Points .. 6.12 Dust Suppression. CONCRETE... 1) POND LINING 81 Clay Liners. B14 Materials. re ™ 21 8.1.2 Sub Grade Preparation. 8.1.3 Clay Liner Placement. 8.2 High Density Polyethylene (HDPE) Liner System B21 SOMO cs cecssseesssseesseecsseeeesseseoseeeenseeseneeeemsensnmeenenennne _ .. 22 8.2.2 Sub Grade Preparation 23 8.2.3 Bedding Material es 23 824 _ Liner System Installation Preparation 23 8.2.5 Non-Woven Geotextiles - Materials yun 24 8.2.6 Non-Woven Geotextiles — Placement veces 24 82.7 High Density Polyethylene (HDPE) Liner - Materials. evn 25 8.28 HDPE Liner Visual Inspections... 26 8.2.9 High Density Polyethylene (HDPE) Liner - Placement 26 8.2.10 Field Seaming — Liner Welding . 26 8.2.11 ANCHOR TRENCHES seeeaeenneness 31 8.2.12 LINER HOLD DOWNS 31 PIPING REQUIREMENT! 9.1 General 9.2 9.3. Manual Drains and Vents...10. 1. 12. 13. 9.5 Pipe Burials for Sheet flow and Fauna Crossings... 9.6 Creek Crossings / Flood Crossings. 9.7 Check Valves 9.8 Isolation Butterfly Valve: 9.9 Relief Valve: 9.10 Sample Points 9.11 Pond Fill Piping 9.12 Pump Suction Pipin 9.13 Pipework Pump Discharge to the Relief Valve 9.14 Hoses... 9.15 Pipe Supports. 36 . 36 PUMP REQUIREMENTS, 10.1 Pump General Requirements 10.2 Surface Protection... 10.2.1 Corrosion Protection - Painting ese 36 10.2.2 Corrosion Protection - Galvanising 37 10.3 Pump Testing 10.4 Installation and Commissioning .. 10.5 Pump selection. 10.6 Skid Mounted Diese! Pumps 10.7 Electric Fixed Vertical Turbine Pumps ... 10.8 Electric Skid Mounted Pumps... 10.9 Electric Plinth Mounted Pumps. 10.10 Floating Suctions / Floating pumps. 10.11 NPSH DIESEL GENERATORS DIESEL STORAGE AND PIPING 12.4 Diesel Fuel Pods 12.2. Diesel Pipi 12.3 Additional Diesel Bunding and Uprated Piping Specification.. INSTRUMENTATION...13.1 Flowmeters. 13.2 Pond Level Transmitters. 13.3. Pressure Transmitters 13.4 Diesel Motor Monitoring 13.5 Diesel Fuel Level Monitoring. 13.6 Instrumentation Cables 14, CONTROL, TELEMETRY AND SYSTEM INTEGRATION 14.4 Control Logic Overview 14.2 Alarms and Controls. 44.3 Pump Control and Monitoring. 15. | MAINTENANCE AND OPERATIONAL REQUIREMENTS 16. SURFACE WATER. 16.1 Footpath 16.2 Light Vehicle tracks 16.3 Safety Egress Netting 16.4 Flotation aids / Lifebuoys .. 16.5 Fencing... 16.6 Fire Protectior 16.7 Lightening Protection 16.8 _Lighting/lllumination... 16.9 Level Indication 16.10 Electrical and Control 17. COMMISSIONING REQUIREMENTS, 17.1. Dry Commissioning 17.2 Wet Commissioning 18. QUALITY. 18.1 Quality System .. 18.2 Shop and Site Access 18.3. Inspection and Test Plan 18.4 Hold Points 18.5 Audits. EE a18.6 Non-Conforman 49. SUPPLIER DATA. NN eeList of Tables Table 1: Definitions, Abbreviations and Acronyms Table 2: Standards and Codes. Table 3: Applicable Project Documents List Table 4: Clay Liner Material Properties Table 5: BIDIM A14 Geotextile Test Requirements Table 6: Smooth HDPE Geomembrane Test Requirements Table 7: Check Valve Material Requirements... Table 8: Butterfly Valve Material Requirements. Table 9: Relief Valve Material Requirements Table 10: Pump Materials Requirements Table 11: Pump and Structural Steel Painting Requirements1. SCOPE This specification covers the design and construction technical requirements for water ponds at FMG Facilties. This includes settlement ponds, transfer ponds, water storage ponds and standpipe turkey's nest. This scope covers civil, process, piping, liners, mechanical, electrical, instrumentation and associated fuel storage technical requirements. This specification provides specific technical requirements for the above items including design requirements, risk assessment, testing and commissioning, transport, quality assurance, and documentation This specification does not cover dams built for storage of mine tailings, or high risk water storage reservoirs which may require licenses or works approvals under DOW, DER, DMP or other Government Agencies. This specification does not cover bulk main pipe work after the agreed supply and discharge battery limits. This specification does not provide project management and commercial requirements, which are found in the Scope of Work and contractual documents. 11 Terminal Li 's /Battery Limits for this specification The terminal limits for the applicability of this specification shall be: © Existing ground surface ‘+ Agreed flange on the supply pipe(s). ‘© Agreed flange on the discharge pipe(s). «Telemetry signal transmission * Fuel fill point on diesel storage unit or * Electrical termination point for main electrical supply. 12 General The supplier shall provide the specified equipment or materials in accordance with the intent and the provisions of this specification and all other documents, codes, standards and requirements referred to or included in this specification. Obligations not expressly mentioned in the specification, but which are necessary for the satisfactory provision of complete and operational equipment or materials, ready to install and commission, shall be deemed to be included in the contract at no additional cost to the Principal. The supplier shall provide all resources and technology, processes, plant, equipment, materials and support facilities, necessary to enable the supplier to provide the specified equipment or materials to the purchaser, including without limitation engineering, planning, supply of material, temporary work, warehousing, labour, supervision, fixed equipment and plant, infrastructure, emergency and first aid facilities, tools, miscellaneous materials, minor parts, commissioning spares, communications, services and each and every item of expense, unless expressly excluded from the scope of supply in the provisions set out hereunder. All the supplier's works shall conform to the site data and project requirements, Equipment Data Sheets and supplier data requirements, equipment specifications, standard specifications and AY WET ><:current applicable standards adopted by Standards Australia, unless specifically instructed otherwise further in this specification All materials shall be new and of the best quality available for the purpose. Equipment shall be selected to ensure standardisation across the Principal's various operations where possible. 2. DEFINITIONS Table 1: Definitions, Abbreviations and Acronyms. Term AMSL aR BA DER MP ON Dow G Rating ‘DP. Geotextile ‘Geomembrane RI HOPE IF KPa MARV MMDD MPa NBR ome PN PREN Principal Shall Should ‘SMD Definition ‘Above Mean Sea Level California Bearing Ratio Decibels. -weighted Department of Environment Regulation Department of Mines and Petroleum Diameter nominal Department of Water ‘The geometric mean of the drop cone and CBR burst test results for a Geotextile Ground Disturbance Permit Nonwoven Geotextles High Density Polyethylene Liner Geosynthetic Research institute Density Polyethylene Issued for Construction Kilopascal Minimum average roll value Maximum modified dry density Megapascal ‘Newton Nitfile Butadiene Rubber (Optimum Moisture Content Pressure Number stance Equivalent Number Metals Group Ltd and their representatives Compulsory Optional Standard Maximum Dry DensityEF REFERENCE DOCUMENTS. Equipment shall be supplied in conformance to the following standards and project documents. In the case of conflicting information the Principal must be advised. However, the following precedence shall apply: Contract and Scope of work Equipment Data Sheets This Engineering Specifications Site Data Sheet Standard Engineering Drawings Standards and Codes PAerona 3.1 Standards and Codes The supplier shall conform to all of the currently published applicable Australian standards and also the additional standards and codes nominated below. Where no Australian standard exists, clarification shall be sought from the Principal. Table 2: Standards and Codes Document No. Title AS 1144 Methods for sampling and testing aggregates _ As 1182 Speccaton or Test Steves “AS 1200 _| Occupational nose management AS 12890 Method of Testing Sol or Engnesng Puposea ~ General equrement ad lal f mnths 751289601 Metreds for etn sole for engineering purposes ~ Method 6.9.4: Sol Svengh and Consolidation Test — Determination of stiffness of soil - Clegg Impact Value (CIV) AS14709 Heath and sey at wrk — pines end precios AS 1554.1 - ‘Structural steel welding — Welding of steel structures a8 1728 Geotecnial te vestigations AS 17022 Manual of unform Wa contol deve ~ va antl dvies fr general use “A82700 | Color stands for general pupese8 _ “as 3000 Eleccalinstaltions “as 3008 Eleciclistalaions- Seleaon of cables - Cables for alemaing vatagos upto and ineuclng 06" KV. Typeat hustler nsaision condone AS 3500 National plumbing and drainage - 7 AS 3705 Gectetle specication 78 3708: Geotetles ~ Mtrads afta = General reurements “A837084 | Geoestles ~ Methods of test ~ Determination af bust svorah a AS37085 Geoteiles~ Methods oftest~ Determination of puncture resistance AS 3706.6 | Geotextiles - Methods of test - Determination of seam strength AS 3798 Guidelines on Earthworks fr Conmercl and Residenel Developments AS 3782 Acoustics NeDocument No. Title ‘ASINZ 3905.2 Quality systems guidelines ‘AS 3990 Mechanical Equipment ~ Steelwork ‘AS 4024.1 Safety of machinery — (Includes all elated codes in 4024 series) AS 4687 ‘Temporary Fencing and hoarding ‘ASINZS ISO 8001 ‘Quality management systems — Requirements ASINZS ISO 9002 ‘Quality systems ~ Model for quality assurance in production. Installation and servicing ASME B16.5 Pipe Flanges and Flanged Fittings ‘ASME 831.3 Process Piping ‘ASNT SNT-TC-1A Personnel Qualification and Certification in Nondestructive Testing ASTIN 792 Density and Specific Gravity of Plastics by Displacement ‘ASTM 1004 Test Method for intial Tear Resistance of Plastic Fs and Sheeting ‘ASTM D 1805 Density of Plastics by the Density-Gradient Technique ‘ASTM D 4218, “Test Method for Determination of Carbon Black Content in Poiyethylene Compounds by Muffle-Fumace Technique ‘ASTM D 4595 ‘Standard Test Method for Tensile Properties of Geotextiles by the Wide - Width Strip Method astmo4s73 | Standard Guide or detfcaton, Storage and Handing of Geosynthetics Ros and samples ASTMD 5261 __| Standard Test Method for Measuring Mass per Unit Area of Geotextiles ‘ASTM D 6392 Determining the Integrity of Non-reinforced Geomembrane Seams Produced Using Thermo-fusing Methods ‘ASTM D 6693, “Test Method for Determining Tensile Properties of Non-reinforced Polyethylene and Non-reinforced Flexible Polypropylene Geomembranes ‘AGPTO4G/09 ‘Austroads Guide to Pavement Technology Part 4G: Geotextles and Geogrids AWS D1.1 | Structural Welding Code — Stee! _ ASTM E1444 ‘Standard Practice for Magnetic Particle Testing DIN EN 10168 Steel products - Inspection documents - List of information and description DIN EN 10204 Metallic products - Types of inspection documents GRI Test Method GM13 | Test Methods, Test Properties and Testing Frequency for High Density Polyethylene (HDPE) Smooth and Textured Geomembranes MRWA Specification 602. | Guide posts 3.2 Applicable Project Documents In addition to the Equipment Data Sheets listed in section 1.1, the following project documents shall apply, it should be noted that this is not a comprehensive list of the Principal's Policies and Procedures, Table 3: Applicable Project Documents List Site Data Sheet Title of Document 45-FL-SA-0002 Contractor Mobilization Flow Chat 45-PLEN-0018 Borrow Pit Management Plan 45-STWWM-0002 Standard Engineering Specification for Dewatering infrastructure Fortescue ec) a aSite Data Sheet Title of Document 100-DS-£6-0001 Site Data Sheet 100-MA-SA-0004 Health and Safety Management Systern Manual 100-PR-PM-0013 Safely n Design Procedure 100-PL-CT-0001 Minimum Requirements for Contractors - HSES 100-PL-EN-1000 Corporate - Groundwater Management Plan — Rall, Port and Mine Plan 100-PL-EN-1017 Weed Management Plan 1100-PO-EN-0001 Policy - Environment 4100-PR-OP-1005 Packing, Marking and Documentation Specification 100-PR-EN-0004 Ground Disturbance Permits 100-PR-OP-0010 Standard Specification for Supply of Manuals 100-PR-SA-0068 Standard Engineering Specification Gycione Zones and Securing Infrastructure 100-S°-ci-0002 Road Design for Projects 100-SP-CI-0003, Standard Engineering Specification for Concrete 100-SP-CI-0004 Standard Engineering Specification for Drainage and Flood Protection 100-SP.Ci-000; ‘Standard Engineering Specification for Site Earthworks Construction 100-SP-C1-0009 __| Standard Engineering Specification for Roadworks 100-SP.C1-0010 Road Design, Construction and Maintenance 100-SP-0¢-0002 Vendor Data Requirements Specification 100-SP-EL-0009 Preferred Electrical Equipment 4100-SP-EL-0013 ‘Standard Engineering Specifications — LV Induction Motors 100-SP-IN-0001 ‘Standard Engineering Specification — Preferred instrumentation Equipment 4100-SP-IN-0002 ‘Standard Engineering Specification for Control & Instrument Design Criteria 100-SP-ME-0002 Standard Engineering Specification for Mechanical Equipment 100-SP-ME-0008 ‘Standard Engineering Specification for General Guarding Requirements 100-SP-ST-0004 Standard Engineering Specification for Protective Coating Systems ~ Painting 100-SP-P1-0001 Standard Engineering Specification Pipe Work and Valves S0080.00000-PR-EN- | PROCEDURE - Solomon Projects Fauna nur, Relocation and Euthanasia §0050-00000-PR-EN- | PROCEDURE - Solomon Projects - Fauna Egress Monon 4. GENERAL REQUIREMENTS The equipment and all major components shall be designed for operation in an environment as specified in the Site Data Sheet (100-DS-EG-0001 The pond and equipment shall comply with the pond datasheet as approved by FMG. The equipment shall be supplied as a complete and functional unit. It shall include all auxiliary equipment necessary for complete operation. The ponds and equipment shall incorporate standard and proven designs and the Supplier shall not deviate from this philosophy where practicable. The Supplier shall highlight any specific sections within this specification that force the Supplier away from standard or proven designs. Preference shall be given to equipment for which the Supplier carries an adequate supply of spare parts. Standard replacement / spare parts shall be readily available within Australia, NN ee)Equipment design shall facilitate ease of access for handling, transportation, installation, adjustment, control, maintenance and repair. All components requiring regular replacement, inspection and adjustment shall be readily accessible with minimum dismantling, The Supplier shall include all special tools required for assembly, erection and maintenance. Special tools shall be itemised in the tender and a brief description of the purpose of each tool shall be given. The equipment shall be designed to eliminate or minimise corrosion. The manufacturer and origin of all main components shall be approved by the Principal Metric bolts shall be used, unless otherwise approved by the Principal. Bolts or screws assembled into tapped holes shall have an approved thread locking compound applied to them. 4. Design and Design Changes The design calculations and drawings shall be formally approved and issued for construction by FMG prior to construction commencing All design changes shall be formally communicated to FMG. 42 Risk Assessment and Risk Control Risk assessment shall be conducted by the contractor at all stages of the design. Design shall generally comply with the FMG requirements for safety in design 100-PR-PM-0013. As a minimum the following risk control activities must be included: 4.2.1 __Design/HAZOP style risk assessment Prior to commencement of this risk assessment the following documents shall be signed off: Piping and instrumentation Drawing (P&ID) including all finalised instruments. General Arrangement Drawing Process control philosophy document Alarm and Control Table Instrument selection finalised The risk assessment and associated actions shall be documented and approved by FMG. 4.2.2 Construction Risk Assessment / CRAW Prior to commencement of construction a CRAW shall be completed. Issued for Fabrication (IFC) drawings shall be available prior to conduct of the CRAW. 43 Noise Noise levels for equipment need to be determined from the context in which they will operate. Noise exposure limits shall be determined in accordance with Australian Standard AS 1269: ‘Occupational noise management - Overview and general requirements, and the mines regulations, Noise exposure limits shall be based on 12 hour shifts. NAAs per the mines regulation Div 1 part 7.4 noise shall be reduced as far as practicable. A noise report (as defined in the mines regulations) shall be performed during the commissioning of a new pond. Noise levels shall be measured as per AS1269.1: Occupational noise management - Measurement and assessment of noise immission and exposure and AS3782: Statistical methods for determining and verifying stated noise emission values of machinery and equipment In addition to consideration of noise levels within a facility, noise levels at the plant boundary must also meet operating license requirements For equipment that is part of or adjacent to accommodation units in camps the equipment noise levels will need to be set to achieve acceptable levels for personnel to sleep at any hour of the day or night 44 Guards Equipment design, construction of guards, sheet and wire mesh sizes, clearance distances and other relevant details shall be in accordance to the 100-SP-ME-0003:Standard Engineering Specification for General Guarding Requirements, AS 4024.1: Safety of Machinery and shall satisfy the statutory authorities having jurisdiction All moving components shall be guarded with safety guards requiring a tool for removal. Guards shall allow visual inspection and thermal imaging during operation without constituting a hazard, Guard sections removable by hand must not exceed twenty (20) kilograms, unless approved by the Principal in writing, 5. POND SIZING AND PROCESS REQUIREMENTS 5.1 Flow Rates and Pressures Ponds shall be capable of receiving the maximum inflow rate as specified in the data sheet. Ponds shall be capable of delivering the minimum and maximum out-flow rate as specified in the data sheet at the discharge pressure specified on the data sheet at the battery limit of the discharge piping for the pond. Where an overflow weir is specified the weir shall be capable of discharging through the overflow a flow rate equal to the maximum inflow rate to the pond. Where the discharge pumps are capable of exceeding the design pressure of the discharge pipework at least one relief valve shall be provided. The relief valve(s) shall be capable of discharging the full flow that the pumps are capable of delivering in accordance with any margins as specified in the piping code. 5.2___ Water Storage Volume Ponds shall have a normal water storage volume exceeding that specified on the data sheet. This effective volume shall not include any freeboard required to prevent over topping, or dead volume below the minimum water suction level for pump suction. If an “emergency" water storage volume is specified then the effective volume between the High High level and the over toping level shall exceed this volume. Ww Fortescue tteIf an “alarm response” water storage volume is specified then the effective volume between the High alarm level and the High High alarm level shall exceed this volume. If an “operating contingency- fil” water storage volume is specified then the effective volume between the normal operating level and the High alarm level shall exceed this volume. tf an “operating contingency-drain’ water storage volume is specified then the effective volume between the normal operating level and the low alarm level shall exceed this volume. Consideration shall be made to the fill times for the “emergency’, “alarm response” and operating contingency fill and drain water volumes. 5.3 Solids Settling Rates and Calculations This section only applies if the pond has a settling function, it does not apply to storage ponds with no settling requirements specified. The solids settling rate shall be calculated using stokes law for particles larger than 100 micron. For particles smaller than 50 micron Newtonian drag shall be calculated. For particles between 50 and 100 micron settling rates can be interpolated between Stokes and Newtonian. Settling calculations shall have a safety factor added of not less than 30%. For settling rate calculations a solids density of 2800kg/m3 shall be used. The liquid density shall be as per the data sheet. If not specified a value of 1070kg/m3 may be used For settling rate calculations the water viscosity shall be as specified on the data sheet. Where a specific solids settling requirement is specified on the datasheet then the pond shall be sized to achieve this settiing rate. 5.4 Solids Storage Volume The solids storage volume of the pond shall be maximised for settling ponds. The solids storage volume shall exceed that specified on the datasheet, but shall not be less than 6 months of normal operation at the specified nominal flow rate and solids loading. Settling ponds shall have at least one weir (two weirs are preferred) to prevent solids migrating to the pump suction sumps. The solids storage volume shall be calculated assuming solids settle in a horizontal manner with a "beaching slope" of not greater than 1:1000 being assumed. The solids storage volume calculated shall be such that solids cannot be entrained into the pump suction strainer. For settling ponds floating suction or elevated suctions are preferred to prevent solids being entrained in the pump suction piping. 5.5 Solids migration Weirs Settling ponds shalll have at least one solids migration weir (preferably two, coarse and fine) ‘Solids migration weir heights shall not exceed the normal operating water level of the pond, Weir flow rates shall be calculated using a recognised method and calculations shall be provided for review by FMG prior to construction. Solids migration weir flow rates shall not exceed an average water velocity of 0.1m/s under any circumstances, 5.6 __ Solids Clean out Arrangements for Specified Settling Ponds Fortescue atThis section only applies if specified on the datasheet. Settling ponds with possible high solids loads, such as tailing decant return ponds, shall have some permanent solids clean out arrangements in place to minimise downtime associated with solids events. Where this is specified the solids storage areas shall have a continuous slope towards a cleanout sump. The sump shall be suitable for cleanout with a water hoses and a solids handling sump pump. HDPE liners shall be double thickness in the solids cleanout sump. These settling ponds shall have at least two DN150 tees with bind flanges and an isolation valve to enable clean out with standard fire pump booster setup from the supply water system, The two flanged connections shall be on the opposite side of the pond to the solids handling sump. 5.7___Spillway Weirs Spillway flow rates shall be calculated using a recognised method and calculations shall be provided for review by FMG prior to construction. 6. POND CIVIL REQUIREMENTS Earthworks specified in this section shall be in accordance with 100-SP-CI-0007 - FMG. Standard Engineering Specification for Site Earthworks Construction. Where necessary or as directed by the Principal, the Contractor will be responsible for constructing and maintaining a temporary safety windrow on crests to eliminate open edges during construction. Windrows will have a minimum height of 4 the wheel height of the largest plant operating in the area. Any clearing and topsoil stripping that the Contractor elects to perform for his own purposes, such as for constructing temporary haul roads, equipment yard, etc. shall be subject to the approval of the Principal and shall be performed at the Contractor's own expense. At the end of the Contract, all such areas shall be reinstated and rehabilitated by the Contractor, at his own expense, to meet the Principal's requirements and environmental obligations. The Contractor shall provide, maintain and operate, any temporary drainage and/or pumping facilities required to dispose of water in order to keep the excavations dry and stable during the construction phase. Any reworking of materials affected by lack of the above controls shall be at the Contractor's expense. Disposal of the water removed from excavations will take place at the discretion of the Principal. All earthworks shall be suitably maintained during the construction period to minimize the effect of inclement weather. 6. Setting Out of the Works The contractor shall be responsible for setting out all of the works on site in accordance with the contract documents and tolerances stated. The contractor shall provide all survey stakes, ancillaries and consumables. 6.2 Pond Batters Pond batter slopes shall be smoothly shaped to a uniform plane from top to bottom and shall generally not exceed a slope gradient of 33% or 1V:3H. This is intended to ensure that pond batter slopes are accessible, can be properly compacted and lined, are maintainable and that erosion risk due to stormwater run-off velocity is minimized.The batters shall be placed, prepared and compacted in accordance with the Technical Specification for Earthworks. Where necessary, the embankment shall be overfilled, compacted and then cut back or trimmed to the final geometry to ensure that poorly compacted material is not left exposed on the batters of the embankment. 6.3 Clearing and Grubbing Clearing Works shall comply with the relevant Ground Disturbance Permit (GDP) or LUC and be completed in accordance with FMG's best practice. The area of clearing and grubbing shall extend a minimum of 3m beyond the pian area of the, Works as shown on project drawings unless otherwise indicated. Along the length of all proposed new permanent access roads, clearing and grubbing shall be undertaken to a horizontal width of 15m minimum unless otherwise instructed. The area of clearing and grubbing shall be kept to the minimum required to complete the Works All trees, bushes and other vegetable matter shall be stockpiled at a location agreed to by the Principal. The vegetation stockpile shall not exceed 2m in height or have side slopes steeper than 1:3 (V:H). Grubbing shall be carried out for the full extent of areas specified on project drawings or as directed by the Principal. Grubbing can be defined as the removal of all stumps and roots, greater than 100mm in diameter, to a depth of 600mm below the natural or final finished surface, and all other vegetation and boulders (particles greater than 200mm in diameter) to a depth of 300mm below the natural surface. The debris, together with all roots, shall be deposited in the stockpile areas nominated by the Principal. Subsequent Works shall not commence until approval has been given by the Principal (hold point) 6.4 Topsoil Removal Topsoil, for the purpose of this Specification, shall be defined as soil of any gradation or degree of plasticity which contains significant quantities of visually identifiable vegetable matter, sod, roots or humus. Stripping means the removal of all topsoil to a maximum depth of 300 mm. On completion of vegetation clearing the topsoil shall be stripped and removed from the Work area to the approval of the Operational Projects team. The stripped topsoil shall be placed in stockpiles not exceeding 2m in height at a location agreed to by the Principal. Side slopes shall not be steeper than 1:3 (V: H). 6.5 Site-Foundation Preparation Following clearing and grubbing and topsoil stripping, all soft spots and unsuitable areas shall be identified and these areas excavated and backfilled with general fill materials and compacted using normal procedures in accordance with the Principal's Earthworks Specification. All unsuitable material removed by the Contractor shall be stockpiled in areas nominated by the Principal. Prior to fill placement, the existing surface shall be ripped to a depth of 200mm, moisture conditioned to +2% of Optimum Moisture Content (OMC), and proof rolled/compacted to minimum 92% of Standard Maximum Dry Density (SMDD). Upon compietion of the foundation preparation the ground surface is to be trimmed to a smooth surface free from cavities and projecting rocks and all areas to receive fill shall be left in a clean and suitable condition to allow an uninterrupted placement of fill. No fll shall be placed until the base of the prepared surface has been inspected and approved by the Principal. Fortescue Bt6.6 Excavation Prior to carrying out any excavation or penetration of the ground, the Contractor shall ensure that a current, approved GDP is in place. All excavations shall be free draining and fall to the nominated outlets without obstruction. The stability of each excavation shall be assessed and managed with regard to personnel safety, equipment, existing services, nearby buildings, structures etc. All excavations shall be maintained in safe condition for the duration of the works, including the erection of suitable safety barricades, warning signs and hazard lights, if required. All excavations shall be kept free and clean of loose material, water and rubbish. All reasonable efforts shall be made to divert or otherwise control any surface and ground water to ensure that runoff or impounded water does not damage or affect the works. Excavated material that is unsuitable for backfilling or other filling requirements, or is otherwise not required for re-use in the works, shall be removed from the site and disposed of at an approved spoil site. All rock excavations and blasting shall be carried out in accordance with 100-SP-Cl-0007 FMG Standard Engineering Specification for Site Earthworks Construction. ‘The extent of the rock area shall be agreed between the Contractor and the Principal, before any excavation or blasting of rock is to commence. ‘Once the classification of rock has been agreed with the Principal, the surface of the rock shall be exposed and surveyed by the Contractor. 6.7 Backfill AIL ill is expected to be sourced from excavations within the pond or GDP footprint area. Borrow pits if required and approved by the Principal shall be opened, maintained, operated and restored in accordance with 100-SP-C!-0007: FMG Standard Engineering Specification for Site Earthworks Construction, 6.8 Pond Construction 6.8.1 General Construction and compaction of pond walls shall be to the lines, grades and dimensions as specified on the construction drawings. Al fill shall consist of well-graded material free of organics, trash, clay balls or other deleterious material. The pond subgrade shall be compacted in accordance with these specifications and the IFC drawings. The subgrade shall be protected from desiccation prior to the placement of liner. Protection, if required, may consist of a thick plastic protective cover installed over the sub grade. Subgrades found to have desiccation cracks greater than 10mm in width or depth, or which exhibit swelling, heaving or other similar conditions shall be replaced or reworked prior to liner installation. 6.8.2 Compaction It shall be the Contractors responsibility to assess the compaction effort needed to meet the requirements of this specification and to select suitable methods and provide appropriate equipment capable of achieving those requirements. If at any time during the progress of the works, tests performed by the Principal or Contractor indicate the specified degree of A WEE +compaction is not being achieved, the Contractor's equipment and/or methods shall be replaced or modified to obtain the specified compaction. Construction of the pond embankments shall use loose lifts not exceeding 350mm in height and shall be compacted be to a minimum dry density as stated on the IFC drawings or 100-SP-Cl- 0007: Standard Specification for Site Earthworks Construction. The lifts shall be compacted though out their entire depth to achieve the required density for the full depth of the lif. Testing of the backfill lifts after compaction shall be using Clegg Hammer and testing shall be in accordance with AS1289.6.9.1: Methods of testing soils for engineering purposes - Soil strength and consolidation test Determination of stiffness of soil 6.9 Burial of Pipe through pond walls. Where specified on the IFC drawings, HDPE pipes shall be direct buried through the pond walls during construction. All pipe buried through pond walls shall be a minimum pressure rating of PN12.5. This section of pipe shall be vacuum tested prior to back filing The pipe shall be laid on a prepared pipe bedding of sand or fine <6mm particle size select fill material. The pipe shall be backfilled with cement stabilised material consisting of base course material or other suitable approved material by the Principal. Cement shall be in proportion of 100kg of type GP Portland Cement to one cubic meter of un-compacted backfill material. Water used for cement stabilization shall be clean and potable. The stabilized material shall be placed to. amaximum height of 300mm above the pipes obvert and 300mm either side. 6.10 _Spillways Spillways shall be provided with a rock fill apron constructed in accordance with the details included on the IFC drawings. Non-woven geotextile fabric (e.g. BIDIM A14) shall be placed on the prepared spillway formation to separate the embankment fils from the rock armour. Geotextile fabrics are discussed in greater detail under the pond lining section of this specification The source rock for the spillway protection shall consist of clean, sound, durable and hard rock. The rock used shall be fresh to slightly weathered and of very high to extremely high strength, as defined in AS1726. Rock that is laminated, fractured, porous or otherwise physically weak is unacceptable. Flat slab-like rock pieces, with the breadth or thickness less than one third its length, should be avoided due to poor interlocking and easy dislodgement by water flow. Unless otherwise indicated on the IFC drawings, the rock protection is to meet the size requirements for Facing Class Rock provided in Table 7 of 100-SP-CI-0007: Standard Specification for Site Earthworks Construction All rock shall be placed to the minimum thickness and height indicated on the IFC drawings. Unless otherwise indicated the thickness of the rock layer shall be equal to Dyax of the facing class rock. All rock shall be placed by excavator with bucket in such a manner that the rock rests firmly upon and does not displace the underlying material. The rock shall be interlocked by mechanical compaction. The methods proposed for placing and dressing shall require approval of the Principal. Any segregation of coarse and fine rock fractions shall be rectified to preserve the specified grading in place. Facing Class rock shall be individually placed so that it rests firmly against at least three other rocks in the same layer. Rock shall be placed progressively along the face of the protection. 6.11 __ Conveyor Belt at High Wear Points NN ee‘When conveyor belting is specified for protecting high wear areas such as at the inlet pipe to prevent wearing of HDPE liner the used belting will be supplied by the Principal unless otherwise specified. The contractor shall provide at least 2 months’ notice of conveyor belt requirements, and specify the width, length required and the location for drop off. 6.12 __Dust Suppression Dust suppression measures shall be implemented on all earthworks, tracks, roads, borrow! spoil areas and construction areas at all times during construction to minimise airborne dust and the hazard and nuisance to personnel on the site. Water will be provided by the Principal unless otherwise specified i CONCRETE All conerete shall comply with FMG specification 100-SP-CI-0003 : Standard Engineering Specification for Concrete CSS-0003. 8. POND LINING All Water Ponds shall be constructed with an appropriate liner that minimizes leakage, the main liner categories include clay lining and HDPE liner systems. This specification does not cover geosynthetic clay lining (GCL). 81 Clay ers The swelling and hydraulic conductivity of clays are highly dependent on the pore fluid and in general as salinity increases the permeability of clays may also increase. Under brackish and saline conditions the efficiency and suitability of in-situ or imported clay materials for use as a liner will need to be properly investigated, clay liners shall only be installed when they are specified in the IFC design documents. The work shall consist of compacting clay soil to construct a soil liner to control seepage in a Water Pond 8.1.1 Materials Unless otherwise specified, the clay soil shall be in-situ materials or clay soils from a designated borrow source. The clay soils should be well graded, of low permeability and conform to the particle size distribution, plasticity index and other characteristics listed in Table 4. The clay soils shall contain no organic materials such as roots, vegetation, manure or other perishable materials Table 4: Clay Liner Material Properties ter ‘Acceptance Criter Particles passing 53mm sieve | 100% Particles passing 19mm sieve | > 90% Particles passing 236mm sieve | > 70% Particles passing 0.076 mm sieve | > 30% Maximum Particle 40mm _ Plasticity Index > 10% and above Casagrande A ine Ligui Limit 30 to 60% _ Pa ANtern (eceptance Criteria Permeability 1x 10% misec Emerson Glass Number 4 Dry Density 95% Moisture Content 0% to +3% of Optimum 8.1.2 Sub Grade Preparation All sub-grade surfaces shall be finished smooth and free of surface rocks larger than 25mm in diameter, stones, sticks, roots, sharp objects and debris of any kind. The surface is to provide a firm unyielding foundation, with no sudden changes in grade. No standing water or excessive moisture shall be present. Also if water is encountered while preparing earthworks, the site should be dewatered and dried to an appropriate level before being lined with clay. Compaction shall be in accordance with 100-SP-CI-0007: Standard Specification for Site Earthworks Construction 8.1.3 Clay Liner Placement Unless specified otherwise in the IFC documents, the compacted clay liner must have a minimum thickness of 300 mm and shall be placed in two compacted lifts of 150 mm each. Compaction and permeability requirements following compaction are listed in Table 4. In no case shall the moisture content be allowed to drop below the specified minimum level at the time of compaction. Compaction shall be achieved through the use of pad footed rollers, An effective bond should be created between successive layers. Prior to placement of each layer the surface of the previous layer should be scarified and moisture conditioned if necessary, to bond the layers to prevent laminations at the layer interface. The final surface should be smooth and evenly graded and the finished liner thickness must be surveyed to confirm it meets the design specifications and be tested in-situ to ensure that it meets the specified permeability criteria (AS: 1289 6.7.3). Clay lining should be maintained to avoid desiccation during construction. A protective cover of soil, if required, shall be applied to the surface of the compacted clay liner as soon as practical after the uppermost has been compacted. Compaction and moisture content of the protective layer shall be as specified on the IFC drawings 8.2___High Density Polyethylene (HDPE) Liner System 8.2.1 General When pond liners are indicated on the drawings, the material used shall be black HDPE that conforms to the Geosynthetic Research Institute (GRI) Test Method GM13. The Contractor shall submit certified test results and statements of quality for the proposed HDPE liner to the Principal, indicating without exception that the proposed liner meets the requirements of GM13 as presented in this specification Geosynthetics shall be supplied, handled, stored and installed in conformance to: ‘Australian Standards (refer to applicable standards listed in Table 2) or other listed standards; «The manufacturer's recommendations; and NN es* Requirements indicated on the drawings. ‘The geosynthetics manufacturer shall be a specialist in the manufacture of geosynthetics with at least 5 years of experience in the production of geosynthetic products and shall have earned ISO 9002 certification for its quality management system of manufacturing for all processes from base resin through finished product. Unless otherwise indicated on the drawings, when HDPE pond liners are used they shall be placed on: + Prepared sub grade; Beading course; and © Geo-fabric. 8.2.2 Extending HDPE Lining over batters The HDPE liner may be extended over the batters if required to mitigate the risk of batter erosion where batters are poorly constructed. In this case the risk of UV degradation reducing the effective pond life shall be assessed and controlled. Where this is done a safety hazard of slippage shall be actively managed, 8.2.3 Sub Grade Preparation Alll sub-grade surfaces shall be finished smooth and free of surface rocks larger than 6mm in diameter, stones, sticks, roots, sharp objects and debris of any kind. The surface is to provide a firm unyielding foundation, with no sudden changes in grade. No standing water or excessive moisture shall be present. Compaction shall be in accordance with 100-SP-CI-0007: Standard Specification for Site Earthworks Construction, 8.2.4 Bedding Material The bedding course shall consist of granular material, loam or sandy clay, free of organic matter and coarse or sharp particles. The bedding course shall have a minimum thickness of 150mm over any irregularities or protrusions in the subgrade formation, unless shown otherwise on the drawings. The surface shall be watered and rolled with a steel drum roller to obtain a smooth uniform finish. All intersections between planes shall be made along straight lines. Particular attention shall be paid to achieving adequate subgrade compaction adjacent to pipe penetrations, structures and in corners where mechanical plant cannot be effectively deployed The Earthworks Contractor shall seek approval from the Principal's Representative prior to the installation of the geo fabric. Compaction shall be in accordance with 100-SP-CI-0007: Standard Specification for Site Earthworks Construction, 8.2.5 Liner System Installation Preparation Fortescue it}Prior to installation of the liner system, a site inspection of the pond site shall be conducted to verify the measurements, structures and surface conditions to support the liner system. The Contractor shall provide written documentation that the pond floor and embankments surfaces have been inspected and are acceptable for installation of the liner system. Each panel used for the installation shall be given an identifier consistent with the drawings and linked with the roll numbers. Liner panels shall be of such length and width, and laid out in a manner to reduce field seaming to a minimum. 8.2.6 Non-Woven Geotextiles - Materials This section details the technical requirements for the supply of non-woven needle punched Geotextiles for use as underlayment between the prepared subgrade and the geomembrane in a pond liner system. The materials supplied and the installation performed shall be in accordance with these requirements and to the drawings. The Geotextile shall be manufactured under a Quality Management System that is 3° party certified to !SO 9001 Standards. The fibres of the Geotextile shall consist of long chain synthetic polymers composed of at least 95% by mass of polyolefins or polyesters. Geotextile filaments shall be rot-proof, chemically ‘stable and with low water absorbency and shall be resistant to UV degradation, biological and chemical environments normally encountered in soils. Filaments shall resist delamination and maintain their relative dimensional stabilty in the Geotextile. Coatings or protection layers should in no way reduce the strength, flexibility or elongation characteristics of the base material. The Geotextile shall have filaments bonded by the needle punching process. The Geotextile shail be free of any flaws, which may have an adverse effect on the physical and mechanical properties of the Geotextile. The Geotextile for use in a pond liner system shall be BIDIM A14 or equal meeting the mechanical and hydraulic properties indicated in Table 4. Unless otherwise indicated the strength parameters are expressed for machine direction and cross machine direction (XD/XMD) and all values in the Table are the minimum required mean average roll values (MARV) or otherwise indicated. Table 5: BIDIM A14 Geotextile Test Requirements Property ‘Method Test Value Mass 'AS3706.1/ASTM 05261 3140 gi? Wide Strip Tensile Strength | AS3706.2-00 11.009.5 KNIm Trapezoidal Tear Strength | AS3706.3-00 3007270 N ‘CBR Burst Strength 'AS3708.401 1720N “Grab Tensile Strength | AS2001.2.3 “| 7201650 N G Rating ‘Austroads AGPTOAGIOG 15006 Pore Size ‘AS3708.7-80 <110 um Permitivity 'AS3706.0-01 2.3587 Coeficiont of Permeability | AS3706.9.01 33 mis Flow Rate @ 100mm Head | AS3706.9.01 236 us 8.2.7 Non-Woven Geotextiles — Placement Fortescue it}The Geotextile shall be placed, installed, jointed and anchored as shown on the drawings and to the manufacturer's installation guidelines with approved modifications to account for site- specific conditions. Handling of the Geotextile shall be minimised to ensure it retains its form and shape. The Geotextile is not to be stretched tight but allowed to conform to the underlying profile of the prepared ground; The Geotextile shall be laid smooth without wrinkles or folds and secured with anchor pins; Where stitched joints are used the seam efficiency shall be a minimum of 80% of the un- seamed strength, in both the machine and cross machine directions, determined in accordance with AS 3706.6; Placement and overlapping shall be in accordance with the manufacturer's recommendations. The overlap shall be a minimum of 900mm; The Geotextile width may be specified to minimize installation concerns around overlapping or seaming. It is recommended the widest Geotextile available be used, consistent with the project layout; Where lapping with concrete structures is required, the Geotextile shall be properly anchored adjacent to the concrete structure in accordance with the Drawings or to the manufacturer's recommendations. Where this is not possible a minimum overlap of 900mm is to be used; Overlying material is to be placed so as to not damage the Geotextile under layer. Rocks and other coarse material are not to be dropped onto the Geotextile from a height greater than 500mm; and ‘+ Geotextile that has been displaced or damaged during placement of the overlaying material shall be re-installed at the cost of the Contractor. 8.2.8 High Density Polyethylene (HDPE) Liner - Materials The pond liner membranes shall be black polymer HDPE containing carbon black that is homogeneously distributed throughout the membrane. The material shall be manufactured for durability with high temperature and high UV resistance and shall be manufactured under a Quality Management System that is 3" party certified to ISO 9001 Standards. Unless otherwise indicated on the drawings, the pond liner is to be smooth surfaced 1.5 mm smooth HDPE geomembrane, free of any flaws which may have an adverse effect on the physical and mechanical properties of the liner. ‘The physical and mechanical properties of the liner material shall comply with the values in Table 3, it should be noted that unless otherwise noted these are minimum average values. Table 6: Smooth HOPE Geomembrane Test Requirements T TestValue Minimum Density ‘ASTM 01505 or D792 0.940 glee | ASTM D1238 (190°C/2. 16g) 0.59/10 minutes Yield Strength ‘ASTM 06693 Type IV 22 kNim - Break Strength ‘ASTM 06693 Type IV 40 kNim — Yield Elongation ‘ASTM 08693 Type lV | 12% Break Elongation ‘ASTM 08693 Type IV 700% Modulus of Elasticity ASTM D882 550 MPa Tear Resistance (initiation) | ASTM D1004 187N Fortescue meProperty Test Method] Test Value Puncture Resistance ‘ASTM 04833, 320N Carbon Black Content ‘ASTM 01603, 2.0% min Material thickness measured in accordance with ASTM D 1593 shall be within + 10% of the specified value at any point, and within +10% - 0 average for any roll The liner shall be of new, first quality products and shall be designed and manufactured specifically for the purpose of this work. It shall have been satisfactorily demonstrated by prior use to be suitable and durable for such purpose. The liner material shall be uniform in colour, thickness, size and surface texture. The liner shall be supplied as a single ply continuous sheet with no factory seams. The liner roll length and width should be maximised to provide the largest manageable sheet for the fewest field seams. ‘The HDPE liner shall be produced free of holes, blisters, undispersed raw material or contamination by foreign matter. 8.2.9 HDPE Liner Visual Inspections The Contractor shall inspect all liner materials prior to use. 8.2.10 _ High Density Polyethylene (HDPE) Liner - Placement The HOPE liner shall be placed, installed, welded and anchored as shown on the drawings and to the manufacturer's installation guidelines with approved modifications to account for site- specific conditions. Handling of the HDPE liner shall be minimised to ensure it retains its form and shape. Information related to panel placement including date, time, panel number, roll number, panel dimensions and location must be recorded on a Panel Placement form; Any panels installed in locations other than that shown on the panel layout drawing shall be indicated and marked up on the “As-Constructed’ drawings; The liner shall be anchored and sealed to structures and other types of penetrations in accordance with approved plans, drawings and details prepared by the Contractor; Sand bags shall be positioned during the liner placement to prevent uplift due to wind Sandbags shall be plastic or close-knit fabric to preclude leakage of fines. Paper bags shall not be permitted and burlap bags must be lined with plastic. Bags shall contain not less than 18kg nor more than 27kg of sand having 100 percent passing a no 8 sieve (2.36mm) and closed with plastic ties. Bags that are split, tom or otherwise losing their content shall be removed from the work area and any spills cleaned up; Cleaning solvents may not be used unless the product is approved by the liner manufacturer; and Slightly rounded corners shall be provided in accordance with the manufacturer's requirements to avoid sharp bends in the geomembrane. 8.2.11 Field Seaming - Liner Welding All seaming of liners shall be carried out strictly in accordance with the manufacturer's written instructions and by a suitably qualified or accredited person. The Contractor shall provide a complete method statement detailing the proposed methods, liner panel size and configuration, types of seaming used, their applications and the equipment used to carry out the seaming. The liner panel size and configuration shall provide for the minimum number of seams. NN ee‘Supervision and Personnel Before commencing the work, the Contractor shall demonstrate that the selected welding supervisor has a proven background in installation of lining systems and materials similar to those specified, ‘+ The supervisor shall be responsible to administer the Contractor's quality assurance programme; ‘© The supervisor will verify that the welding technicians are following proper welding procedures; + No seaming shall be carried out without direct supervision; and * All personnel employed in welding shall be experienced in the use of the equipment. Seam Welding Equipment Field seams between liner panels shall be made using approved welding systems, equipment and techniques. Acceptable welding systems include extrusion fillet welding and fusion welding equipment approved by the liner manufacturer and the Principal. For long continuous welding, the machine shall be mounted on a carriage to operate at controlled speed. The carriage wheels shall be such that they do not compromise the integrity of the liner. In all cases, the temperature at the point of fusion shall be monitored and controlled, with an interlock to the drive mechanism so that welding is stopped if the temperature falls outside the range. Where the welding procedure includes provision for heated extrudate to be incorporated in the weld, any degraded extrudate that has been overheated or heated and cooled in the barrel shall be purged prior to the resumption of welding with fresh material Equipment shall be maintained on a regular basis to ensure efficient performance throughout. ‘Seam Strength Requirements ‘Seams shall be welded to produce a joint stronger in direct tension and peel modes than the liner sheet without weakening the liner material, as demonstrated by test welds and destructive test samples. Breadth and depth of fusion between sheets shall be as required to meet these criteria, Where extrudates are included in the weld the extrudate material after fusion shall be fully compatible physically and chemically with the liner material. Care shall be taken to avoid overheating the liner material during welding, so that crystallisation, oxidation, perforation or degradation of the sheet does not occur. Weather Conditions Field seaming of pond liner shall be performed only when the temperature of the panels is between 4°C and 32°C. The design requirements related to weather are provided on the site datasheet 100-DS-EG-0001, er Surface Preparation The welder, prior to seaming, shall clean the immediate seaming area of all dust, dirt, moisture, debris of any kind, and foreign material such as clay or sand. Where the liner manufacturer's instructions require the surfaces to be abraded prior to welding, this shall be carried out no more than one hour in advance, using appropriate mechanical grinding equipment. Care shall be taken to restrict grinding to the immediate area of the seam, and to avoid over-grinding which may reduce the effective liner thickness adjacent to the seam. AG WY =: 2%Lr TN Seam Lap Field seams for HDPE liner panels shall be lap seams, formed by lapping the edges of the liner with a finished minimum overlap of 100mm for fusion welding and 150mm for extrusion welding, unless specified as greater by the liner manufacturer; Each seam made in the field shall be numbered in such a way that it is compatible with the panel layout drawing(s). The information to be recorded shall include the seam number, welder ID, machine number, temperature setting and weather conditions; ‘Seams are to be lapped and aligned with the fewest possible wrinkles; No “fish mouths” shall be allowed within the seam area and shall be eliminated for seaming. Where they occur, the material shall be cut, overlapped, and an overlap extrusion weld shall be applied. All welds on completion of the work shall be tightly bonded. Lap Interface Welding of HDPE Liners Lap interface welding of HDPE liners may be accomplished either with or without addition of heated extrudate to the interface. For interface welding without added extrudate, the seam shall consist of a double weld produced by surface fusion with an air gap between, Pressure nipping rollers shall press the molten surfaces together immediately behind the hot air stream or hot shoe to complete the weld. For interface welding with added extrudate, the seam may comprise either a single or a double weld, provided that the strength requirements are met ‘Surface Welding of HDPE Liners for Repair or Detailed Work ‘Surface welding shall be achieved by fusion of an extrudate on to the top surface of both sheets at the lap. The depth and width of engagement of the extrudate shall be as required to achieve the strength requirements. The means of deposition of the extrudate shall provide for full integration with the surface of the sheets, so that the weld becomes homogeneous with the liner. Penetration and Connection to Structures Connections to liner penetrations and adjoining structures shall be made in accordance surface welding requirements and the details shown on the drawings. Connections shall be at least equivalent in strength to the normal lap seams, and the security of containment shall not be diminished. Local stressing of the membrane at connections shall be minimised. All materials used in welded connections shall be fully physically and chemically compatible with each other. Non-destructive Testing Close visual and non-destructive testing of all (100% coverage) seams and repairs shall be made by the Contractor under the observation of the Principal. The purpose of non-destructive testing is to check the continuity of the seams. It does not provide information on the seam strength. Testing shall take place as the seaming work progresses and not at the completion of all field seaming. * For double-welded fusion seams air pressure testing shall be used by inflation of the space between the welds to 200 kPa. The pressure shall be held for 15 seconds and the test shall be considered satisfactory ifthe pressure loss does not exceed 10 kPa ‘© For single welded fusion and extrusion seams, testing shall be achieved using a glass fronted vacuum box and soap solution. If no bubbles appear while the vacuum is held for 15 seconds, the test is satisfactory. Test Welds Fortescue itrw Test seams shall be made to verify that adequate conditions exist for field seaming to proceed in the following conditions: * Prior to the commencement of each shift, each welder shall produce a test seam to determine the peel and shear strength of the seams; * At any time during seaming production to verify equipment, operator performance and seam integrity; ‘* Following any break in operations where seaming has been suspended for more than one half hour; ‘+ When a breakdown of the seaming equipment occurs a test seam shall be produced prior to resumption of the seaming operation; and ‘* Following any significant adjustment to welder controls, The test seam samples shall be made at least one metre in length using liner material and subgrade conditions as for the work currently in progress with the seam centred lengthwise. Test seams shall be marked with the date, time, ambient temperature, operator's name and welding ‘machine number. ‘Two direct shear and peel strength tests shall be carried out on 25mm wide test strips cut from opposite ends of the test panel, using a field tensiometer. The weld will be considered acceptable if the test piece fails away from the joint. If the field test fails then further test welds shall be made after appropriate adjustment of the welder controls, and retested until a satisfactory result ensues. Field test results shall be recorded and test pieces marked and stored. The Principal's Representative reserves the right to take further test pieces from the test panel for independent tests off-site. Destructive Testing After the initial welding of any seam, testing and repairs shall be completed within three (3) working days. Seam strength testing shall be done as the seaming work progresses and not at the completion of field seaming. Destructive shear and peel strength tests shall be performed for every 150m of seaming performed. Sampling and testing shall be done under an approved QAJQC plan and all samples shall be marked with the date, ambient temperature, location and welding machine number. ‘Samples for destructive testing may be taken from finished seams at locations as directed by the Principal’s Representative at a frequency of up to one sample per 150m of seam. If any sample fails field testing, then additional samples may be taken to define the extent of sub-standard seam. Each sample shall be 400mm long parallel to the seam by 300mm wide, with the seam central in the width. The sample shall be cut into three sections as follows: * Field test section - 100mm long x 300mm wide for thickness and two shear and peel strength tests to be made, as described for Test Welds; * Independent test section - 150mm long x 300mm wide for three shear and peel strength tests, in compliance with ASTM D-638 at an offsite testing laboratory; and * Record section - 50mm long x 300mm wide to be marked and submitted to the Principal's Representative together with the corresponding field test report, and reference of the test specimen submitted to the independent testing Results of tests that have failed shall be forwarded immediately to the Principal for determination of corrective measures. Field Repairs and Patching of HDPE Liner Fortescue ah‘© Documentation of completed installation, including all submittals, liner as-constructed drawings and reports, is complete. 8.2.12 | ANCHOR TRENCHES ‘Anchor trenches shall be constructed to the lines and widths shown on the design drawings. The trenches shall be kept well drained to avoid softening during rain periods. Comers in the anchor trench shall be slightly rounded where the liner membrane adjoins the trench to minimise sharp bends in the liner membrane. Backfilling of trenches to take place only when the lining has settled and air trapped beneath the liner has been vented. Backfiling shall occur in the early morning when the liner membrane is at maximum contraction. Backfilling shall be carried out in a planned, logical sequence to avoid overstressing of the liner membrane. The backfill material may consist of reworked excavated material, free from sharp stones or objects, with a maximum particle size of 10mm. Perimeter fencing may be co-located in the anchor trenches. 8.2.13 LINER HOLD DOWNS Sufficient Terrafix Soft Rock bags or conventional sand bags shall be permanently installed to prevent the liner lifting when the pond is empty and to prevent the liner floating during operation in the event of a leakage. The spacing and arrangement of the sand bags shall be determined by the pond designer. 9 PIPING REQUIREMENTS 91 General Piping shall strictly comply with the latest revision of 45-ST-WM-0002: Standard Engineering Specification for Dewatering Infrastructure - Water Projects Engineering. For special purposes and with FMG approval specification 100-SP-PI-0001: Standard Engineering Specification for Pipe Work and Valves may be used instead. Any pre-fabricated spools shall be sealed to prevent contamination during transport and installation with 12mm marine ply and be bolted in place for transport. 9.2 Air Valves Air valves shall be installed at. * all high points, ‘the pressure side of isolation valves; and ‘+ ata spacing not exceeding 600m intervals. 9.3 Manual Drains and Vents Provision shall be made to enable manual venting and draining of all pipework in the scope with the exception of buried pipework, for which drains are not required IY Fortescue oft) Pw9.4 Light Vehicle Crossings LV road burials shall be as per specification 45-ST-WM-0002 : Standard Engineering Specification for Dewatering Infrastructure - Water Projects Engineering. 9.5 Pipe Burials for Sheet flow and Fauna Crossings Fauna burials shall be as per specification 45-ST-WM-0002 : Standard Engineering Specification for Dewatering Infrastructure - Water Projects Engineering section 6.1.5. 9.6 Creek Crossings / Flood Crossings Creek crossing burials shall be as per specification 45-ST-WM-0002 Standard Engineering Specification for Dewatering Infrastructure - Water Projects Engineering. 9.7 Check Valves ‘One check valve is required in the pipework on each pump discharge to prevent recycling between manifolded pumps. One additional check valve is required on the common discharge pipework for the pond to reduce the chance of backflow unless specified otherwise. The check valve shall be of either the double flap type or the swing disc type. Double flap style checks shall be of the wafer style for fitting between two Table E flanges. Swing disc type shall be flanged with Table E flanges The orientation of the check valve shall comply with the manufacturer's recommendations. Check vaives shall comply with the material specifications listed in Table 7. Table 7: Check Valve Material Requirements ‘Component Body Disc / Plate Valve Seat / Flange Seat Hinge Pin ! Spring Pin Spring Other wetted metalic components Other non- wetted metalic components Bushing rings External Paint work Material Specification Cast Iron / Ductile iron’ | SAF 2507 or better (PREN > 40) NBR ‘SAF 2507 or better (PREN > 40) ‘SAF 2507 or better (PREN > 40) ‘SAF 2507 or better (PREN > 40) Cast Iron / Mild Steel Tefon NBR Epoxy - 300 micron complying with ASAI58, 9.8 lsolation Butterfly Valves Isolation valves shall be provided to enable the isolation of the pond for maintenance. Isolation valves shall be provided to enable the isolation of each individual pump for maintenance.Isolation valves shall be provided to enable isolation of each basket strainer for cleaning. ‘The butterfly valves shall comply with the material specifications listed in Table 8: Table 8: Butterfly Valve Material Requirements Component Body Disc Valve Seat / Flange Seat Stem / Shaft Other wetted metalic components Other non: wetted metalic compone Bushing/Packing rings Botting (non- wetted) External Paint work Material Specification Cast Iron / Ductile iron With resilient seat EPDM. | SAF 2507 or better (PREN> 40) | NaR ‘SAF 2507 or better (PREN > 40) ‘SAF 2507 or better (PREN > 40) Cast Iron / Mild Stee! DELRIN or better NBR ‘Structural Epoxy - 300 micron complying with AS4158, 99 Relief Valves Relief valves shall be provided as required by AS4041: Pressure piping. Pilot operated relief valves are preferred by FMG. One relief valve shall be provided at the discharge pump manifold to protect the downstream pipework. Alternatively multiple relief valves may be manifolded together to achieve the required flow rate The pipework and valves between the pump discharge and the relief valve(s) shall be pressure rated in excess of pump dead head pressure. The relief valve shall be set to discharge at a pressure of S00kPa (g) unless otherwise specified. If two or more relief valves are fitted the first relief valve shall be set at 485kPa and the second shall be set at 500kPa(g). The relief valve shall be sized to discharge the full flow from all pumps (including any future provisions) at the specified discharge pressure. The relief valve shall be pressure rated to specified design pressure at 60°C. Relief valves shall be serviced annually. Relief valves shall be corrosion resistant, plastic components are preferred. The following are the minimum requirements for materials: Table 9: Relief Valve Material Requirements a al . terial Spec Material Specification Component requiring written Preferred AE SeSeE Body Plastic ‘Cast Iron / Ductile iron ‘SAF 2507 or better (PREN Wetted components > 40) or plastic NAsofal Spee Comeceead ee See ties rare ae Elesioneric components | NER or Teton WA Ne wated eit cava tel Catton Stet Pilot Tubing Nylon preferred Inconel tubing 9.10 __ Sample Points For all pipe flows entering the pond a %" BSP sample point with an isolation ball valve shall be provided. For the common discharge pipe exiting the pond a vale shall be provided. BSP sample point with an isolation ball 9.11 Pond Fill Piping Pond fill piping shall be white co-extruded PN6.3 HDPE unless specified otherwise. Pond fill piping shall generally be ground supported. All pond fill pipes shall contain an isolation valve to control level and prevent overtopping Where solids clean out is specified the required connections shall be incorporated in the pond fill piping The discharge point into the pond shall be anchored with sand bags to prevent pipe movement. The quantity and arrangement of sand bags shall be specified in the design. 9.12 Pump Suction Piping Pump suction piping shall be PN12.5 up to the suction manifold or pump impeller unless specified otherwise. Where the maximum specified discharge flow rate is greater than 150lt/sec only N630 piping shall be used. ‘Where multiple pump impellers are installed the suction pipework shall be manifolded with an above ground manifold to enable cross connection or balancing of suction flows. The suction manifold shall be PN12.5 unless specified otherwise. Where the maximum specified discharge flow rate is greater than 150lt/sec only DN630 piping shall be used. The height between: a) the minimum specified water level for pumping (as per the volume calculations) and b) the centreline of the pump suction shall not exceed 5.0m under any circumstances. Please refer to the section on NPSH for additional requirements that apply. Pump suction pipework shall be sized to achieve the required process performance, however the average velocity across the pipe bore shall not be higher than 0.4m/s under any circumstances. The pump suction inlet shall be such that large contaminants that could cause a pipe blockage shall be prevented from entering the inlet. If required the suction inlet may be fitted with a vortex breaker. Fortescue atEach suction inlet shall be firmly anchored to prevent movement. A basket style inline suction strainer shall be provided on each pump suction inlet. The basket strainer shall be rated for at least twice the specified pump flow to allow for fouling. ‘There shall be no sudden change in pipe diameter for pump suction pipework. HDPE “step” style reducers are not permitted. Converging conical reducers in the pump suction pipework shall have a convergence angle of not more than 1:5 or 11°. Converging conical reducers in the pump suction pipework shall be concentric unless otherwise approved in writing, Diverging reducers in the pump suction pipework are not permitted under any circumstances. If diverging reducer is proposed then the upstream pipe work size shall be increased. ‘Where the suction pipework penetrates the pond liner the pipework shall be welded to the liner to achieve a reliable seal. Pump suction pipework should be internally de-beaded where practical. 9.13 __ Pipework Pump Discharge to the Relief Valve Pump discharge pipework shall be buried where practical. Pump discharge pipework shall be PN12.5 up until the first relief valve unless otherwise specified or required. The discharge piping upstream of the relief valve shall be pressure rated in excess of pump dead head pressure. Pump discharge pipework shall be sized to achieve the required process performance. However the average velocity across the pipe bore shall be not higher than 1.0m/s under any circumstances, including any future provisions, 9.14 Hoses Hoses shall be used on the suction and discharge side of pump skids to minimise vibration. Hoses shall generally be 1.5m flange to flange so as to minimise the requirement for additional supports, Hoses shall not be used to accommodate for piping misalignment. The use of hose clamps is strictly prohibited. The use of through bolts on the hose body is strictly prohibited. The use of quick disconnect fittings on hoses (such as Camlock and Bower style fittings) is strictly prohibited All hoses shall have a flange on at least one end of the hose or fixed piping able to rotate/swivel to enable the bolt holes to be aligned. Hoses with integrally manufactured flanges are preferred by FMG. All hoses shall have a pressure rating appropriate for their intended use. Hoses on the pump suetion side shall be rated for the maximum vacuum pressure that can be generated by the pump or pump priming mechanism. Hoses on the pump discharge side shall be rated for the maximum pump discharge pressure that can be generated by the pumping unit, this may include “overclocking” scenarios if the equipment is capable of this. 9.15 Pipe Supports Pipe supports if required within 7m of the suction and discharge side of fixed pumps or skid mounted pumps shall be galvanised steel stool fabrications with U-bolts and concrete footings. CN eePipe anchors adjacent to piping relief valves shall be with sand bags or concrete and U-bolts, Pipes shall be restrained with sand bags at the discharge points into the ponds. Pipes supports outside of the above are not specifically required and HDPE pipe may be directly run along the ground, in accordance with the requirements of 45-ST-WM-0002 Standard Engineering Specification for Dewatering Infrastructure - Water Projects Engineering unless otherwise specified. 10. PUMP REQUIREMENTS 10.1___ Pump General Requirements Minimum materials for all pump types are presented in Table 10 Table 10: Pump Materials Requirements Cloudbreak site Duty | Solomon _| Cloudbreakchrstmas | cristmas Crook eer Saline Service ump ipa, Casing ‘components, flvanised Carbon | Galvanised Carbon Stee! | Galvanised Carbon Steel (On skid pipework ernie Carbo Stee! Sched XS minimum Sched XS minimum ‘Structural Painted structural Galvanised Structural Components one Painted structural Steel | S243 Note: * Pitting Resistance Equivalence Number (PREN) shall be calculated as PREN = 1 x %Cr + 3.3 x %Mo + 16 x %N Values used shall be the minimum composition for each element as per material specification, not the average values. Where minimum nitrogen content is not specified it shall be omitted from the calculation Pump redundancy requirements shall be as specified in the pond datasheet. 10.2 Surface Protection 10.2.1 Corrosion Protection - Painting Where specified pump and structural steels shall use the painting system identified in Table 12 as a minimum Table 11: Pump and Structural Steo! Painting Requirements CoatlLayeriStep Details Abrasive Blast to Class 2.5 Primer - luxepoxy 66 primer or equivalent ‘60 micron thickness Top Coat - Durebild HSE or equivalent £250 micron minimum thickness. Other requirements shall be as per 100-SP-ST-0004, Fortescue htAlternative specifications may be permitted, and should be submitted to the principal for approval. High gloss finishes, chrome plating and copper plating which affect the use of thermography equipment shall not be used around bearings and glands, unless approved by the principal. Machined surfaces shall not be painted and shall be protected by a coating of rust preventative grease or similar material during shipping and storage. The preventative shall be easily removable in the field with solvents and without the need for wire brushing or other mechanical removal methods. 10.2.2 _ Corrosion Protection - Galvanising All galvanising shall fully comply with 100-SP-ST-0004 : Standard Engineering Specification for Protective Coating Systems - Painting system G and AS4680 : Hot-dip galvanized (zinc) coatings on fabricated ferrous articles. 10.3 Pump Testing All pumps shall have a Factory Acceptance Test (FAT) test covering curves and NPSH requirements prior to delivery to site. FAT's shall be witnessed by FMG personnel. Pump performance / testing shall comply with the requirements of AS2417 : Rotodynamic pumps - Hydraulic performance acceptance tests - Grades 1 and 2 with acceptance criteria as per grade ‘unless otherwise specified. NPSH performance shall be considered a contractual requirement. Contractual performance requirement shall include the entire operating range claimed rather than a single performance point. Pump performance shall be steady (not fluctuating) over the operating range claimed. 10.4 Installation and Commissioning The pump vendor shall provide details of all installation and commissioning requirements for the pump. All vendor specified installation and commissioning requirements shall be followed by the contractor. 10.5 _ Pump selection Where: 1. The flow is such that three or more pumps are required or 2. The minimum and maximum flow ranges cannot be achieved with skid mounted diesel pumps or 3. Pumps are required to, or have future provision for, perform a boosting function. For ‘example in a pond bypass or partial bypass configurations. Then electric pumps shall be used with appropriately sized generators and not skid mounted diesel pumps. Mounted Diesel Pumps Fortescue a}Skid mounted diesel pumps shall be in accordance with FMG specification 100-SP-HY-0002: ENGINEERING SPECIFICATION FOR DIESEL DRIVEN CENTRIFUGAL PUMPS. 10.7 Electric Fixed Vertical Turbine Pumps Details of any vertical turbine pumps proposed shall be forwarded to FMG for detailed review and approval. 10.8 Electric Skid Mounted Pumps Electric skid mounted pumps shall comply with FMG specification 100-SP-ME-0042 : Standard Engineering Specification: Centrifugal Pumps. Skid materials shall comply with requirements of 10.1 10.9 Electric Plinth Mounted Pumps Electric plinth mounted pumps shall comply with FMG specification 100-SP-ME-0042 : Standard Engineering Specification: Centrifugal Pumps 10.10 _ Floating Suctions / Floating pumps Floating suctions and pump floats shall be made from welded or rotary cast HDPE. Alternative materials shall be subject to FMG approval. Floating suctions shall prevent accidental ingress of solids in the event that the float/pump rests ona solids layer i.e. suck air not solids. Floating suctions shall not have damaging protrusions that may puncture a HDPE liner. Floating/Skimming suctions shall float level, not at an incline. Provision for removal of the floating suction / floating pump shall be incorporated into the design. This may include crane pads for removal andior floating walkways for maintenance. 10.11 | NPSH NPSH calculations shall be provided for review prior to the commencement of construction NPSH calculations shall include a minimum 2.0m additional allowance for partial suction strainer blockage unless otherwise approved in writing by FMG. 11. DIESEL GENERATORS Diesel generators shall be as per FMG specification 100-SP-EL-0031 : Standard Engineering ‘Specification - Portable Low Voltage Generators, Diesel Generator Redundancy requirements shall be as specified on the datasheet. 12. DIESEL STORAGE AND PIPING Diesel Storage requirements shall be as per the Mines Regulations and Dangerous Good Regulations. 12.1 Diesel Fuel Pods If there is one diesel consumer then one diesel storage pod shall be provided.If there are more than one diesel consumer then at least two separate diesel storage pods shall be provided. This is to provide increased redundancy to the pond operation. Diesel Fuel Pods shall be as per FMG Specification 100-SP-HY-0008: ABOVE GROUND RECTANGULAR FUEL TANKS FOR STATIONARY DIESEL MOTORS AT MINE SITES Fuel pods shall be self bunded. Diesel fuel ponds shall strictly comply with the requirements of AS1940: The storage and handling of flammable and combustible liquids. Diesel Storage volume shall provide for approximately 72 hours of run time without refuelling unless otherwise specified. Diesel Level Transmitters shall be provided for all Diesel fuel pods shall be located at least 5m away from other diesel pods or from diesel ‘consumers to minimise the risk of a fire spreading. sel storage pods as per section 13.5. 12.2___ Diesel Piping Diesel Piping if required shall be provided from fuel pods to diesel consumers. Where there is more than one fuel pod it should be piped to not more than half of the diesel consumers. This is to maximise redundancy for the pond. The intent is that if one diesel pod runs low or is contaminated then only half of the pumping capacity for the pond is lost. Diesel piping shall comply with FMG specification 100-SP-P1-0001: Standard Engineering Specification for Pipe Work and Valves to piping class C5 and shall be DN25 unless stated otherwise. Diesel piping shall be as short as practical. The final joint to the diesel consumer shall be an appropriately rated fuel hose. Diesel piping shall be above ground only and shall be supported on elevated cable trays or pipe supports at spacing not exceeding 2.4m The diesel piping shall have an isolation ball valve that is safely and easily accessible on each fuel pod and on each diesel consumer. Diesel piping shall not be run adjacent to electrical or instrumentation cabling, 12.3 Additional Diesel Bunding and Uprated Piping Specification This section only applies is specified on the data sheet. For some environmentally sensi areas additional diesel bunding may be specified on the data sheet. In such cases concrete slabs and curbing shall be provided under the following areas: * Diesel trailer/LV fill position ‘Diesel fuel pod storage * Diesel fuel lines ‘© Diesel consumer skid base. For some environmentally sensitive areas up-rated piping spec to FMG Specification 100-SP- P1-0001 : Standard Engineering Specification for Pipe Work and Valves, Piping class S2 may be specified on the datasheet. 13, INSTRUMENTATION NN ee13.1___ Flowmeters Inflows and Outflows from all ponds shall be measured using Magnetic flow meters, Optionally if specified flowmeters may be required on each pump discharge. Flowmeter shall be installed on an inclined (>15°) or vertical section of piping such that the flowmeter is always full. Flowmeters shall not be installed in horizontal pipework without prior written approval Flowmeters shall have an air trap and air valve upstream to remove air from the flow to be measured, Flowmeters shall have a minimum of 3D piping on the supply side and 5D of piping on the discharge side of straight pipe without changes in direction or branches. 13.2 Pond Level Transmitters All sections of the pond that can have a different water level shall be measured separately using a pressure based level sensor For pond overflow weirs shall have two redundant instruments available such that a single failure cannot directly cause an environmental discharge. It some cases measurement of two separate pond areas may provide the required redundancy on weir level measurement without fitting an additional instrument. 13.3 Pressure Transmitters Each discharge pump shall be provided with an independent pressure transmitter. Each pump suction shall be provided with an independent pressure transmitter capable of measuring to full vacuum. A pressure transmitter shall be provided at the battery limit of pond discharge piping. 1 jesel Motor Monitoring For each diesel motor the following shall be recorded as a minimum: Diesel Speed Engine oil temperature Coolant Temperature Engine diagnostics and general faults Diesel Fuel Level Monitoring eevee 13: All fuel tanks shall have fuel level monitoring. Level transmitters shall be 4-20mA, loop powered 12V/24V DC. Contractor shall recommend a make and model for approval by FMG. 13.6 Instrumentation Cables Instrument cable run lengths shall be minimised. All cables shall be run in appropriately sized conduit. 14. CONTROL, TELEMETRY AND SYSTEM INTEGRATION Telemetry System14.1 Control Logic Overview Unless otherwise stated the following pond logic shall apply to ponds. Under normal circumstances the water flows into the pond will not be controlled by the pond. The water level closet to the suction pump shall be controlled by adjusting the discharge flow rate around a nominal level set point. Individual pumps shall be either turned onloff or have their speed adjusted to achieve a continuous smooth flow profile. Sudden changes to flow rates, or step changes shall not be permitted. In the event that one or more of the water levels is lower than the low limit then a warning alarm shall be raised on the local HMI and through telemetry to SCADA, In the event that the water level closet to the suction pump is lower than the low low limit then the pump shall be stopped and a critical alarm raised on the local HM and through telemetry to SCADA This water level shall be set to accommodate NPSH requirements. In the event that the pressure transmitter on the pump suction is lower than the low limit then a warning alarm shall be raised on the local HMI and sent through telemetry to SCADA. In the event that the pressure transmitter on the pump suction is lower than the low low limit then a critical alarm shall be raised and the appropriate pump shall be stopped to prevent cavitation damage. A password protected override shall be available so that in an emergency situation the pump can be restarted and remain operational. In the event that one or more of the water levels exceeds the high limit then a warning atarm shall be raised on the local HMI and through telemetry to SCADA. In some cases the discharge flow rate may be automatically increased to reduce overtopping risk. This is to prevent an environmental discharge due to the spillway weir overtopping In the event that one or more of the water levels exceeds the high high limit then the discharge pumps shall continue at the maximum achievable flow, the automated isolation valve to the pond shall be closed and a critical alarm shall be raised. This is to prevent an environmental discharge due to the spillway overtopping. In the event that there are multiple isolation valves this may be progressively implemented at separate trigger points. Pump discharge pressure shall be monitored. In the event of a sudden reduction of pressure (10 kPa in 5 seconds) that is not associated with a change in flow occurs then a warning alarm shall be raised to the operator through the local HMI and through telemetry to SCADA. This may indicate a burst pipe scenario which requires urgent investigation. If the pump discharge pressure decreases below the low pressure set point a warning alarm shall be raised to the operator through the local HMI and through telemetry to SCADA. This may indicate a burst pipe scenario which requires urgent investigation. The low pressure set point shall be readily adjustable by the operator to prevent nuisance alarms. 14.2 Alarms and Controls For each pond an alarm and control table shall be generated. This shall be approved by FMG prior to the risk assessment 14.3 Pump Control and Monitoring Each pump shall have a Controller that can be interfaced via RS-485 Modbus Communication suitable for use with a MIRI Radio Telemetry Unit (RTU). The controller shall have the following indication and controls: + Each pump shall be able to be started and stopped both locally and remotely via Telemetry. Fortescue ff* Each pump shall have speed adjustment (where applicable) both locally and remotely. + Monitor all engine diagnostics (Oil and coolant temperatures, general faults, etc) * Allcontrol logic as per section 14.1 15. MAINTENANCE AND OPERATIONAL REQUIREMENTS 16. SURFACE WATER All pond infrastructure sensitive to surface water shall be located in an elevation which surface water modelling has indicated is free from flooding risk. This will include all pumps, fuel pods, diesel generators, skid mounted pumps and control cabinets. 16.1 Footpaths Dedicated footpaths are not required, however the areas around all equipment should be suitable for pedestrian traffic and free from hazards. 16.2 Light Vehicle tracks Light vehicle tracks are required to access all pumps, instrumentation, control panels, generators, fuel storage and pipe work. 16.3 __ Safety Egress Netting Conveyor belt, supplied by the Principal, and egress netting is required to be anchored down at each ‘egress location as indicated on the IFC drawings. Unless otherwise indicated, a minimum of one egress point is required at each comer of the pond. Egress netting is to consist of 12mm white UV stabilized polypropylene rope, knotted into a 250mm x 250mm mesh 1m wide by the length specified to access the pond. The installation and anchorage of the conveyor belting and egress netting is detailed on standard drawing CO-00000-DR-CI-0083. Ponds should comply with the DMP Guidelines for fauna egress. 16.4 _ Flotation aids / Lifebuoys One lifebuoy is required per pond and for every 500m of pond perimeter. Lifebuoys shall be mounted in a protective enclosure such as the Plastimo Ring Lifebuoy Container. The lifebuoy(s) shall have a minimum diameter of 75cm and be affixed with a minimum of 30m of throwing line. 16.5 __ Fencing Unless otherwise specified on the datasheet, the Contractor is to supply and install perimeter exclusion fencing and access gates in accordance with standard drawing CO-00000-DR-Cl- 0082. The fencing is a ring-lock stockade style intended to prevent livestock and wildlife entrapment. There shall be two (2) non-locking access gates for each pond. At the location of access gates the surface shall be levelled and nearly horizontal and the area where the gate(s) swing shall be similarly levelled. Gates shall be located and hung as Fortescue ait) as. ONindicated on the IFC drawings. Gates shall be consistent with the fencing on either side of the gate unless otherwise directed by the Principal. 16.6 Fire Protection ‘5kg dry powder fire extinguishers are required near diesel motors and diesel storage. These should preferably be one from each approaching direction (maximum of 3) to the diesel motors and diesel storage. ‘A 5m fire brake shall be provided around the perimeter exclusion fencing. 16.7 Lightening protection should be provided if it is economic to do so and should be assessed on a case by case basis. Use of other structural steel (e.g. standpipes) should be maximised where possible to minimise costs. 16.8 __Lighting/Illumination Area lighting is not required unless otherwise specified, 16.9 Level Indication Visual level indictors shall be provided to enable physical confirmation of level by visual inspection. Details of level indication shall be submitted to FMG for approval. 16.10 _Electrical and Control Electrical and control shall conform to the standards specified in this specification. Electrical installation shall satisfy the requirements of AS 3000: Electrical installations (known as the Australian/New Zealand Wiring Rules) and AS 3008 : Electrical installations - Selection of cables - Cables for alternating voltages up to and including 0.6/1 kV - Typical Australian installation conditions. All controls must be in accordance with the statutory requirements and as per AS 4024.1 Safety of Machinery. All instrumentation and control shall be designed to be failsafe. All motor driven equipment shall be permanently marked with arrows to indicate the required direction of rotation of the drive motor. Control and operation functionality of the overall pond functionality shall reside locally in the Miri RTU. A local HMI shall be provided and shal! have full functionality. In the event of telemetry loss all functionality shall continue through local control and the local HMI 17. COMMISSIONING REQUIREMENTS. 17.1__Dry Commissioning For each project a dry commissioning punch list shall be developed to cover (as a minimum):+ Pumping © Piping © Civil + Liners Instrumentation 17.2___ Wet Commissioning For each pond a wet (energised) commissioning plan shall be developed. This shall include testing of all aspects of pond performance. This shall include testing all process controls and interlocks, and all required flow rates. Arisk assessment shall be done for all components of the commissioning plan prior to it being implemented. A noise report (as defined in the mines regulations) shall be performed during the commissioning of a new pond. 18. QUALITY 18.1 Quality System The Contractor shall specify and maintain a quality management system to ensure the quality of all work, to be provided under the contract meets the design and performance requirements specified by the Principal The Contractor shall provide, for review and approval by the Principal, a Quality Management Plan for the works, which shall incorporate as a minimum, all procedures, check sheets, ITP's, hold points and proposed lot definitions for the works. 18.2 Shop and Site Access The Principal will be entitled, at all times to inspect, examine and test the materials and workmanship to be provided under the contract. Such inspection, examination or testing, if made, will not release the Contractor from any obligation under the contract. The Contractor will cooperate with and provide full opportunity to the Principal to monitor regularly the progress of the works of the Contractor and his Subcontractors to the detailed extent necessary to satisfy progress relative to the construction program. All pertinent information to enable the Principal to determine the adequacy of the advance planning for material procurement, machine and manpower resources to meet the construction program will be made freely available to the Principal. These requirements will be incorporated in orders placed with Subcontractors. 18.3 Inspection and Test Plan HY Fortescue attyThe Contractor is responsible for completing all inspections, notifying the Principal of hold points and witness points for approval and record keeping for the works, as required by the Contractors Quality Management Plan and in accordance with the Contract. The Contractor must submit at least weekly to the Principal in hardcopy format copies of all ITP sheets for approval and signoff. ITP’s shall be accompanied by copies of any material or ‘compaction results or other results relating to the portion of the works. ITP’s shall also be accompanied by a signed surveyors ‘as constructed! record relating to the portion of the works. Progress claims for completion of sections of the works will be rejected where submission and approval of ITP's for that section of the works is outstanding. The Contractor shall prepare and submit a copy of the Contractor's ITP template and proposed lot plan for approval as part of the Contractor's Quality Management Plan. 18.4 Hold Points Throughout the Works, hold points shall apply whereby the Contractor shalll submit relevant information to the Principal for approval prior to commencing with the next stage of the Works. The Contractor shall provide the Principal a minimum of 48 hours’ notice prior to request for approval. The Contractor shall not precede beyond the hold points prior to receiving written approval from the Principal. If the Contractor proceeds to construct beyond the designated hold point without the Principal's inspection and without the Principal's approval then the Principal may direct the Contractor to uncover and remediate the Works to the hold point, at the Contractor's expense. The Contractor shall be deemed to have allowed for all time delays and costs associated with the hold points during the Works. 18.5 Audits ‘The Principal reserves the right to perform an audit on any aspect of the works. The supplier shall make available all such records and evidence as may be required. The audit shall be by arrangement after the Principal gives written notice of the requirement to audit, 18.6 Non-Conformance ‘Any equipment or work not in accordance with the contract or purchase order, standards and codes, Equipment Data Sheets or specifications is considered to be a non-conformance. The supplier shall notify the Principal in writing of reportable deviations and non-conformances immediately upon their identification. Any deviation or non-conformance to be rectified by the supplier shall be at no cost to the Principal. 19. SUPPLIER DATA The supplier shall submit documentation listed in appendix 1 These requirements represent the minimum technical requirements. Additional project management and commercial documentation requirements may be found in the Scope of Work. FortescueAll seams and seals of the liner shall be tightly bonded on completion of the work. Any liner surface showing damage due to scuffing or penetration by foreign objects, or showing distress, shall be replaced or repaired using accepted methods. Alll repairs shall be completed within 3 working days of the initial seam, + Small holes shall be repaired by extrusion welding, If the hole is larger than 10mm it shall be patched; ‘* Blisters, large holes undispersed raw materials and contamination by foreign matter and tears shall be repaired by patching; ‘Liner surfaces to be patched shall be abraded and cleaned no more than 15min prior to the repair. No more than 10% of the thickness shall be removed; * Patch materials shall be of the same material, type and thickness as the material being repaired. A patch shall be a minimum of 150mm larger in all directions than the area requiring the repair. All patches must be rounded prior to patching to reduce stresses at sharp comers; +The contractor shall mark adjacent to all welds and repairs the seam number, equipment number and technician performing the work. + Allrepairs shall be non-destructively tested. Repairs shall also be inspected by the Principal for deficiencies prior to panel acceptance and seam acceptance; and ‘* Inthe event that capping of a field seam is required, the contractor shall use a cover strip of the same thickness as the liner (and from the same roll, if available) that is a minimum width of 300mm. It shall be positioned over the centre of the field seam and welded to the liner using a fillet weld on each side. Capping strips shall meet all the requirements for patches as above. Records Full records of liner testing and inspection shall be submitted progressively to the Principal's Representative as the work proceeds. Final completion will not be certified until all records have been submitted. Records shall include the following: ‘= Contractors panel layout drawing showing panel numbers and seam numbers, to be marked up progressively with roll number used for each panel, and locations of samples taken for destructive testing. «Manufacturer's roll production test reports for all rolls used in the work; ‘Daily vacuum box or seam inflation test reports, referenced to seam numbers; * Daily field test weld reports referenced to seam numbers, equipment identification, operator, weather conditions, and any adjustments to equipment controls; «Destructive test field report and record of submission for laboratory test, referenced to seam number; and «Laboratory test reports, to be available within two weeks from time of sampling. Liner Acceptance The Contractor shall retain all ownership and responsibility for the installed liner until accepted by the Principal. The liner shall be accepted by the Principal in writing when all of the following conditions are met: «Installation has been completed; * Verification of the adequacy of all field seams and repairs, including associated testing, is complete; and ee