0002-SPC-HOBWT03-ME-8006 - C General Mechanical Specification Bryn Estyn Water Treatment Plant

Bryn Estyn Water Treatment Plant- Detailed Design
General Mechanical Specification
0002-SPC-HOBWT03-ME-8006 | C
08/12/20
TasWater CDO
General Mech anical Specific atio n

TasWat er CDO
Bryn Estyn Water Treatment Plant- Detailed Design
Project No: 0002-HOBWTO3

Document Title: General Mechanical Specification
Document No.: 0002-SPC-HOBWT03-ME-8006
Revision: C
Document Status: <DocSuitability>
Date: 08/12/20
Client Name: TasWater CDO
Client No: .
Project Manager: Shaun O'Brien
Author: Sohail Yamin
File Name: 0002-SPC-HOBWT03-ME-8006_C General Mechanical Specification Bryn Estyn Water
Treatment Plant
Jacobs Group (Australia) Pty Limited

ABN 37 001 024 095
Floor 11, 452 Flinders Street
Melbourne VIC 3000
PO Box 312, Flinders Lane
Melbourne VIC 8009 Australia
T +61 3 8668 3000
F +61 3 8668 3001
www.jacobs.com
© Copyright 2019 Jacobs Group (Australia) Pty Limited. The concepts and information contained in this document are the property of Jacobs.
Use or copying of this document in whole or in part without the written permission of Jacobs constitutes an infringement of copyright.
Limitation: This document has been prepared on behalf of, and for the exclusive use of Jacobs’ client, and is subject to, and issued in accordance with, the
provisions of the contract between Jacobs and the client. Jacobs accepts no liability or responsibility whatsoever for, or in respect of, any use of, or reliance
upon, this document by any third party.
Document history and status
Revision Date Description Author Checked Reviewed Approved

A Issued for Internal Review SY JB BA
B 20/11/20 Issued for JV comments SY JB BA
C 08/12/20 Issued for Use SY JB BA BA

Sohail
Digitally signed by Jon Bates
Digitally signed by Sohail Yamin DN: C=AU + CN=Jon Bates +
DN: cn=Sohail Yamin, c=AU, E=jon.bates@jacobs.com Digitally signed by Bradley Allpike
o=Jacobs,
email=sohail.yamin@jacobs.com
Jon Bates Reason: I have reviewed this
document Date: 2020.12.11 08:07:50+08'00'
Date: 2020.12.11
Yamin Date: 2020.12.11 05:20:41

+11'00'
12:40:34+11'00'
0002-SPC-HOBWT03-ME-8006 i
Contents
1. Definition and Abbreviations .............................................................................................................................. 4
2. Purpose..................................................................................................................................................................... 7
2.1 Scope ........................................................................................................................................................................................... 7
2.2 Works Not Covered................................................................................................................................................................. 7
3. Standards, Codes & Regulations ........................................................................................................................ 8
3.1 General........................................................................................................................................................................................ 8
3.2 Order of Precedence .............................................................................................................................................................. 8
3.3 Australian Standards ............................................................................................................................................................. 8
3.4 TasWater Standards ............................................................................................................................................................ 11
3.5 Other Standards ................................................................................................................................................................... 12
4. General Design Requirements ......................................................................................................................... 14
4.1 Units of Measurement........................................................................................................................................................ 14
4.2 Environment .......................................................................................................................................................................... 14
4.3 Ambient Conditions ............................................................................................................................................................ 14
4.4 Design Life .............................................................................................................................................................................. 14
4.5 Equipment Selection and Design .................................................................................................................................. 14
4.6 Design Loads ......................................................................................................................................................................... 15
4.7 Base frames and skids ........................................................................................................................................................ 16
4.8 Machines without Separate Base Frames ................................................................................................................... 16
4.9 Piping and Tubing................................................................................................................................................................ 16
4.10 Welding and Cutting ........................................................................................................................................................... 17
4.11 Contamination of Stainless Steel .................................................................................................................................. 17
4.12 Passivation of Stainless Steel .......................................................................................................................................... 18
4.13 Materials and Coating ........................................................................................................................................................ 18
4.14 uPVC piping............................................................................................................................................................................ 19
4.15 PE piping ................................................................................................................................................................................. 19
4.16 Painting .................................................................................................................................................................................... 19
4.17 Vibration .................................................................................................................................................................................. 20
4.18 Noise ......................................................................................................................................................................................... 20
4.18.1 Design Limits ......................................................................................................................................................................... 20
4.18.2 Measurement Method........................................................................................................................................................ 21
4.18.3 Soundproofing Devices ..................................................................................................................................................... 21
4.19 Access, Platforms, Walkways, Stairs and Ladders ................................................................................................... 21
4.20 Equipment Maintainability ............................................................................................................................................... 21
4.20.1 Alignment and Settings..................................................................................................................................................... 22
4.21 Workmanship......................................................................................................................................................................... 22
4.22 Limits and Fits ....................................................................................................................................................................... 23
4.23 Tolerances .............................................................................................................................................................................. 23
0002-SPC-HOBWT03-ME-8006 ii
4.24 Surface Finish ........................................................................................................................................................................ 23

4.25 Labelling and Signs ............................................................................................................................................................. 23
4.25.1 Equipment Name Plate Information ............................................................................................................................ 24
5. General Mechanical Components ................................................................................................................... 25
5.1 Packing and Shims .............................................................................................................................................................. 25
5.2 Fasteners ................................................................................................................................................................................. 25
5.3 Safety Equipment ................................................................................................................................................................ 26
5.3.1 General..................................................................................................................................................................................... 26
5.3.2 Guards ...................................................................................................................................................................................... 26
5.3.3 Personnel Clearance ........................................................................................................................................................... 27
5.3.4 Safety Signs............................................................................................................................................................................ 27
5.4 Gearboxes and Gears.......................................................................................................................................................... 27
5.5 Bearings ................................................................................................................................................................................... 28
5.6 Lubrication Systems............................................................................................................................................................ 28
5.7 Vendor Supplied Steelworks ........................................................................................................................................... 29
6. Electric Motors ..................................................................................................................................................... 31
7. Factory Testing .................................................................................................................................................... 32
8. Preparation for Shipment ................................................................................................................................. 33
9. Remote Assistance for Commissioning, Performance Testing and Training ....................................... 34
0002-SPC-HOBWT03-ME-8006 iii
1. Definition and Abbreviations
Definitions and Meaning Description / Definition

Abbreviations
ADWG Australian Drinking Water Guidelines

ACH Aluminium Chlorohydrate solution
Alum Aluminium Sulphate solution
AS Australian Standard
AS/NZS Australian/New Zealand Standard
BAF Biological Activated Carbon Filter
BCA Building Code of Australia
BoD Basis of Design
CCP Critical Control Points
CCTV Closed-circuit television
CDO Capital development office
CHAIR Construction Hazard Assessment A systematic review by key stakeholders to help
Implication Review identify and eliminate (or minimise) inherent
risks in construction, maintenance, repair and
demolition associated with the design
CIP Clean in Place
CPB UGL JV CPB UGL Joint Venture
CWS Clear Water Storage
D&C Design and Construct
DBYD Dial Before You Dig
DFT Dry Film Thickness
DI Ductile Iron
DN Nominal Diameter
ELV Extra Low Voltage
EPA Environmental Protection Authority
Victoria
EP Extreme Pressure Additives used in lubrication to decrease wear of
the parts of the gears exposed to very high
pressure.
FAT Factory Acceptance Test
FSL Finished Surface Level
GRP Glass Reinforced Plastic
HAZOP Hazard and Operability study A hazard and operability study is a structured and
systematic examination of a complex planned or
existing process or operation in order to identify
0002-SPC-HOBWT03-ME-8006

Abbreviations
and evaluate problems that may represent risks
to personnel or equipment
HDPE High Density Polyethylene
HDG Hot Dip Galvanised
HMI Human Machine Interface
HV High Voltage
IFC Issued For Construction
ITP Inspection and Test Plan
kA kilo Amps
kL/d kilolitre per day
kPa kilopascal
LCP Local Control Panel
LPHO Low Pressure High Output
LV Low Voltage
m metre
MC Maintenance chamber
MCC Motor Control Centre
MH Maintenance hole
ML/d Megalitre per day
mm millimetre
MRWA Melbourne Retail Water Agencies
MSB Main Switch Board
MSCL Mild Steel Concrete Lined
NATA National Association of Testing
Authorities
NSL Natural Surface Level
O&M Operation and Maintenance
OEM Original Equipment Manufacturer
OD Outside Diameter
PDF Portable Document Format
PE Polyethylene
PID Piping and Instrumentation Diagram
PLC Programmable Logic Controller
PVC Polyvinylchloride
QMS Quality Management System
RTU Remote Telemetry Unit

Abbreviations
SAT Site Acceptance Test

SBS Sodium Bisulphate
SCADA Supervisory Control And Data
Acquisition
SDS Safety Data Sheet
SiD Safety in Design
STP Sewage Treatment Plant
TQ Technical Query
The Contractor Company completing the work
The Principal TasWater
The Site The location of the works
The The Principals representative
Superintendent
The Works The scope covered by this document.
TasWater Tasmanian Water& Sewerage
Corporation
UPS Uninterruptable Power Supply
USB Universal Serial Bus
UV Ultraviolet
UVT Ultraviolet Transmissivity at 254 nm
VSD Variable Speed Drive
WHS Work Health and Safety
WI Wrought Iron
WUC Works Under the Contract
WSAA Water Services Association of
Australia Inc.
WSAA PSXX WSAA Product Specification
WTP Water Treatment Plant
2. Purpose
2.1 Scope
This specification covers the general design, selection, manufacture, surface protection, workshop assembly,
testing, inspection, labelling, packing, delivery, commissioning and performance testing requirements for vendor
supplied Mechanical Equipment including all necessary accessories.
This specification defines the general and technical requirements applicable to General Mechanical
Requirements for the Bryn Estyn WTP upgrade project. It is applicable to the procurement of all mechanical
equipment including skid mounted equipment, pumps, piping, valving, mixers and accessories.
Unless specified in the Contract, mechanical equipment installation at site shall be carried out at site by Others.
Requirements for site installation are specified separately.
2.2 Works Not Covered

The following work are not covered:
§ Piping and equipment external to the equipment being supplied.
§ Speciality piping (Oxygen, Ozone and Chemicals)
§ All concrete works associated with supplied equipment
§ Access platform and structures for the equipment which are outside equipment supply.
§ Supply and installation of cast-ins.
§ Power and control cabling to and from, and termination into Supplier equipment.
3. Standards, Codes & Regulations

3.1 General
Mechanical Plant and Equipment shall comply with the requirements of national and local Statutory Authorities
having jurisdiction over their design, manufacture, installation and operation. Design and construction of the
mechanical equipment shall be executed, in accordance with the latest edition of the relevant parts of the
applicable codes and standards.
The Design shall be in accordance with this specification and with the documents listed in this section. Unless
specified otherwise, any standard or other document referred to in this specification shall be the latest edition
(including amendments) of that standard at the date of calling of tenders for this contract.
The Supplier’s design, manufacturing and testing shall be in compliance with all relevant TasWater and
Australian Standards. The Supplier shall still be accountable for their responsibilities through omission, or error,
in identifying the latest prevailing issue or other applicable legislation, regulations, directives and Australian
standards.
3.2 Order of Precedence
This technical specification shall be read in conjunction with the following documents, which together detail the
technical requirements for the contract. The order of precedence for the project specific technical specifications
shall be:
a) Applicable Legislation and Statutory Requirements
b) This specification
c) Project specifications referenced in this specification
d) Non-project specific codes and standards referenced in this specification
e) Drawings referenced in this specification
f) Codes, standards and drawings not specifically referenced in this specification
Any inconsistencies in the referenced documentation shall be referred to the CPB UGL JV who will resolve the
inconsistency.
3.3 Australian Standards

The equipment shall conform to the following standards:
Table 1: List of Applicable Australian Standards
Number Description
AS 1065 Non-destructive testing – Ultrasonic testing of carbon and low alloy steel forgings
AS 1081.1 Acoustics - Measurement of airborne noise emitted by rotating electrical machinery -
Engineering method for free-field conditions over a reflective plane
AS 1081.2 Acoustics - Measurement of airborne noise emitted by rotating electrical machinery -
Survey method
AS 1101 Graphic symbols for general engineering
AS 1110.1 ISO metric hexagon bolts and screws – Product Grades A & B
AS 1111.1 ISO metric hexagon bolts and screws – Product grade C
AS 1112 ISO metric hexagon nuts
Number Description
AS/NZS 1163 Cold-formed structural steel hollow sections

AS 1210 Pressure Vessels
AS/NZS 1214 Hot dipped galvanised coatings on threaded fasteners (ISO metric coarse thread series)
AS 1237 Plain washers for metric bolts, screws and nuts for general purposes
AS/NZS 1252 High strength steel bolts with associated nuts and washers for structural engineering
AS 1275 Metric Screw Threads for Fasteners
AS 1319 Safety signs for the occupational environment
AS 1353 Flat synthetic-webbing slings
AS 1397 Steel sheet and strip – hot dipped zinc coated, or aluminium/zinc coated
AS 1403 Design of rotating steel shafts
AS 1418.1 Cranes, hoist and winches, Part 1, General requirements
AS 1418.3 Cranes, hoist and winches -Part 3: Bridge, gantry, portal (including container cranes)
and jib cranes
AS 1418.10 Cranes, hoist and winches, Part 10: Mobile elevating work platforms
AS 1442 Carbon steels and carbon-manganese steels – Hot rolled bars and semi-finished
products
AS 1443 Carbon steel and carbon-manganese steels – cold finished bars
AS 1444 Wrought alloy steels – Standard, Hardenability (H) series and hardened and tempered
to designated mechanical properties
AS 1448 Carbon steel and carbon-manganese steels – Forgings (ruling section 300 mm
maximum)
AS 1449 Wrought alloy steels - Stainless and heat-resisting steel plate, sheet and strip
AS 1548 Fine Grained, Weldable Steel Plates for Pressure Equipment
AS/NZS 1554.1 Structural steel welding, Part 1: Welding of steel structures
AS/NZS 1554.6 Structural steel welding, Part 6: Welding stainless steels for structural purposes
AS/NZS 1559 Hot-dip galvanised steel bolts with associated nuts and washers for tower construction
AS/NZS 1594 Hot-rolled steel flat products
AS 1627 Metal Finishing – Preparation and pre-treatment of surfaces
AS 1657 Fixed Platforms, Walkways, Stairways and Ladders – Design, Construction and
Installation
AS 1666 Wire-rope slings
AS 1674 Safety in welding and allied processes - Fire precautions
AS 1721 General purpose metric screw threads
AS 1722.2 Pipe threads of Whitworth form - Fastening pipe threads
As 1755 Conveyors - Safety requirements
AS 1769 Welded stainless steel tubes for plumbing application
AS 1796 Certification of welders and welding supervisors
Number Description
AS 1830 Grey Cast Iron

AS 1831 Ductile Cast Iron
AS 1988 Welding of Steel Castings
AS 2074 Steel Castings
AS 2177 Non-Destructive Testing – Radiography of welded butt joints in metal
AS/NZS 2205 Methods of destructive testing of welds in metal
AS 2207 Non-Destructive Testing – Ultrasonic Testing of Fusion Welded Joints in Carbon and
Low Alloy Steels
AS 2312 Guide to the protection of structural steel against atmospheric corrosion by the use of
protective coatings
AS 2317 Lifting points
AS 2321 Short-link chain for lifting purposes
AS/NZS 2327 Composite structures
AS 2528 Bolts, stud bolts and nuts for flanges and other high and low temperature applications
AS/NZS 2574 Non-Destructive Testing – Ultrasonic Testing of ferritic Steel Castings
AS 2625 Mechanical Vibration – Evaluation of machine vibration by measurements on non-
rotating parts
AS2670.1 Evaluation of human exposure to whole-body vibration, Part 1: General requirements
AS 2671 Hydraulic Fluid Power – General Requirement for Systems.
AS 2741 Shackles
AS 2759 Steel Wire Rope – Use, operation and maintenance
AS 2788 Pneumatic Fluid Power – General Requirements for Systems
AS/NZS 2845.1 Water supply—Backflow prevention devices, Part 1: Materials, design and performance
requirements
AS 2845.2 Water supply - Backflow preventions devices, Part 2: Registered air gaps and registered
break tanks
AS/NZS 2845.3 Water supply - Backflow prevention devices, Part 3: Field testing and maintenance of
testable devices
AS/ISO 3452 Non-destructive testing – Penetrant testing
AS/NZS 3500.1 Plumbing and drainage, Part 1: Water Services
AS/NZS 3500.2 Plumbing and drainage
AS/NZS 3500.3 Plumbing and drainage, Part 3: Stormwater drainage
AS 3507.1 Non-destructive Testing – Guide to radiography for ferrous castings
AS 3507.2 Non-destructive testing – Radiographic determination of quality of ferrous castings
AS 3569 Steel wire ropes
AS/NZS 3678 Structural steel – Hot-rolled plates, floor plates and slabs
AS/NZS 3679 Structural steel
Number Description
AS 3920 Pressure equipment - Conformity assessment

AS 3978 Non-destructive testing – Visual Inspection of Components and Products
AS 3990 Mechanical Equipment – Steelwork
AS 3992 Pressure Equipment – Welding and brazing qualification
AS/NZS 4020 Testing of products for use in contact with drinking water
AS 4024 Safety of machinery
AS 4037 Pressure equipment – Examination and testing
AS 4041 Pressure piping
AS 4087 Flanges for pipes, valves and fittings
AS 4100 Steel structures
AS 4343 Pressure equipment – Hazard levels
AS 4458 Pressure equipment – Manufacture
AS/NZS 4534 Zinc and zinc/aluminium-alloy coatings on steel wire
AS/NZS 4600 Cold formed steel structures
AS/NZS 4671 Steel reinforcing materials
AS/NZS 4673 Cold formed stainless steel structures
AS/NZS 4680 Hot-Dipped Galvanised (Zinc) Coatings on Fabricated Ferrous Articles
AS/NZS 4791 Hot-dip galvanised (zinc) coatings on ferrous open sections, applied by an in-line
process
AS/NZS 4792 Hot-dip galvanised (zinc) coatings on ferrous open sections, applied by a continuous or
a specialised process.
AS/NZS 4854 Welding consumables-Covered electrodes for manual metal arc welding of stainless
and heat-resisting steels - Classification
AS 4991 Lifting devices
AS/ISO 9001 Quality Management Systems – Requirements
AS/ISO 9934 Non-destructive testing - Magnetic particle testing
AS 60529 Degrees of protection provided by enclosures (IP Code)
AS 60034.1 Rotating electrical machines- Rating and performance
3.4 TasWater Standards
The Principal’s standard specifications nominate below in Table 2 are the minimum requirements applicable to
the work or facilities. Where Australian Standards apply as minimum requirements, the order of precedence
stated in this section shall still apply if the Australian Standard is less stringent. Otherwise, the Australian
Standard will take precedence over the Principal’s standard specifications
Table 2 TasWater Standards
Number Description
0001-SPC-TWCDO-DE-0001_2 CDO Drawing and Drafting Requirements, Standard Technical Specification
Number Description
0001-STN-TW-DE-0004_4 TasWater Supplement to Water Supply Code of Australia

0001-STN-TW-EL-0003_1 General Electrical Requirements Technical Standard
0001-STN-TW-EL-0004_1 Instrumentation Technical Standard
0001-STN-TW-EL-0024_1 Water Treatment Plant Electrical Asset Design Standard
0001-STN-TW-EL-0029_1 Removal of Redundant Electrical Cables Procedure
0001-STN-TW-EL-0043_7 Alarm Philosophy for SCADA Alarms
0001-STN-TW-OM-0001_2 Operations and Maintenance (O&M) Manual Technical Standard
3.5 Other Standards
Other codes and standards that can be considered.
Table 3 Other Standards and Codes
Number Description
WSA 03 Water Supply Code of Australia

ISO 7.1 Pipe threads where pressure-tight joints are made on the threads, Part 1:
Dimensions, tolerances and designation
ISO 281 Roller bearing -Dynamic load rating and rating life
ISO 1683 Acoustics — Preferred reference values for acoustical and vibratory levels
ISO 3740 Acoustics- Determination of sound power levels of noise sources-
Guidelines for the use of basic standards
ISO 3741 Acoustics- Determination of sound power levels and sound energy levels of
noise sources using sound pressure- Precision methods for reverberation
test rooms
ISO 3744 Acoustics — Determination of sound power levels and sound energy levels
of noise sources using sound pressure — Engineering methods for an
essentially free field over a reflecting plane
ISO 3746 Acoustics — Determination of sound power levels and sound energy levels
of noise sources using sound pressure — Survey method using an
enveloping measurement surface over a reflecting plane
ISO 4413 Hydraulic fluid power- General rules and safety requirements for systems
and their components
ISO 12100 Safety of machinery- General principles for design- Risk assessment and
risk reduction
ISO 13373 Condition monitoring and diagnostics of machines-Vibration condition
monitoring-Part 1: General procedures
ISO/TR 18792 Lubrication of Industrial gear drives
ISO 21940 Mechanical Vibration-Rotor Balancing-Part 11: Procedures and tolerances
for rotors with rigid behaviour
ABMA Standard 9 Load rating and fatigue life for ball bearings
ABMA Standard 11 Load rating and fatigue life for roller bearings
Number Description
ASTM A380/ A380M Standard Practice for Cleaning, Descaling and Passivation of Stainless Steel
Parts, Equipment, and Systems
ASTM A967/A967M-17 Standard Specification for Chemical Passivation Treatments for Stainless
Steel Parts
4. General Design Requirements

4.1 Units of Measurement
The International System of Units (SI) metric system shall be used.
4.2 Environment
Suppliers of equipment shall observe all local regulations and nominated Project environmental requirements
relevant to supply and delivery and shall furnish equipment which satisfies all specified operational
environmental requirements.
4.3 Ambient Conditions
Unless otherwise specified all mechanical equipment shall be designed to operate in ambient conditions as
specified in the datasheets.
Equipment nominated as being located outdoors shall be designed to operate assuming direct exposure to the
midday sun.
The annual mean daily global solar exposure (2019) at Hobart is in order of 3.9 kW/m2.
4.4 Design Life
Table 4 specifies the design service life expectancy for the various components
Table 4: Service Life
Area Life expectancy
Buildings 50 years
Structural Steelwork 50 years
Concrete Structures 100 years
Pipework, Valves 50 years
Stairs and platform 25 years
Protective Coating on Steel Works 15 years
Steel Tanks 50 years
GRP/ Plastic Tanks 25 years
Mechanical Equipment 25 years
Electrical Equipment 20 years
Instrumentation, PLC, SCADA and Telemetry equipment 15 years
4.5 Equipment Selection and Design

§ Design equipment to suit the environment conditions defined in the Datasheets.
§ Sizing of equipment shall be based on the design flow rates, capacities, temperature, pressure, etc. as shown
on the Datasheets and equipment shall also be capable of sustained operation at maximum design rates,
and minimum design rates whichever results in worst case operation.
§ Supply equipment complete with minor and incidental items necessary for the correct functioning of the
whole system, even if not specifically detailed or mentioned.
§ Supply efficient, effective, durable equipment that is reliable in operation.

§ Design equipment for continuous and intermittent use.
§ Provide equipment that is of a proven design, suitable for the intended purpose.
§ All proprietary mechanical equipment must be of a reputable make and model having a proven track record
in Australia for use in water applications and be supplied by a company having demonstrable after-sales
service in Australia.
§ Unless otherwise specified, mechanical equipment shall be designed to operate in an environment where it
may be exposed to dust, heat, and hose-down by process/ service water, direct sunlight, rain and high wind
conditions.
§ Where possible, provide equipment pre-assembled and aligned on common base plate or frame (skid).
§ Design equipment for ease of operation, inspection and maintenance, corrosion resistance and wear, safe
operation and ease of cleaning of equipment and surrounding areas.
§ Design equipment to provide for the replacement of wearing parts with the least possible time.
§ Where practical, mechanical design, equipment and components shall be standardised to reduce spares
inventory. This includes shaft sizes, bearings, sheaves, valves, etc. as well as the manufacturer, type, size and
ratio of motors, speed reducers and pneumatic equipment.
§ Design equipment so that there must be no single points of failure for the WTP, other than where a risk
assessment has shown the risk of failure is sufficiently low.
§ Where redundant equipment is supplied, redundant equipment shall be installed, connected, live and
available for automatic and immediate use on response to equipment failure.
4.6 Design Loads

Equipment design shall accommodate the maximum loading to which the equipment will be subjected to during
its design life. Design loads for mechanical equipment shall be the most adverse combination of loading that is
possible and shall include, but may not necessarily be limited to the following:
§ Dead loads.
§ Live load.
§ Thermal loads.
§ Wind loads including cyclonic winds for equipment both full and empty.
§ Earthquake loads.
§ Pressure induced loads.
§ Loads applied by machine action (e.g., torque) – active forces and reactions.
§ Acceleration or deceleration (inertia) loading (e.g., braking forces).
§ Impact loads.
§ Shock loads due to changes in fluid flow or fluid density.
§ Loading produced by expansion or contraction of materials of construction.
§ Loading produced by material spillage or abnormal operation.
§ Loading produced during plant maintenance (e.g. resting equipment on platforms included in the package).
§ Loading occurring during transport and construction.
4.7 Base frames and skids

§ Machine and drive base frames shall be of rigid construction and may be of either fabricated or cast
construction.
§ In corrosive areas base frames shall be fabricated from stainless steel or composites.
§ Machine and drive base frames shall be stress relieved post welding and before final machining. No welding
shall be undertaken after post weld stress relief or final machining.
§ Mounting surfaces on base frames shall be machined to maintain equipment location accuracy and
tolerance.
§ Base frames shall prevent the retention of water, dust and other material.
§ Hollow sections shall be closed, and seal welded.
§ Piping connections shall terminate with a flange 25 mm inside the base frame boundary. Drains, vents,
utilities and other multiple connections shall be fixed to a single connection manifold per service at the
base boundary.
§ Lifting lugs shall be provided and shall be designed for lifting of the fully assembled unit. Lugs shall be
located such that the lifting slings do not contact equipment. The weight of assembled units shall be
indicated on the equipment tag.
§ Where spreader bars are required for lifting these shall be provided with the equipment.
§ Design loads shall include the loads associated with lifting when a fully assembled unit is lifted by sling
attached to the lifting lugs.
§ Piping terminations shall be located on one side of the base unless specified on the drawings.
§ Provide anti-vibration mounts if required.
§ Equipment, piping, cabling and instrumentation shall be laid out to allow adequate access for operations
and maintenance.
§ Where equipment may require alignment post maintenance or overhaul, galvanized jacking bolts to enable
convenient alignment of the equipment in both the longitudinal and traverse directions shall be provided.
§ Slotted holes shall be provided for hold down bolts. The slotted holes shall have sufficient adjustment to
properly align the equipment.
4.8 Machines without Separate Base Frames

§ Machines without separate base frames which are located on structural steel or concrete foundations shall
have underneath, machined pads or feet, at each hold-down bolt.
§ The machining of these pads shall be to a common level unless the machine design necessitates the use of
multi-level pads.
4.9 Piping and Tubing

§ Unless approved otherwise, all tubing, piping, flanges, fittings, fabrication and welding shall conform to the
appropriate Pipe Specifications.
§ All external pipe connections shall be preferred sizes to standard industrial practice. Where required
approved adaptors shall be provided to match specified standard connectors.
§ Unless specified otherwise, connections of 50 mm and smaller shall be screwed BSP, 80 mm and larger
shall be flanged per AS4087 Standard (PN16 as a minimum) unless noted otherwise. Bolt holes shall
straddle the Plant North/South or vertical centre line.
§ All piping materials (pipe, fittings, valves, strainers, filters, hoses, etc.) interconnecting a pre-engineered
equipment package shall be furnished, installed, supported, tested and cleaned, unless otherwise noted in
the specification.
§ All manual valving shall be safely and easily accessible from the operating floor level.
§ Flexible connectors for external piping connection shall be furnished by the Vendor. Open connections shall
be provided with temporary plugs to maintain cleanliness.
§ When plant air is required for equipment operation, air filter-regulator-lubricator sets shall be furnished
with the equipment.
§ Piping and valve materials shall suit the duty requirements for the fluid, pressure, temperature, abrasion
and corrosion conditions.
§ Pipe rack supports shall be suitably sized with appropriate routing.
4.10 Welding and Cutting

§ All pipe welding shall comply with the requirements of AS 4041.
§ All flame cutting shall comply with the requirements of AS 1674.
§ Where possible, perform all welding in a factory or workshop prior to delivery to site.
- Where site welding is to be employed, the work shall be planned in sections which shall permit a
maximum amount of welding to be completed at ground level. The work shall be planned in a manner
to limit, as far as possible, the amount of overhead welding.
- The welding machine’s earth shall be connected as close as possible to the work to prevent the risk of
stray current damage to bearings and gearing.
§ Unless otherwise specified, all welds to be continuous welds to ensure that crevices and sandwiched faces
are effectively sealed to prevent corrosion.
§ All welds subject to fatigue loading shall be subject to 100% visual examination.
§ All full penetration butt welds shall be subject to 10% radiographic examination.
§ The Vendor shall select material thickness and fabrication procedures to minimise the extent of welding
and distortion.
§ Unless otherwise specified, all steel fabrications subject to fatigue loading (as assessed according to
AS 4100) shall be stress relieved prior to machining.
§ All post weld heat treatment or stress relieving shall be undertaken following the completion of all
welding/fabrication in accordance with AS 4458 prior to finish machining.
§ These requirements shall also apply to welding and fabrication works associated with site installation.
4.11 Contamination of Stainless Steel

§ Stainless Steel components shall be stored and worked upon separately to carbon steel components at all
times.
§ Tools used for stainless steel work shall be dedicated to the use of work with stainless steel. Tools which
have been in contact with mild steel must not be used for the stainless-steel installation.
§ Care shall be taken when handling the stainless steel before, during and after fabrication to prevent
contamination with mild steel materials, dust, shavings and the like. Such care is particularly important
after passivation and during transport to site, storage and installation, as these small particles rust quickly
and discolour the surface of the stainless steel. This can destroy the protective oxide film and render it
liable to pitting corrosion.
4.12 Passivation of Stainless Steel

§ All stainless-steel welds and heat affected zones both external and internal shall be cleaned and passivated
following fabrication in accordance with the requirements of ASTM A380.
§ All stainless-steel fabrications shall be passivated after all welding have been completed. Passivating
preferably shall be carried out in the fabricator's works.
§ Passivation shall be carried out using chloride free preparations and thoroughly rinsed with water
afterwards.
§ In order to limit the quantity of passivation paste used on site, the majority of the external weld surface shall
be passivated off site. The only on-site passivation shall be site welds and clean-up of contaminated areas.
§ After passivation, fabricated components shall have a clean, matt finish free from scale and discolouration
caused by welding or heating.
4.13 Materials and Coating

Materials shall be suitable for the purposed duty and durability. As a minimum, the following factors shall be
considered during material selection:
§ Location e.g. above or below ground, inside or outside of a building, or inland environment.
§ Nature of process liquid that is in contact with or in the vicinity of the equipment.
§ Exposure to physical damage.
§ Corrosion and wear resistance.
§ Meet service life requirements.
§ Proven use in similar application.
For materials in contact with water or its constituents use:
§ Stainless steel Grades 316 or 316L.

§ Steel with protective coating with design life of 50 years and complying with AS 4020.
§ Alternatively use non-metallic corrosion resistant materials such as FRP, UPVC and polyethylene.
The following materials are prohibited and must not be included in any components of the equipment supplied:
§ Asbestos and materials containing asbestos.

§ Polychlorinated biphenyls (PCBs) and materials containing PCBs.
§ Any materials containing lead which may be ingested, inhaled or absorbed including lead in paints.
The following materials shall not be used without specific approval:
§ Ceramic Fibres.
§ Radioactive materials unless as part of an instrumentation system.
Following considerations should be made for material selection:
§ Stainless steel shall be minimum Grade 316. Welded stainless steel items shall be fabricated from
316L grade.
§ Mechanical components of grey cast iron shall not be used. Spheroidal graphite cast irons are
acceptable where iron castings are required.
§ Unless specified otherwise, galvanised mild steel coated as defined in table C1 of AS 2312 can be used
for structural steelwork that are not submerged or in splash zone.
§ Provide hot-dip galvanized coating that complies with AS 4680. Hot dip galvanising shall be done after
fabrication, for example, pipes, machinery, supports, platforms, stairs, handrails, base plates, covers,
and the like. The quality, thickness and minimum weight of coating shall be as specified in AS 4680.
§ Isolate connections between dissimilar metals with glass reinforced epoxy or phenolic insulating
washers and insulating sleeves.
§ Coat mating machined ferrous surfaces that are in permanent, static contact with a thin mixture of
graphite in oil, or other approved proprietary anti-seize compound before assembly.
§ Do not use protective coatings for exposed surfaces of liners and wear plates, however coat unexposed
liner and wear plate mounting surfaces where they are subject to corrosion e.g. mild steel.
4.14 uPVC piping

§ Equipment where uPVC piping is used, installation of uPVC shall be in accordance with AS 2032.
§ Fittings shall have a pressure rating not less than the adjacent pipe and shall have socket connected with
solvent welded joints. Threaded connections between piping components is not permitted.
§ All pipes, fittings and solvent cement shall preferably be of the same manufacture. Solvent cement and
primer shall conform to AS/NZS 3879 and shall be compatible with process fluid.
§ Above ground uPVC piping exposed to direct sunlight shall be avoided, if UV exposed piping is unavoidable
it shall be coated with two coats of UV resistant latex paint. Where piping system design is included in
vendor packages, the piping system design shall take thermal expansion into account, utilising expansion
loops or other proprietary devices as required.
4.15 PE piping
§ Where PE piping is used, Installation of PE pipelines shall be in accordance with AS/NZS 2566.2 and WSA-
01.
§ All jointing shall be butt fusion weld style and shall be done by a qualified welder per approved welding
procedures.
§ Tapping saddles may be used for tapping up to 30% of the size of the main pipe or a maximum diameter of
50mm. Where larger offtake sizes are required, then a reducing tee section should be used. Tapping saddles
shall be electrofusion type.
§ Above ground PE pipe installation shall take thermal expansion and contraction into account. In such
instances PE pipes shall be laid directly on cable ladders by snaking the pipe during installation and
allowing the pipe to move freely in service.
4.16 Painting
§ Factory standard coating systems may be used after formal review and approval.
§ Unless otherwise approved, equipment of a pre-engineered or proprietary design shall have all surfaces free
of dirt, scale, or other deleterious coatings before spraying with manufacturer's standard primer and
finishing coats provided it is suitable for the specified service conditions.
§ The following surfaces and materials shall not be blasted or painted unless specifically directed:
- Nameplates and tags shall not be painted and shall be kept clean and legible.
- Flange faces.
- Threads of bolting and adjusting screws, stud bolts and nuts for flanges.
- Instruments and fittings including gauges, valve stems and grease fittings.
Maintain written records of the painting work so that complete traceability of all work and materials is
maintained. As a minimum, these records should include appropriate information concerning the following:
- Job identification (work area).

- Surface preparation performed and equipment used.
- Painting applied and equipment used.
- Material used, batch number, colour and thinner.
- Application details including area covered, which coat was applied, wet film thickness and dry film
thickness.
- Weather conditions, including temperature of air and surface during application; relative humidity and
general weather conditions.
4.17 Vibration
§ Equipment shall run without excessive vibration under normal conditions of operation.
§ Dynamic and vibration loadings shall be isolated from the supporting structure and connecting pipework.
§ The method of isolation shall meet the recommended Vibration Limits and Guidelines as set-out in
Australian AS 2670.1 and British Standards BS 6841.
§ Vibration isolators shall be selected in accordance with the weight distribution and the manufacturer’s
recommendation to produce reasonably uniform deflection.
§ Vibration isolation shall be provided as required for equipment, ductwork and piping.
§ The natural frequencies of all components shall be at least 10% away from the frequency of all periodically
applied forces, except that the main shafts shall have their natural frequencies 20% outside the running
speed range.
§ Design rotating mechanical equipment to operate with minimal torsional and translational vibration to
minimises the vibration levels transferred to other plant and equipment. The acceptable limits for particular
equipment are:
- Provide equipment with an installed power of not more than 300 kW and a mounting category II in
accordance with AS 2625.4 that have a maximum vibration severity of 2.8 mm/sec (r.m.s) when
installed and commissioned.
- For a typical mounting category III factory test shall not exceed a vibration severity 4.5 mm/sec (r.m.s).
4.18 Noise
4.18.1 Design Limits
Equipment shall be selected and installed so that the noise level (Sound Pressure Level) in all normal operating
modes and with combination of other supplied equipment does not exceed the Australian national standard for
exposure to loud noise in the occupational environment in an eight-hour shift.
§ Unless specified otherwise, noise emissions from equipment shall not exceed 80dB(A) at 1m.
§ For multiple supplied equipment (multiple units operating duty/duty or upstream and downstream units)
and pipework connecting multiple items, each noise emitting item shall be considered separately for
determination of specified noise level.
§ Equipment shall operate within noise exposure standards and in instances where noise limits cannot be met,
sound dampening and/or acoustic protection shall be provided.
4.18.2 Measurement Method

§ Sound pressure level of noise generating equipment shall be measured with a precision, calibrated sound
level meter conforming to ISO 3740, or applicable international standard.
§ Sound measurements and supply information shall be completed in compliance with the procedures laid
down in one or more of the following standards and any subsequent amendments:
- ISO: 1683, 3740, 3741, 3744, 3746, and AS 1081.1 & 2.
§ The maximum tolerance allowed on guaranteed sound pressure level will be 2 dB(A).
4.18.3 Soundproofing Devices

§ The design of soundproofing enclosures or devices shall:
- Form an integral part of the equipment;
- Provide sufficient flow of cooling air to prevent the motor temperature from rising above the maximum
allowable operating temperature;
- Provide clear and unobstructed access for inspection and maintenance;
- Made from fire-resistant materials; and
- Provide clear and unobstructed access and visibility for emergency stop button(s).
4.19 Access, Platforms, Walkways, Stairs and Ladders

§ Where specified, platforms, walkways, stairs and ladders shall be designed, fabricated and erected in
accordance with AS 1657.
§ All frequently operated, inspected, lubricated or maintained items shall be accessible by means of stairs and
platforms.
§ Platforms shall be of sufficient strength to support workmen, tools and portions of plant which may be
placed on them during overhaul and inspection periods.
§ Adequate space shall be provided on the platforms to support workmen and tools and portions of plant
which may be placed on them during overhaul and inspection periods.
§ Walkway and stair width shall be minimum 1000 mm.
§ Headroom clearance shall be minimum 2,100 mm above grade level or accessible platform.
§ Stair ways are to terminate at a landing rather than directly to the target structure.
§ Ladders shall not be used to access any place where monthly operator maintenance access is required or
where the operators are required to carry instruments or tools to carryout maintenance task.
§ Unless otherwise specified, ladders shall be step type.
§ Ladders shall be Inclined ladders. Vertical ladders are not acceptable.
§ Where practical, the top of each ladder will be provided with a self-closing safety gate.
4.20 Equipment Maintainability

§ The equipment shall be designed to minimise operating and maintenance costs, with an efficient layout that
will permit safe access for operation, repair and maintenance.
§ All items of equipment (over 20 kg mass) shall be furnished with lifting lugs for crane handling. Lifting lugs
shall comply with the following:
- Designed to AS 4991 and marked with load limits.
- The lifting lugs with the centre of gravity of the equipment shall be shown on the drawings.
- Lifting lug rating shall be stamped on the lug.

- Clearly identifiable by painting the lifting points in yellow.
- Design lifting points that are suitable for shackle or sling attachment.
§ Provide lifting handles for the following equipment:
- Guards.
- Removable panels, covers, hatches and walkways (recess handles if appropriate).
- Provide at least one handle if weight is less than or equal to 20 kg for a one person lift and at least two
handles if the weight is between 20 kg and 40 kg for a two-person lift.
- Choose handle locations for ease of lifting to minimise any risk of harm to personnel e.g. back or
muscle strain.
4.20.1 Alignment and Settings

§ Install and align equipment in accordance with the manufacturer’s written instructions
§ When installation is carried out by others, provide documents that set out the detailed installation
procedures for equipment.
§ The installation instructions shall include the following information:
- A procedure for installing each component of equipment supplied.
- Drawings, sketches, diagrams showing in detail all the main components to be installed along with
their overall dimensions and weights.
- Details of the size and loading limits that apply to the equipment.
- A method for safely lifting and handling equipment.
- Details of methods, settings tolerances and adjustments required to correctly install the equipment
and make it ready for operation.
- A list of equipment and instruments required for adjusting and checking the accuracy of settings and
adjustments that are specified by the manufacturer.
- Alignment of couplings shall be performed by laser type alignment tooling strictly in accordance with
the laser alignment equipment manufacturer’s instructions.
4.21 Workmanship
§ All workmanship shall be in accordance with the best modern trade practice, relevant standards and codes
of practice and shall comply with contract documents.
§ All workmanship shall be carried out by appropriately qualified and experienced tradesman and under the
supervision of a competent foreman.
§ All workmanship shall result in high standard of construction and leave a thoroughly efficient, robust, tidy
and fully operational and safe installation.
§ Machining shall be concentric, square to line and true.
§ All sharp edges and burrs shall be removed.
§ Bolt holes shall be drilled, and spot faced for bolt head and nut.
§ Mating parts shall be match-marked and dowelled.
§ Defective work shall not be repaired by welding, filing, plugging or any other process without formal
approval.
4.22 Limits and Fits

§ Limits and fits shall be in accordance with AS 1654.
§ Fits between standard proprietary equipment and custom designed components supplied by the Vendor
shall be strictly in accordance with the standard proprietary component manufacturer’s recommendation.
4.23 Tolerances
§ All identical parts of plant shall be manufactured to such tolerances as to ensure that they are fully
interchangeable.
§ Custom designed components supplied by the Vendor shall be manufactured to the tolerances specified by
the Technical Specifications and Drawings.
§ Where tolerances are not provided by the above documents, they shall be in accordance with the relevant
Australian Standard (s).
4.24 Surface Finish

§ The principal parameter used for describing and quantifying surface roughness (finish) shall be the
Arithmetic Mean Deviation (Ra) expressed in microns (μm).
§ Surface finish on surfaces of custom designed components supplied by the Vendor, mating with surfaces on
standard proprietary equipment shall be strictly in accordance with the standard proprietary equipment
manufacturer’s recommendation.
§ Where the surface finish required is not provided by the proprietary equipment manufacturer or specified by
the drawings, it shall be in accordance with the relevant Australian Standard/s.
§ Verification of the specified Ra value shall be by the use of a visual roughness comparator in accordance
with AS 2382.
4.25 Labelling and Signs

§ Fit permanent identification labels to all major items of equipment. Label each item of equipment clearly
with its equipment number and description in accordance with the equipment numbers shown on the
equipment data sheets, P&ID’s or other referenced drawings or as directed.
§ Locate labels for each item of equipment in a clearly visible and readily discernible position.
§ All labelling shall be plainly visible at the angle from which the equipment is likely to be viewed.
§ Equipment labels can be made of SS316 or Traffolyte. Stainless engraved letters must be filled in black.
Traffolyte labels must be engraved white on black.
§ Adhesive nameplates or labels shall not be used unless otherwise approved. Fixings shall be of similar
material as the label or nameplate. All labels shall be in English.
§ Lettering shall be black on white background, unless expressly specified otherwise. Nameplates for major
material items shall be engraved in lettering 16 mm in height. Labels identifying ancillary items shall be
engraved in lettering 5 mm in height. The minimum size for labels shall be 65 mm x 12 mm. The quality
and text of the nameplates shall be subject to approval.
§ Attach labels to a principle component so the labels are not discarded with replacement of parts.
§ Labels shall be attached to the main body of the equipment with 316 stainless steel screws and nuts or
tapped holes and screws. Self-tapping screws will not be acceptable.
§ Where labels are attached to equipment with wire or chain, labels shall have rounded edges. Where tags are
attached to equipment with wires, these shall have their edges folded and tapped to prevent injury.
§ Machines shall have a direction of rotation arrow cast into casing and/or indicated on a stainless-steel plate
mounted on the bearing housing or machine pedestal close to the drive end.
§ Valve number and direction of opening/closing should be indicated on the valve covers.
4.25.1 Equipment Name Plate Information
Equipment shall show all information necessary for the proper identification, servicing, maintenance and
operation of equipment, and shall include the following, information where applicable:
- Manufacturer's name, model number, size and serial number.
- Date and country of manufacture.
- Critical operating (capacity) data and adjustments such as pump capacity (l/s).
- Head (mWG).
- Design and hydrostatic test pressure (mWG).
- Impeller or rotor type and size.
- Rotating equipment speed (rpm).
- Gauge readings and identification.
- Lubrication—type, quantity, frequency, and fill levels.
- Direction of rotation and/or flow.
- Warning notices.
- Temperature limits.
- Weight (dry or wet but this must be specified).
- Machine bearing identity drive end and non-drive end.
- Safety information.
- Maintenance instructions.
- Tag number in accordance with piping and instrument drawing.
- Name of equipment.
- Electrical requirements.
Machines shall have a direction of rotation arrow cast into casing and/or indicated on a stainless-steel plate
mounted on the bearing housing or machine pedestal close to the drive end.
5. General Mechanical Components

Unless specified otherwise, either within this document for particular applications, or in specifications for
particular equipment, components shall comply with this section.
5.1 Packing and Shims

§ Packing and shims shall be:
- Stainless steel for thickness 6 mm and less.
- Machined steel for greater than 6 mm.
§ All shim and packer corners and edges shall be radiused.
§ Cover the mating faces.
§ Shims and packers shall be the same size as the base they are under and shall not protrude out from the
mating surfaces being shimmed.
§ Made from uncoated new material only, having flat surfaces free from indents or burrs.
§ Shims shall be cut from stainless steel shim material and shall sit flat with no raised areas such as kinks or
lips.
5.2 Fasteners
§ All bolts, screws and nuts shall be ISO metric (coarse pitch series threads in accordance with AS 1275)
hexagon type. Materials shall be either:
- Hot dipped galvanised in accordance with AS 1214 or;
- Where embedded in concrete or submerged or in splash zone 316 stainless steel.
§ All bolts, screw and nuts shall comply with one of the following standards:
- AS 1110 ISO metric hexagon precision bolts and screws.
- AS 1111 ISO metric hexagon commercial bolts and screws.
- AS 1112 ISO metric hexagon nuts.
- AS 1237 Flat metal washers for general engineering purposes.
- AS 1252 General grade high strength steel bolts with associated nuts and washers.
- AS 2528 Bolts, stud bolts and nuts for flanges and other high and low temperature applications.
§ Flat washers shall be in accordance with AS 1237 and shall be hot-dipped galvanised in accordance with
AS/NZS 4680 unless otherwise specified. Taper washers shall be provided on bolted sections whenever
required by the shape of the sections being connected.
§ All bolted connections used for mechanical equipment shall be designed and manufactured in accordance
with AS 4100.
§ Tightened bolts shall project no less than two (2) full threads through nuts and not more than half of the
bolt diameter. Bolt length shall be based on the design grip thickness plus one (1) flat washer and one (1)
full hexagon nut unless otherwise specified or approved. Bolt length shall be selected from the
commercially available range to meet this requirement.
§ Cutting of bolts shall be avoided, however if necessary, bolts shall be workshop lathe cut prior to
installation. In the case where bolt length is found to be excessive during installation, the bolts shall be
removed and cut in a workshop by lathe where available or by saw when not. Bolts shall not be cut in-situ.
§ Where bolts are cut, the cut ends shall be chamfered and dressed free of sharp edges. Damaged end
threads shall be thread die chased and file de burred. Galvanised bolts shall be repaired by touch up in
accordance with relevant Australian Standards.
§ All shop and site drilled bolt holes shall be drilled. Holes may be punched where indicated by the drawings.
Oxy acetylene torch burning of holes is not permitted.
§ To prevent bolts from loosening during service tension them to at least 60% of yield strength of the bolt or
to equipment manufacturer’s specified torque.
§ When bolted connections are subject to vibration use self-locking nuts.
§ Small misalignment in the matching of holes, e.g. less than 5 percent of the hole diameter may be corrected
by reaming.
§ Isolate connections between dissimilar metals with phenolic insulating washers and insulating sleeves.
§ Coat stainless fasteners threads, prior to assembly, with an approved nickel based anti-seize compound or
molybdenum disulphide anti-seize compound.
5.3 Safety Equipment
5.3.1 General
§ Design equipment that complies with the requirements of the OH&S Act and Regulations, the WorkSafe
Codes of Practice, AS 4024 – Safety of Machinery, and affords maximum protection and safety for operating
personnel.
§ Safety equipment shall include guards, access covers, inspection covers, emergency stop equipment,
walkways, stairs, ladders, handrails, safety interlocks, and other devices as required. The equipment and
installation shall comply with the relevant Australian Standard.
5.3.2 Guards
§ Guards shall be fitted to equipment, in accordance with relevant statutory requirements, to prevent contact,
by accident or intent, of personnel with moving parts. For V-belts and chain drives these shall be
weatherproof.
§ Identification of hazards and risks and the principles of guarding shall be in accordance with AS 4024.1.
§ All guards shall be designed in accordance with AS 1755.
§ Guards should be an integral part of the design of the machine or machinery.
§ Pump shaft seal space shall be covered such that the possibility of accidental splashing of fluids in the event
of seal failure is removed.
§ Guards should be designed so that they do not allow the build-up of material.
§ Guards shall be strong enough to withstand personnel and other loads during maintenance and inspection
activities.
§ Fabricate guards with inspection ports or fit them with expanded metal sections to allow inspection without
having to remove the guards.
§ Inspection covers shall be readily opened without the use of tools. Provide grilles, bars, or mesh behind
covers where moving equipment may be reached. Alternatively, provide interlocks to stop equipment if
covers are opened.
§ Guards for vee belt drives shall be designed to allow for adjustment of shaft centres and have provision for
tachometer access for the driven shaft without removing the guard. V-belt guards shall permit sufficient
ventilation to prevent the build-up of heat.
§ Chain drives and gear drives shall be enclosed in oil-tight casings designed for oil-bath lubrication. Casings
shall have inspection doors and shall be of the horizontally split type (where possible) for easy removal.
§ All guards shall be marked with warning signage or labels "DANGER – Isolate equipment energy source
before removing."
5.3.3 Personnel Clearance

§ A minimum equipment clearance for maintenance and access shall be 800mm.
§ Where there is the possibility of personnel becoming trapped between moving equipment and any fixed
object, there shall be a minimum clearance of 600mm.
§ Where there is less than 600mm clearance, personnel access to the offending area shall be prevented by
suitable handrailing and the posting of warning signs.
5.3.4 Safety Signs

§ Supply and install safety and warning signs associated with the mechanical aspects of the plant. Install signs
that comply with AS 1319 where necessary and required by the WorkSafe Tasmania.
§ Signs shall as a minimum:
- warn of potential hazards;
- assist in preventing accidents;
- give operational and emergency procedures for potentially hazardous situations; and
- provide warnings where equipment may start automatically and where equipment may move without
warning and where other potential hazards may occur.
§ Where electrical interlocks are required provide labels that describe the operation of the interlock. Mount
labels permanently with 316 stainless steel screws and nuts and ensure label is clearly visible from the
operating position or walkway.
§ Safety signs shall be located where they can be easily seen and legible from a distance of not less than
10 m away and clearly visible from the operating position or adjacent walkway.
5.4 Gearboxes and Gears

§ Gearboxes shall be supplied by well established, reputable suppliers (e.g. Flender, Falk, SEW, Brevini or
approved equivalent) and shall be handled and installed strictly in accordance with the manufacturer's
recommendations.
§ All gearing shall be designed for a service life equal to the specified design of the plant based on
continuous, 24 hour per day, 365 day per year operation at rated motor load and speed unless otherwise
specified.
§ Gear quality shall be suitable for heavy-duty applications and shall be designed for a service life greater
than 100,000 hrs.
§ All gearing and gearboxes shall be designed to accommodate those maximum short-term loads generated
under motor stall conditions or under worst case braking conditions.
§ As a minimum, all gearing, and gearboxes shall be capable of withstanding six (6) evenly spaced full load
drive starts per hour assuming DOL starting of the drive motor.
§ For gearbox lubrication mineral based oils without EP additives are preferred.
§ Gear drives shall be enclosed in oil-tight casings designed for oil-bath/splash lubrication complying with
the requirements of AGMA 9005 is preferred to forced circulation oil lubrication.
§ All gearboxes shall include the following fittings which shall be located in readily accessible positions:
§ A dust tight dipstick, clearly marked with the correct, maximum and minimum oil levels for when the
gearbox is stationary and in operation.
§ A replaceable element filtered breather of adequate capacity and designed to prevent the ingress of all
foreign matter, gearbox pressurisation and oil escape.
§ A magnetic sump element.
§ A sampling point suitably located to enable the collection of a representative sample of oil shall be
provided. The sampling point shall be fitted with a cock and tubing to enable convenient collection of the
sample.
§ A plugged oil drain point. For gearboxes having oil capacities in excess of 4.5 litres, this drain shall be
extended to a convenient location and fitted with a full-bore ball valve and screwed blank plug. Where
gearboxes are located on elevated platforms and where the oil capacity is 20 litres or more, this drain shall
be extended so it terminates at an easily accessible area, preferably 1200 mm above ground level to enable
drainage directly into a 200 litre drum.
§ The internal surfaces of gear casings shall be painted with a suitable paint system for protection against
corrosion.
§ A light oil film shall be applied to all bare metal surfaces. This film shall offer sufficient protection against
corrosion during transport and storage and shall not require flushing from the gearbox prior to filling with
oil. Alternatively, a vapour phase inhibitor may be used.
§ In all cases, the gearbox shall be cleaned and flushed ready for the application of the first lubricant fill
without a requirement for further cleaning and flushing on the project site.
5.5 Bearings
§ All bearings shall be of standard types and sizes readily available. The number of different sizes and types
used shall be minimised.
§ Unless noted otherwise in the equipment specifications, ball or roller bearings shall be rated in accordance
with ISO 281or equivalent International standard.
§ Lubricated components shall be sealed to prevent product ingress, lubricant leakage and ingress of dust
and fumes.
§ All bearings shall be mounted in accordance with the bearing manufacturer's recommendations.
§ The minimum acceptable “L10 Life” for roller bearings unless otherwise specified is to be derived using the
procedures laid down in ISO 281 (Note, the equivalent Australian Standard was AS 2729 but has been
withdrawn since 2017).
§ Bearings, Seals and Lubrication Rolling element bearings shall have B10 life calculated in accordance with
AFBMA Standards 9 and 11, based on continuous operation under design load conditions. The specified
B10 life shall be 60,000 hours, as a minimum.
5.6 Lubrication Systems

§ All equipment shall be designed to allow for routine lubrication to be safely performed whilst in normal
operation.
§ All application points for lubricants shall be readily accessible.
§ The Vendor shall advise the grade and volume requirement for flushing (if required) and first fill lubricants.
Lubrication intervals shall be maximised. The Vendor shall provide a list of equivalent lubricants.
§ All bearings, gears etc. lubricated from a common console shall be designed for the same lubricant viscosity
and temperature.
§ Lubricant wells and reservoirs shall have adequate fill and drain openings and means for readily
determining the level of lubricant. After shop test run-in period, gear-cases and reservoirs shall be drained,
inlet and outlet plugged, and tagged to indicate that the equipment must be filled at commissioning.
§ Electric motors that are supplied with sealed bearings do not require any facility to grease bearings.
§ For electric motors that permit the addition of grease, provide a manufacturer installed greasing system
that prevents over lubrication of bearings.
§ Grease canisters may be used in critical applications where daily application is required.
§ Grease lubricated bearings shall be packed with lubricant during assembly.

§ Grease lubrication systems shall be installed strictly in accordance with the manufacturer's
recommendations.
§ Grease points shall be extended with tubing to permit routine lubrication during operation without removal
of any guard. Equipment with multiple lubrication or purging points within reasonably close proximity to
one another shall have their grease nipples mounted on a common bulkhead. All grease nipple bulkheads
shall include a hinged dust cover to protect the nipples.
§ For equipment with moving grease points or frequent lubrication requirements, automatic lubrication
systems shall be installed to maintain lubrication during normal operation.
§ Individual nipple greasing shall only be acceptable for where there is a very small number of readily
accessible lubrication points spaced far enough apart to make it un-economic to install a manual hand
pump dispensed, central lubrication unit.
§ Where possible, self-dispensing, single point mechanical lubricators shall be considered. Where there is
more than four (4) lubrication points in reasonable proximity to one another, a hand pump dispensed,
centralised manual lubrication system shall be provided.
§ Grease fittings shall be the standard BSP button-head type. Where grease nipples are installed, they shall be
orientated such that ready and convenient access for grease gun attachment is provided.
§ All grease lines shall be routed to minimise the possibility of damage or interference with maintenance
operations. Grease lines shall have a minimum clearance of 200 mm from all moving equipment. Where a
grease line is exposed and there is the risk of damage is significant, the grease line shall be protected.
§ Grease lines shall be manufactured from stainless steel grade 316 seamless tubing with minimum 6mm
diameter.
§ All grease line tube fittings shall be plain stainless steel "Swagelok" compression type fittings or approved
equivalent.
§ All tubing joins shall be made by connection fittings. Grease lubrication tubing shall not be welded.
§ Tube wall thickness shall not be less than 1.5 mm.
§ Tubing shall be cut using a tube cutter with the ends being reamed and thoroughly cleaned of all loose
metal particles.
§ Cutting of tube by hacksaw shall not be permitted.
§ All grease lines shall be rigidly supported with tube clamps at a maximum spacing of 1 m.
§ All tube support clamps shall be through bolted to existing or purpose-built steel supports. Screws shall not
be used.
§ All grease lubrication systems and lines shall be cleaned and flushed in such a manner that the risk of
lubricated component damage due to foreign particle contamination is eliminated.
§ Tubing ends, fittings and injector/divider ports shall be supplied by the manufacturer thoroughly sealed
with plastic plugs and/or tape. These plugs and/or tape shall only be removed upon assembly or
installation.
5.7 Vendor Supplied Steelworks

§ All steel fabrication with mechanical equipment such as chute and hopper plate work, machine and drive
base fabrications, support frames, bases etc., shall be in accordance with Australian Standards.
§ Steel shall have minimum yield strength of 250 MPa.
§ Assessment as to whether or not a steel fabrication is to be designed as a steel fabrication subject to fatigue
loading shall be in accordance with AS 4100.
§ Fabrications exempt from fatigue assessment shall be designed in accordance with AS 4100 (limit states
design method) or AS 3990 (working stress design method).
§ Fabrications subject to fatigue loading shall be designed in accordance with AS 4100.
§ Steelwork for site erection shall be marked before leaving the fabrication shop for identification at site.
§ Steel fabrication not subject to fatigue loading shall be in accordance with AS 4100 or AS 3990 with
welding in accordance with AS 1554.1 Cat SP.
§ Fabrications subject to fatigue loading shall be de welded in accordance with AS 1554.5.

§ Steel shall comply with AS 3678 and AS 3679 or equivalent international standard.
6. Electric Motors
§ Motor shall be conformance with Project specification for Packaged plant.
§ Unless otherwise specified, motors shall be rated to IP56 in accordance with AS 60529.
§ Unless otherwise specified, motors shall be suitable for at least 12 DOL starts per hour for motors under 15
kW and at least 10 DOL starts per hour for motors above 15 kW. Supplier shall nominate the maximum
allowable Start-Stops permissible for each motor.
§ Motors have shall have a minimum efficiency type to meet requirements of IE3 premium efficiency under
IEC 60034-30.
§ Pump motors shall be sized to be non-overloading at maximum conditions.
§ Motor rotor shall be dynamically balanced.
§ Motors shall be suitable for operations with variable speed drives.
§ Motor housing shall be machined from one-piece casting except for cable entry glands and the lifting
attachments. Lifting lugs shall be fitted to all motors.
§ Motor shall be rated to not overheat during continuous operation under any conditions.
§ If auxiliary air cooling is proposed for very low speed duties these shall be temperature/speed controlled to
automatically switch-off when the motor is operating at normal speeds.
§ Motors bearings shall conform to a L10 bearing life in excess of 100,000 hours for direct coupled
applications.
§ Motors rated at 22 kW and above shall have re-greaseable bearings with the grease entering on the inboard
side of the bearings and flushing all old grease out through the outboard side. V-ring seals shall be
provided on these motors.
§ Bearings shall be metrically dimensioned, stock standard and available locally with specialist bearing
suppliers.
7. Factory Testing
§ Factory acceptance testing (FAT) shall be carried on each piece of equipment and instrumentation being
supplied under the contract as specified in individual equipment specification and datasheets.
§ Where possible all equipment shall be completely shop assembled to check fit prior to shipment. All critical
dimensions shall be verified, and all motors checked and tested in the shop.
§ Shipping assemblies shall be as large as transportation facilities and access to the job site will allow.
§ Lifting lugs shall be correctly designed and supplied for bulky and heavy items.
§ Unless otherwise specified, all pressure parts, including heating and cooling jackets shall be capable of
withstanding a hydrostatic pressure without leakage for at least 30 minutes.
§ Unless otherwise specified/approved, the test pressure shall be 150% of the maximum data sheet pressure
for the part. A full speed running test for at least 30 minutes shall be conducted to prove operation free of
overheating, excessive fluid leakage, vibration and noise.
§ Parts proven defective by testing shall be notified before repairs are carried out.
8. Preparation for Shipment

§ Equipment for shipment shall be accompanied with shipping documents that shall comply with
International Chamber of Commerce (ICC) Incoterms (International Commercial Terms) requirements and
relevant Australian regulations.
§ Timber packaging where proposed should comply to the requirements of ISPM 15.
§ Shipping documents shall be in English and be provided in accordance with the shipping schedule to
prevent delays in shipping and clearance of goods from customs.
§ Machinery and equipment shall be suitably packed for transport to site and shall be sufficient to provide
protection from damage due to the normal handling during transport from the place of manufacture to
port, shipment, port to the delivery point and during storage at site.
§ Provision of suitable blocking straps and skids to protect the plant from damage in transit.
§ Suitable lifting lugs shall be supplied and fitted as necessary to facilitate handling during assembly,
maintenance and transport.
§ Lifting points shall be clearly identified.
§ Before shipment all equipment shall be fully protected against corrosion and damage due to handling, both
during shipment and during site storage.
§ The equipment shall be thoroughly cleaned prior to shipment.
§ All exterior parts of the unit, except machined surfaces shall be painted, as specified.
§ Exposed machined surfaces shall be protected with an easily removable rust preventative.
§ Flanged openings shall be protected with blanks of suitable material to prevent the entry of foreign matter.
After testing, and when prolonged storage is likely, packing used in the tests shall be removed from stuffing
boxes.
§ Cable runs should be packed so that they cannot be kinked or nipped.
§ Switchboards, Breakers and accessories shall be packaged and shipped separately.
§ Spare parts shall be packed separately and protected for long term storage.
§ Protection against vibration and shock.
§ Provision to cover all exposed threaded parts with grease, caps or special protectors.
§ Provision to cover all female threaded openings with tight fitting plastic closures or plugs.
§ Oil lubricated bearings housings shall be drained before shipment, and bearings protected against transport
damage.
§ All shafts fitted with anti-friction bearings shall be suitably strapped to prevent brinelling of the bearings
during transport.
§ Each piece of equipment and all instruments, whether mounted on the equipment or shipped loose, shall
have a rust-resistant metal tag firmly attached by wire or screws. This tag shall be stamped with the
equipment or instrument number. This applies also to equipment components that have been disassembled
and are shipped separately for field mounting.
§ Bolts, nuts, washers and any other small items for field installation or storage shall be packaged and
identified separately for shipment.
§ All shipments shall be accompanied by a packing list attached to the crate or package in a protected pocket.
9. Remote Assistance for Commissioning, Performance Testing and

Training
It is acknowledged that there is a likelihood that travel restrictions due to COVID-19 pandemic conditions may
prevent local and international travel to site to complete commissioning, performance testing and training
obligations.
§ Contractor shall propose an alternative strategy to facilitate performance testing as part of the Tender
submission if they or their local representative are unable to attend site.
§ Where travel to site to deliver collocated, face-to-face training sessions is not possible due to pandemic
conditions, remote training sessions shall be organised via video conferencing Apps such as Zoom, Team,
Webex etc. Alternatively, Contractor can propose Virtual Reality (VR) based training sessions for
consideration.

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Bryn Estyn Water Treatment Plant- Detailed Design

General Mechanical Specification

General Mech anical Specific atio n

Bryn Estyn Water Treatment Plant- Detailed Design

Project No: 0002-HOBWTO3

Jacobs Group (Australia) Pty Limited

Document history and status

Revision Date Description Author Checked Reviewed Approved

B 20/11/20 Issued for JV comments SY JB BA

C 08/12/20 Issued for Use SY JB BA BA

Yamin Date: 2020.12.11 05:20:41

4.24 Surface Finish ........................................................................................................................................................................ 23

1. Definition and Abbreviations

Definitions and Meaning Description / Definition

ADWG Australian Drinking Water Guidelines

Definitions and Meaning Description / Definition

Definitions and Meaning Description / Definition

SAT Site Acceptance Test

2.2 Works Not Covered

3. Standards, Codes & Regulations

3.2 Order of Precedence

3.3 Australian Standards

Table 1: List of Applicable Australian Standards

AS/NZS 1163 Cold-formed structural steel hollow sections

AS 1830 Grey Cast Iron

AS 3920 Pressure equipment - Conformity assessment

3.4 TasWater Standards

Table 2 TasWater Standards

0001-SPC-TWCDO-DE-0001_2 CDO Drawing and Drafting Requirements, Standard Technical Specification

0001-STN-TW-DE-0004_4 TasWater Supplement to Water Supply Code of Australia

3.5 Other Standards

Other codes and standards that can be considered.

Table 3 Other Standards and Codes

WSA 03 Water Supply Code of Australia

4. General Design Requirements

The International System of Units (SI) metric system shall be used.

4.3 Ambient Conditions

4.4 Design Life

Table 4: Service Life

Area Life expectancy

4.5 Equipment Selection and Design

§ Supply efficient, effective, durable equipment that is reliable in operation.

4.6 Design Loads

4.7 Base frames and skids

4.8 Machines without Separate Base Frames

4.9 Piping and Tubing

4.10 Welding and Cutting

4.11 Contamination of Stainless Steel

4.12 Passivation of Stainless Steel

4.13 Materials and Coating

§ Stainless steel Grades 316 or 316L.

§ Asbestos and materials containing asbestos.

4.14 uPVC piping

- Job identification (work area).

4.18.1 Design Limits

4.18.2 Measurement Method

4.18.3 Soundproofing Devices

4.19 Access, Platforms, Walkways, Stairs and Ladders