Sep 70

II'
bhpbiLliton
BHP Billilon Iron Ore
225 ST. GEORGES TERRACE
PERTH, WA
Pages 1 to 33
ATTACHED
STANDARD ENGINEERING PRACTICE
NUMBER SEP 70 ; l JOB No
DESCRIPTION REQUIREMENTS FOR GENERATING A

MANU FACTURER'S DATA REPORT (MDR)
OFFICE OF ORIGIN BHP BILLITON IRON ORE G.A.
WRITTEN BY P G Edwards DATE 28/7/06 B.O.M.
REVIEWED BY O. Stacy DATE 28/7/06 SCOPE
TITLE OF REVIEWER MPDJV Deputy Project Director
STATUS APPROVAL BY BHPBIO RESPONSIBLE MANAGER/ENGINEER
SIGNED DATE REV
PRELIMINARY ON~ ~~ ~ r
ACCEPTED . ~ L ~~ h1 f7/Oh J
ACCEPTED
EXCEPT AS NOTED
R~tSF AND ~~ BMIT

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A ~P ~ ')'t!Y1BJiPE P,RE~~ONSIBLE MANA9J!F

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No. Date Revisions By Ckd Revd BHPBIO
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1
Dec 2002
June 2006
Rewritten to comply with current Procedures & practices
Rewritten to include provision for various

construction works and supplied equipment
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BHP Billiton Iron Ore
225 ST. GEORGES TERRACE
PERTH, W.A.
Pages 1 to 32
ATTACHED
STANDARD ENGINEERING PRACTICE
NUMBER SEP-70 / 1 JOB No
DESCRIPTION REQUIREMENTS FOR GENERATING A

MANUFACTURER’S DATA REPORT (MDR)
OFFICE OF ORIGIN BHP BILLITON IRON ORE G.A.
WRITTEN BY P G Edwards DATE 28/7/06 B.O.M.
REVIEWED BY O. Stacy DATE 28/7/06 SCOPE
TITLE OF REVIEWER MPDJV Deputy Project Director
STATUS APPROVAL BY BHPBIO RESPONSIBLE MANAGER/ENGINEER
SIGNED DATE REV
PRELIMINARY ONLY
ACCEPTED
ACCEPTED
EXCEPT AS NOTED
REVISE AND RESUBMIT
APPROVAL BY BHPBIO RESPONSIBLE MANAGER

DATE :
No. Date Revisions By Ckd Revd BHPBIO

0 Dec 2002 Rewritten to comply with current Procedures & practices TAT PGB
1 June 2006 Rewritten to include provision for various types of PGE PGE OFS PGB
construction works and supplied equipment
REQUIREMENTS FOR GENERATING A Doc. No. SEP 70
Rev 1
MANUFACTURER’S DATA REPORT (MDR) Date 08/06/06
Page 2 of 32
CONTENTS
1.0 INTRODUCTION AND SCOPE

2.0 REFERENCE DOCUMENTS
3.0 DEFINITIONS
4.0 REQUIREMENTS
4.1 General
4.2 Indices
4.2.1 List Of Contents
4.2.2 User Guide
4.2.3 Section of Contents List
4.2.4 Sub-Section Contents List
4.3 Presentation
4.3.1 Compilation
4.3.2 Collation
4.3.3 Paper Sizes
4.4 Attachments and Enclosures
4.5 Duplication of Data
4.6 Progressive Compilation
4.7 Verification and Review
4.8 MDR Index Examples
Appendix A - Typical MDR Structure (Structural/Mechanical Construction Works)

Appendix B – Typical MDR Index Examples
1.0 Camp Works
2.0 Concrete/Civil Works
3.0 Electrical Construction Works
4.0 Supplied Equipment
4.1 Electrical Equipment
4.2 Mechanical Equipment
Rev 1
Page 3 of 32
1.0 INTRODUCTION AND SCOPE
This Document represents the inspection and test results and may include procedures of plant
and equipment during manufacturing, fabrication, installation and / or commissioning offsite.
These records include certificates of conformance, inspection and test reports, inspection
releases, drawing registers and ’as-built’ drawings , lists of authorised deviations and
concessions, material certificates, welding procedure specifications, weld maps, NDT reports,
repair report, air testing reports, survey reports and painting reports. It also defines how these
records are assembled into MDR’s by Contractors who are contracturally obliged to supply such
data to the Company.
2.0 REFERENCE DOCUMENTS
SEP 15 – Numbering and Titling of Engineering Documents & Records

SEP 47 – Preparation, Issuing and Maintenance of Documents & Records
SEP 60 – Internal Registration of Classified Plant Machinery
SPEC 000-G-0001 – Administration & Documentation Requirements for Contractors Work
SPEC 000-S-0061 – Protective Coatings for New & Existing Steelwork & Equipment
3.0 DEFINITIONS
The Company shall mean the Company referred to in the contract.
“Contractor“ shall mean the person or corporation contracting to execute the Works and / or
Purchase Order. The definition “Contractor“ shall be synonomous with “Vendor“, “Supplier“,
“Subcontractor“, and “Consultant“.
“Approval Authority” means a qualified body approved by the Western Australian Department
of Mineral & Petroleum Resources (DOCEP) or Worksafe, engaged by the Company to:
• verify the design, construction and installation of operating plant in Western Australia;
• verify the design, construction and operating condition of statutory certified equipment (such
as cranes and pressure vessels);
• carry out such verification as the DOCEP/Worksafe Director may require;
“Data” means any document which contains written, printed or illustrated information. This can
include, but is not limited to, certification, procedures, drawings, calculations and test results.
“Manufacturer's Data Report” (MDR) means a volume or number of volumes compiled by

Contractors, containing records, certification and objective evidence of compliance with
requirements appertaining to material or equipment for the Project.
Rev 1
Page 4 of 32
“Drawing & Data Requirements“ define the administration and documentation requirements
for a Contractors detailed design, manufacture, testing, delivery, installation and commissioning
of all equipment. Refer SPEC 000-G-0001.
“Verification” is the formal process of confirming and documenting compliance with acceptance
criteria.
4.0 REQUIREMENTS
4.1 GENERAL
The Manufacturer’s Data Reports (MDR’s), shall provide sufficient records to comply with the
Company’s specified requirements of Drawings and Data. They must demonstrate (where
necessary) the achievement of traceability and specified certification requirements.
The data contained in MDR’s shall provide assurance to the Company that the required quality
of workmanship has been achieved. MDR’s shall include certification and traceability records
from Contractors in the appropriate sections. Contractors are responsible for ensuring that their
Suppliers comply with the requirements of this document.
MDR’s or certification provided with Company supplied products must be incorporated in their
entirety into the Contractor’s supplied MDR’s.
4.2 INDICES
4.2.1 LIST OF CONTENTS (Index)
The Contractor shall develop a ‘List of Contents’ (Index) for the MDR considering the
requirements of Appendix A and B and forward to the Company, or Company Representative,
for review prior to start of the work. The list will be reviewed by the Company, or Company
Representative and returned to the Contractor identifying the Company's approval or
requirements for revisions as marked.
The List of Contents (Index) shall be placed at the beginning of the MDR. A typical
Mechanical/Structural Construction Works MDR structure is shown in Appendix A. Other typical
MDR Index Structure examples covering various types of works are shown in Appendix B. A
‘List of Contents’ should identify the Volume, Part and Section information. If the index is
revised, it shall be re-submitted for review.
4.2.2 USER GUIDE
For complex goods, the Contractor shall provide a ‘User Guide’ detailing how the traceability and
identification system works, how to locate materials in an assembly and how to relate records to
materials or other records. The guide shall be submitted for review along with the MDR List of
Contents (refer to Section 4.2.1). The guide shall be placed immediately after the ‘List of
Contents’.
4.2.3 SECTION CONTENTS LIST

Rev 1
Page 5 of 32
A ‘Section Contents List’ - specific to the Section, shall be placed immediately following section
dividers. This list shall identify the contents of the Section to Sub-section level and be consistent
with the overall MDR index.
4.2.4 SUB-SECTION CONTENTS LIST
The Contractor shall provide a ‘Sub-Section Contents List’ if considered necessary by the
Company or the Company Representative. This list shall identify the contents of the sub-section
to the commencing page or section number of individual documents. Such lists are usually
required when traceability is a requirement.
4.3 PRESENTATION
4.3.1 COMPILATION
MDR’s shall be numbered in accordance with the Company’s requirements as noted in SEP 15
paragraph 2.0.
MDR’s shall be supplied in electronic format unless the supply in hard copy format is approved
by the Company. Refer to SEP 47 Appendix C for electronic format.
MDR’s in hard copy format shall be compiled in new, hard covered, four ring, plastic folders with
external pockets for front cover and spine. Folders shall be identified by a full sized title page
and spine title strip.
The folders contents shall not be longer than the folder and shall be clamped in place with a four
ring spring clamp. When the folder (complete with contents) is laid flat, the outer edge shall not
be higher than the bound edge.
MDR’s shall be compiled in Parts, eg. in the case of a purchase order for three separable items,
each item shall have its documentation maintained in a ‘Part’ of the MDR. Parts shall be given a
numeric identifier.
Parts are in turn broken down into sections at discipline level as listed below. Only those
sections which are applicable to the material/equipment being supplied shall be included.
For sections of the report that are not applicable state N/A on the list of contents.
For a typical Mechanical/Structural Construction Works MDR the following should be considered
as the typical sections to be included within the MDR. For other types of works and Supplied
Equipment see Appendix B for examples of typical MDR Index, and use the guide detail as
appropriate.
Section A : Inspection Release/Inspection and Test Plans
Include a copy of the “Inspection Release Certificate“ signed by or on behalf of the Company as
appropriate. Signed-off original Inspection and Test Plans (ITP’s) shall also be included in this
section.
Rev 1
Page 6 of 32
Section B : Material Certificates and Test Reports (TEST)

This section shall contain a register identifying all material certificates/test reports with their
respective part, piece or item number and is to include a copy of the certificate/reports, if
requested by the Company, referred to on the list (see Note 1).
The list shall show the Contractor’s drawing no. of each part/ piece of equipment or bulk material
item number identified with :
(i) Certificate/report number, line item- page number.

(ii) Heat, lot, plate number etc.
(iii) Material supplier
Section C : Certificate of Compliance
This section shall contain certificates of compliance to the purchase order requirements and to
the applicable codes and standards for fabricated pieces of equipment.
Section D : Welding Records
This section shall include a register of accepted and/or approved Welding Procedure
Specifications and Procedure Qualification Records, and other data appropriate. The Company
may request the testing data be included in the MDR as appropriate.
Section E : Welder and Welding Operator Records

This section shall include a register of qualified welders and welding operators, date of
qualification, welder identification number, and name of the qualifying authority and reference to
the test report identification number. The Company may request the testing data be included in
the MDR as appropriate (see Note 1).
Section F : Non-Destructive Testing Records.
(i) In this section include a list, map or summary of all the non-destructive testing performed.
Reference shall be made to the test locations on the equipment/materials.
(ii) Include all certificates/reports that are issued for non-destructive testing performed.
(iii) Include a summary sheet for all non- destructive testing personnel and their
qualifications, when the testing is performed by a non-NATA or equivalent organisation.
Section G : Painting and Coating – (Refer to SPEC 000-S-0061 for report

requirement)
Copies of reports of all surface preparation and coating applications shall be included in this
section.
Section H : Heat Treatment Records
This section shall include certificates and properly scaled charts for all heat treatment
performed, including reference to equipment identification number and date of heat treatment.
Rev 1
Page 7 of 32
Section I : Dimensional Records
Record of final dimensional checks and flange surface finish inspections shall be included in this
section. Dimension checks to consider but not limited to are Slew Bearing drop height
measurements; coupling alignments; wearplate thickness measurements and baseline vibration
measurements.
Section J : Non-Conformance Reports and Concessions
Non-conformance reports, technical queries, and approved concessions registers shall be

included in this section. The registers shall detail the identification, brief summary of topic and
the date raised and closed related to the topic.
Section K : Pressure Test Records
This section shall include hydrostatic and/or pneumatic test records, proof test certificates and
valve body/seat/leak test certificates. The calibration certificate for the testing equipment utilized
shall be attached to the test report. The test report shall clearly identify the testing equipment.
Section L : Mechanical and Performance Test Records
This section shall include reports of mechanical running test, mechanical functional tests,
performance tests, and noise level tests.
Section M : Electrical Certificates and Reports
In this section the following shall be included when relevant.

(i) Electrical and electronic equipment certification schedule and other certificates and
reports.
(ii) Electrical Material Statement of Compliance.
(iii) Electrical Certification - Hazardous operation.
(iv) Other test reports required by the specifications, e.g. factory calibration and parametering
records.
Section N : Instrumentation Certificates and Reports
In this section include the following when relevant.

(i) Instrumentation equipment certification schedule.
(ii) Instrumentation Material Statement of Compliance
(iii) Instrumentation Certification - hazardous operation.
(iv) Other test reports required by the specifications, e.g. factory calibration and parametering
records.
Section O : Drawings – refer to SPEC 000-G-0001 paragraph A3.0
In this section include a list of complete as-built drawings, identifying the supplier, Company
Representative and Company’s drawing numbers, title and revision status.
Section P : Miscellaneous Certificates, Reports and Records

Rev 1
Page 8 of 32
This section shall include all requested certification, reports, records and other data which are
not covered by other sections.
Section Q : Statutory Documents for Cranes, Hoists and Lifts – refer to SEP 60
List and copy of all statutory documentation shall be included in this section. Include the IRCP
face sheets.
Section R : Documentation for Pressure Vessel and Heat Exchangers and Others
List and copy of all statutory documentation shall be included in this section. Include the IRCP
face sheets.
NOTE 1: Where registers are only included within the MDR, the original certification
referenced on the register shall be retained by the contractor/supplier ensuring safety
from damage/deterioration and be available for review by the Company in the event of
failure or the like.
4.3.2 COLLATION
The MDR shall be collated as ‘Volumes’, each folder being a volume with a volume number
identifying the total number of volumes, eg. volume 1 of 6.
Each volume shall clearly show:
• Project Name: - BHP Billiton Iron Ore - (Project Name)

• Contract/Purchase Order Number;
• Contractor’s name;
• Project Goods;
• Volume Identification, (i.e. Volume 1 of 10; Volume 2 of 10);
• Part numbers covered in the Volume.
For a visual representation of the compilation and collation of an MDR refer to Appendix A.
4.3.3 PAPER SIZES
Standard ISO-A series paper is required for all MDR data i.e. A1, A3 or A4. The preferred size
for drawings is A1 and for schedules is A3. The preferred size for Certificates and Reports is A4.
Where use of A4 or A3 size sheets cause legibility problems, a larger A-size (that corrects the
problem) shall be used.
When A1 or A3 size data is provided, it shall be folded to A4 size and placed in suitable four
hole plastic pockets within the folders. Folded data should have the title block uppermost and
visible
4.4 ATTACHMENTS AND ENCLOSURES
Original test certificates and test reports are preferred. Originals shall be readily identifiable
through the use of coloured authorisation stamps. Where originals are not available, legible
copies will be accepted if endorsed “copy complying with original”.
Rev 1
Page 9 of 32
When completing proforma data, the information shall be fully completed in ink. Where there is
no requirement determined when completing check lists the abbreviation for ‘Not Applicable’
(N/A) shall be used to indicate that a response has been considered, ie there shall be no
ambiguous blanks or empty spaces.
4.5 DUPLICATION OF DATA
Duplication of data shall (where possible) be avoided, data common to several ‘Parts’ can be
presented in one ‘Part’. Common data is typically ‘Material Certificates’, ‘Technical Queries’ and
‘Site Instructions’. The Contractor shall identify on the ‘List of Contents’ and ‘User Guide’ any
‘Part’ that has contents for common use.
4.6 PROGRESSIVE COMPILATION
The Contractor shall progressively compile the MDR and keep it up to date at all times during
the execution of the work. When requested, the MDR shall be presented to the Company’s
surveillance personnel or delegate for review. The Contractor, when required, shall also make
the completed or partially completed MDR available to the Approval Authority for their inspection
and review.
During the progressive review and verification of MDR data, verified documents shall be
endorsed (either by the Company or the Approval Authority) by rubber stamp and/or signature,
indicating that a review has taken place at that stage and that data is acceptable.
4.7 VERIFICATION AND REVIEW
During final inspection, the completed MDR shall be presented to the Company’s surveillance
personnel or delegate and, where appropriate, the Approval Authority for verification. Upon
acceptance of the goods and MDR, an Inspection Release Report (INSR) will be issued for the
affected scope of work.
The Contractor shall forward the number of copies of the MDR identified on the contractural
document to the Company for review. The MDR will be reviewed by the Company and returned
to the Contractor identifying the Company’s approval or requirements for revisions as marked.
4.8 MDR INDEX EXAMPLES
Appendix A and B show typical MDR Index Structure for various types of works
indicative of the Contractor’s business, considered as meeting the intent of this
procedure.
Rev 1
Page 10 of 32
APPENDIX A
TYPICAL MDR STRUCTURE FOR STRUCTURAL/MECHANICAL

CONSTRUCTION WORKS
VOLUME PART SECTION SUB DESCRIPTION

SECTION
LIST OF CONTENTS
MDR User Guide
Typical Typical ITEM DESCRIPTION
A Inspection Release/ITPs
A-1 Inspection Release Report
A-2 Inspection and Test Plan (ITP)
B Material Certificates/ Test Reports
B-1 Structural Steel
B-2 Pipe
B-3 Fittings
B-4 Valves
B-5 Others
C Certificate of Compliance
C-1 Certificates of Compliance
D Welding Records
D-1 Welding Procedure Specifications and Register
D-2 Procedure Qualification Records and Register
D-3 Weld Maps and Traceability records (as
applicable)
D-4 Consumable Register and Certificates (as
applicable)
D-5 Production Test Plate records (as applicable)
E Welder and Welding Operator Records
E-1 Welder Register
E-2 Welder Qualification Records and Renewals (as
applicable)
F Non-Destructive Testing records
F-1 NDE Maps and Traceability records
F-2 NDE Reports - UT, RT, MT, PT, Hardness
Tests, etc.
F-3 NDE Personnel Register (as applicable)
G Painting and Coating
G-1 Surface Preparation and Painting records
Rev 1
Page 11 of 32
H Heat Treatment Records

H-1 Heat Treatment records
I Dimensional Records (as applicable)
I-1 Dimensional Verification Records
I-2 Flange Facing Inspection records
I-3 Slew Bearing Drop Height records
I-4 Coupling Alignment records
I-5 Wearplate Thickness records
I-6 Baseline Vibration records
J Non-Confomance Reports and
Concessions
J-1 Non-Conformance Reports
J-2 Approved Concession Requests
K Pressure Test Records
K-1 Hydrostatic Test Records
K-2 Pneumatic Records
K-3 Proof Test Certificates
K-4 Valve Body/Seat/Leak Test certificates
K-5 Air Test records
L Mechanical and Performance Test
Records
L-1 Mechanical Running tests
L-2 Mechanical Functional tests
L-3 Performance Tests
L-4 Noise Level tests
M Electrical Certificates and Reports
M-1 Electrical and Electronic Equipment
Certification Schedule, etc
M-2 Electrical Material Statements of
Compliance
M-3 Electrical Certifications for Hazardous
operations
M-4 Other test reports (e.g. calibration
records, etc.)
N Instrumentation Certificates and
Reports
N-1 Instrumentation Equipment Certification
Schedule
Rev 1
Page 12 of 32
N-2 Instrumentation Material Statement of

Compliance
N-3 Instrument Certification - Hazardous
Operation
N-4 Other test reports (e.g. calibration
records, etc.)
O Drawings
O-1 As-Built Drawings list
P Miscellaneous Certificates, Reports and

Records
P-1 Vendor data for Instruments and
Gauges
P-2 Others
Q Statutory Documents for Cranes, Hoists
and Lifts
Q-1 Cranes, hoists and Lifts IRCP face
sheets
R Statutory Documents for Pressure
Vessels, Heat Exchangers and Others
R-1 Inspection Authority Certificate
R-2 IRCP face sheet
The above is a typical (but very simplified) MDR structure intended to show how the same Section and
Sub-section structure should be repeated in each Part ie for each separable portion of the work.
Rev 1
Page 13 of 32
APPENDIX B
MDR INDEX EXAMPLES
1.0 Camp Works
2.0 Concrete/Civil Works
3.0 Electrical Construction Works
4.0 Supplied Equipment

4.1 Electrical Equipment
4.2 Mechanical Equipment
Rev 1
Page 14 of 32
1.0 TYPICAL MDR STRUCTURE FOR CAMP CONSTRUCTION WORKS

SECTION
LIST OF CONTENTS
MDR User Guide
1. ACCOMMODATION UNITS
1.1 POD 3
1.1.1 Excavation and Backfill Permits
1.1.2 Serial Numbers
1.1.3 ITP
1.1.4 Concrete Pour Sheet and Pre-Inspection
1.2 POD 4
1.2.3 ITP
1.3 POD 5
1.3.3 ITP
1.4 POD 6
1.4.3 ITP
Rev 1
Page 15 of 32

SECTION
LIST OF CONTENTS
MDR User Guide
2. CENTRAL FACILITIES
2.1 BULK STORE
2.1.3 ITP
2.2 BUS STOP

2.2.3 ITP
2.3 CONCESSION SHOP

2.3.3 ITP
2.4 CONTRACTORS ROOMS

2.4.3 ITP
2.5 GATE HOUSE

2.5.3 ITP
Rev 1
Page 16 of 32

SECTION
LIST OF CONTENTS
MDR User Guide
2.6 GYM
2.6.3 ITP
2.7 ICE MAKING ROOMS

2.7.3 ITP
2.8 INDUCTION CENTRE

2.8.3 ITP
2.9 INTERNET ROOM

2.9.3 ITP
2.10 MAINTENANCE WORKSHOP

2.10.3 ITP
Rev 1
Page 17 of 32

SECTION
LIST OF CONTENTS
MDR User Guide
2.11 RECREATION ROOM
2.11.3 ITP
2.12 SPORTING FACILITIES

2.12.3 ITP
2.13 TOILETS
2.13.3 ITP
2.14 WET MESS / BEER GARDEN

2.14.3 ITP
Rev 1
Page 18 of 32

SECTION
LIST OF CONTENTS
MDR User Guide
3. MISCELLANEOUS ITP AND RECORDS
3.1 COMPACTION TESTING RESULTS
3.2 AS-BUILT SURVEY (C/W SERVICES
INSTALLATION)
3.3 FIELD DISTRIBUTION BOARDS &
SWITCHBOARD
3.3.2 ITP
3.4 SERVICES
3.5 FIRE WATER
3.6 COMMS
3.7 POTABLE WATER
3.8 BLACK WATER/GREY WATER
3.9 LIGHT/SMALL POWER
Rev 1
Page 19 of 32
2.0 TYPICAL MDR STRUCTURE FOR CONCRETE / CIVIL WORKS

SECTION
LIST OF CONTENTS
MDR User Guide
A INSPECTION RELEASE/INSPECTION
WAIVER
A1 Inspection Release Report
A2 Completed Inspection Report INSR
B MATERIAL CERTIFICATES/TEST REPORT

TEST
B1 Re-Bar Material
B2 Others
C ROM PAD AREA

C1 Excavation and Backfill Permits
C2 Completed ITPs
C3 Concrete Pre-Pour/Pour Documents
C4 Concrete Delivery Documents
C5 Concrete Test Certificates
C6 Compaction Records
C7 Concrete Placement Identification
D PRIMARY CRUSHING AREA

D1 Excavation and Backfill Permits
D2 Completed ITPs
D3 Concrete Pre-Pour/Pour Documents
D4 Concrete Delivery Documents
D5 Concrete Test Certificates
D6 Compaction Records
D7 Concrete Placement Identification
Rev 1
Page 20 of 32

SECTION
LIST OF CONTENTS
MDR User Guide
E PRIMARY CRUSHING – HYDRAULIC & LUBE
UNIT FOUNDATIONS
E1 Excavation and Backfill Permits
E2 Completed ITPs
E3 Concrete Pre-Pour/Pour Documents
E4 Concrete Delivery Documents
E5 Concrete Test Certificates
E6 Compaction Records
E7 Concrete Placement Identification
F PRIMARY CRUSHING – TRANSFORMER

FOUNDATIONS
F1 Excavation and Backfill Permits
F2 Completed ITPs
F3 Concrete Pre-Pour/Pour Documents
F4 Concrete Delivery Documents
F5 Concrete Test Certificates
F6 Compaction Records
F7 Concrete Placement Identification
G ETC – TO COVER ALL SOW, THEN

FOLLOWING SECTIONS AS APPROPRIATE
H NON-CONFORMANCE REPORTS AND

CONCESSIONS
H1 Non-Conformance Reports
H2 Approved Concession Requests
I INSTRUMENTATION CERTIFICATES AND

REPORTS
I1 Instrumentation Equipment Certification
Schedule
J MISCELLANEOUS CERTIFICATES,
REPORTS AND RECORDS
J1 Vendor Data for Instruments and Gauges
J2 Surveyor Log
Rev 1
Page 21 of 32
K AS BUILT DRAWINGS
K1 As Built Drawings (identifying each area/lot)
K2 Electrical Conduit
K3 As Built Bolts
K4 Complete Survey Records
L SERVICES (eg COMMS, ELECTRIC,

SEWERAGE)
L1 Excavation and Backfill Permits
L2 Completed ITPs
Note: As-builts must also clearly identify all services as appropriate.

Rev 1
Page 22 of 32
3.0 TYPICAL MDR STRUCTURE FOR ELECTRICAL CONSTRUCTION

WORKS

SECTION
LIST OF CONTENTS
MDR User Guide
1.0 LIST OF WORKS UNDERTAKEN
1.1 Description of works undertaken on the project
2.0 CERTIFICATION AND PERMITS

2.1 Energising Permits
2.2 Compliance Certification
3.0 INSPECTION AND TEST PLANS

3.1 11kv Installation and LV feeders ITP 001/1
3.2 Primary Crusher MCC 1200 ITP 001/2
3.3 Train Loadout MCC 1220 ITP 001/3
3.4 Primary Crusher CR 1200 ITP 001/4
3.5 Conveyor CM 1202 ITP 001/5
3.6 Conveyor CM 1203/4 ITP 001/6
3.7 Sample Station SS4 ITP 001/7
3.8 Transfer Station TS1202 ITP 001/8
3.9 Conveyor CM 1201 ITP 001/9
3.10 Train Loadout Control Room ITP 001/10
3.11 Train Loadout ITP 001/11
3.12 Mine Water Treatment Plant ITP 001/12
3.13 Lighting and Small Power ITP 001/13
4.0 INSPECTION AND TEST REPORTS

4.1 11kv Installation and LV feeders
4.2 Primary Crusher MCC 1200
4.3 Train Loadout MCC 1220
4.4 Primary Crusher CR 1200
4.5 Conveyor CM 1202
4.6 Conveyor CM 1203/4
4.7 Sample Station SS4
4.8 Transfer Station TS1202
4.9 Conveyor CM 1201
Rev 1
Page 23 of 32
4.10 Train Loadout Control Room

4.11 Train Loadout
4.12 Mine Water Treatment Plant
4.13 Lighting and Small Power
4.14 High Voltage Cable on Drum Testing
4.15 Fibre Optic Cable Test Results
5.0 NON CONFORMANCE REPORTS

5.1 NCR Register
5.2 Non Conformance Reports
6.0 DRAWINGS AND DATA SHEETS

6.1 List of As-Built Drawings
6.2 Equipment Data Sheets
7.0 MISCELLANEOUS CERTIFICATION,

REPORTS AND RECORDS
7.1 Signatory List of Authorised Inspection
Personnel
7.2 Electrical Test Equipment Certificates
7.3 Product Manufacturers Data Sheets
Rev 1
Page 24 of 32
4.1 TYPICAL MDR STRUCTURE FOR SUPPLIED ELECTRICAL EQUIPMENT

SECTION
LIST OF CONTENTS
MDR User Guide
1. CRUSHER MCC MC101
1.A INSPECTION RELEASE
1A1 Inspection Release Report
1A2 Completed ITPs
1A3 Energise Permits
1B CERTIFICATION OF COMPLIANCE
1B1 Certificate of Short Circuit Rating
1B2 Certificate of Conformity for *** Contractors
1C PAINTING AND COATING

1C1 Painting Procedure and Inspection Records
1D DIMENSIONAL RECORDS
1D1 Steelwork Test Report
1E ELECTRICAL CERTIFICATES AND

REPORTS
1E1 Switchboard Test Report
1E2 Module Test Report
1E3 Module Test Procedure
1E4 Electrical Test Report
1E5 Ductor Test Report
1E6 Test Equipment
1E7 Specimen Signatures
1F DRAWINGS
1F1 As-Built Drawings List
1G VENDOR EQUIPMENT ELECTRICAL

CERTIFICATES AND REPORTS
1G1 Vendor Equipment, Test Sheets & Certification
1H NON-CONFORMANCE REPORTS
Rev 1
Page 25 of 32
1H1 Non-Conformance Reports
2. CRUSHER SUB BD2

2A INSPECTION RELEASE
2A2 Completed ITPs
2B ELECTRICAL CERTIFICATES AND

REPORTS
2B1 Switchboard Test Report
2B2 Module Test Report
2B3 Module Test Procedure
2B4 Electrical Test Report
2B5 Ductor Test Report
2B6 Test Equipment
2B7 Specimen Signatures
2C DRAWINGS
2C1 As-Built Drawings List
2D WELDING RECORDS
2D1 Welding Procedures, Specifications,
Qualifications and Certification Registers
2D2 Welder Qualification and Certification Registers
3. SAMPLE STATION MCC MC102

3A2 Completed ITPs
3B CERTIFICATION OF COMPLIANCE
3B1 Certificate of Short Circuit Rating
3B2 Certificate of Conformity for *** Contractors
3C PAINTING AND COATING

3C1 Painting Procedure and Inspection Records
3D DIMENSIONAL RECORDS
3D1 STEELWORK TEST REPORT
Rev 1
Page 26 of 32
3E ELECTRICAL CERTIFICATES & REPORTS

3E1 Switchboard Test Report
3E2 Module Test Report
3E3 Module Test Procedure
3E4 Electrical Test Report
3E5 Ductor Test Report
3E6 Test Equipment
3E7 Specimen Signatures
3F DRAWINGS
3F1 AS-BUILT DRAWINGS LIST
3G VENDOR EQUIPMENT ELECTRICAL

3G1 VENDOR EQUIPMENT, TEST SHEETS AND
CERTIFICATION
3H NON-CONFORMANCE REPORTS
3H1 NON-CONFORMANCE REPORTS
4. REMOTE I/O PQ103

4A2 Completed ITPs
4B PAINTING AND COATING

4B1 Painting Procedure and Inspection Records
4C DIMENSIONAL RECORDS
4C1 STEELWORK TEST REPORT
4D ELECTRICAL CERTIFICATES & REPORTS

4D1 Switchboard Test Report
4E DRAWINGS
4E1 AS-BUILT DRAWINGS LIST
4F VENDOR EQUIPMENT ELECTRICAL

4F1 VENDOR EQUIPMENT, TEST SHEETS AND
CERTIFICATION
Rev 1
Page 27 of 32
4.2.1 TYPICAL MDR STRUCTURE FOR SUPPLIED MECHANICAL

EQUIPMENT

SECTION
LIST OF CONTENTS
MDR User Guide
A. EQUIPMENT DESCRIPTION
A1 Guillotine Gate and Loading Chute
A2 Hydraulic System
A3 Electrical System
A4 Drawing Index
B. GUILLOTINE GATE AND LOADING CHUTE

FABRICATION
B1 Inspection and Test Plans
B2 Release Certificates
B3 Material Certifications Register
B4 Welding Records
B4(i) Welding Procedure Specifications Register
B4(ii) Procedure Qualification Records Register
B4(iii) Weld Maps and Traceability Records (as
applicable)
B4(iv) Consumable Register and Certificates(as
applicable)
B4(v) Production Test Plate Records (as applicable)
B5 Welder and Welding Operator Records
B5(i) Welder Register
B5(ii) Welder Qualification Records and Renewals (as
applicable)
B6 Non-Destructive Testing Records
B6(i) NDE Maps, Traceability Records and Requests
B6(ii) NDE Reports – UT, RT, MT, Pt, Hardness Tests
etc
B6(iii) NDE Personnel Register (as applicable)
B7 Surface Protection Coating Check Sheets
B8 Heat Treatment Records (if applicable)
B9 Dimensional Records
B10 Non-Conformance Reports and Concessions
B11 Performance Test Record
Rev 1
Page 28 of 32
B12 As-Built GA Drawings List

B13 Equipment Nameplate Detail
C. ELECTRICAL SYSTEM
C1 Inspection and Test Plans
C2 Release Certificates
C3 Test Reports
C4 Commissioning Reports
C5 MCC Switchboard Test Reports
C6 Instrumentation Certificates
C7 As-Built GA Drawings List
C8 Electrical Certificates and Reports
C9 Nameplate Detail
D. HYDRAULIC SYSTEM
D1 Inspection and Test Plans
D2 Release Certificates
D3 Material Certifications
D4 Weld Procedure Qualification Records
D4(i) Weld Procedure Specifications Register
D4(ii) Procedure Qualification Records Register
D4(iii) Weld Maps and Traceability Records (as
applicable)
D4(iv) Consumable Register and Certificates (as
applicable)
D4(v) Production Test Plate (as applicable)
D5 Welder and Welding Operator Records
D5(i) Welder Register
D5(ii) Welder Qualification Records and Renewals (as
applicable)
D6 Non Destructive Testing
D6(i) NDE Maps, Traceability Records and Requests
D6(ii) NDE Reports – UT, RT, MT, Pt, Hardness Tests
etc
D6(iii) NDE Personnel Register (as applicable)
D7 Paint and Coating Reports
D8 Dimensional Records
D9 Non Conformance
D10 Pressure Test
D11 As-Built GA / PID Drawings
D12 Mechanical and Performance Test Records
Rev 1
Page 29 of 32
D13 Miscellaneous Certificates, Reports & Records

E. FACTORY ACCEPTANCE TESTING
E1 Procedures
E2 Mechanical Test Reports
E3 Hydraulic Test Reports
E4 Electrical/PLC Test Reports
E5 As-Built Electrical Wiring Diagrams
Note: Dimensional Records to include all critical data considering but not limited to the
following:
- Slew Bearing Height Measurements;
- Coupling Alignment Checks;
- Wearplate Thickness Measurements;
- Baseline Vibration Data (this may be covered in testing data area).
Rev 1
Page 30 of 32
4.2.2 TYPICAL MDR STRUCTURE FOR SUPPLIED MECHANICAL

EQUIPMENT

SECTION
LIST OF CONTENTS
MDR User Guide
1 A INSPECTION RELEASE / ITPs
A1 Inspection Release Reports
A2 Inspection and Test Plans
A3 Packing Inspection Records
B MATERIAL CERTIFICATES / TEST REPORTS
B1 Structural Steel
B2 Pipe
B3 Fittings
B4 Valves
B5 Others
C CERTIFICATES OF COMPLIANCE
C1 Certificates of Compliance
D WELDING RECORDS
D1 Welding Procedure Specifications Register
D2 Procedure Qualification Records Register
D3 Weld Map and Traceability Records (as
applicable)
D4 Consumable Register and Certificates (as
applicable)
D5 Production Test Plate Records (as applicable)
E WELDER & WELDER OPERATOR RECORDS

E1 Welder Register
E2 Welder Qualification Records and Renewals(as
applicable)
F NON-DESTRUCTIVE TESTING RECORDS

F1 NDE Maps, Traceability Records and Requests
F2 NDE Reports – UT, MT, Hardness Test etc
F3 NDE Personnel Register (as applicable)
Rev 1
Page 31 of 32
G PAINTING AND COATING

G1 Surface Preparation and Painting Records
G2 Consumables Painting
H HEAT TREATMENT RECORDS

H1 Heat Treatment Records
H2 Heat Treatment Procedures
I DIMENSIONAL RECORDS
I1 Dimension Verification Records
I2 Flange Facing Inspection Records
13 Alignment Checks etc
J NON-CONFORMANCE REPORTS AND

CONCESSIONS
J1 Non-conformance Reports
J2 Approved Concession Requests
J3 Technical Queries and Register
K PRESSURE TEST RECORDS

K1 Hydrostatic Test Records
K2 Pneumatic Records
K3 Proof Test Certificates
K4 Valve Body / Seal / Leak Test Certificates
K5 Air Test Records
L MECHANICAL AND PERFORMANCE TEST

RECORDS
L1 Mechanical Running Tests
L2 Mechanical Functional Tests
L3 Performance Tests
L4 Noise Level Tests
M ELECTRICAL CERTIFICATES & REPORTS

M1 Electrical and Electronic Equipment Certification
Schedule
M2 Electrical Material Statement of Compliance
M3 Electrical Certifications for Hazardous
Operations
M4 Other Test Reports, Calibration Records
Rev 1
Page 32 of 32
N INSTRUMENTATION CERTIFICATES AND

REPORTS
N1 Instrumentation Equipment Certification
Schedule
N2 Instrumentation Material Statement of
Compliance
N3 Instrumentation Certification – Hazardous
Operation
N4 Other Test Reports, Calibration Records
O DRAWINGS
O1 As-Built Drawings List
P MISCELLANEOUS CERTIFICATES,
REPORTS AND RECORDS
P1 Vendor Data for Instruments and Gauges
P2 Others
Q STATUTORY DOCUMENTS FOR CRANES,

HOISTS AND LIFTS
Q1 Cranes, Hoists and Lifts IRCP face sheet
R STATUTORY DOCUMENTS FOR PRESSURE

VESSELS, HEAT EXCHANGERS & OTHERS
R1 Inspection Authority Certificate
R2 IRCP face sheet
S SOFTWARE TEST REPORTS AND RECORDS

S1 Test Reports / Sheets

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II'

DESCRIPTION REQUIREMENTS FOR GENERATING A

OFFICE OF ORIGIN BHP BILLITON IRON ORE G.A.

WRITTEN BY P G Edwards DATE 28/7/06 B.O.M.

REVIEWED BY O. Stacy DATE 28/7/06 SCOPE

TITLE OF REVIEWER MPDJV Deputy Project Director

STATUS APPROVAL BY BHPBIO RESPONSIBLE MANAGER/ENGINEER

SIGNED DATE REV

R~tSF AND ~~ BMIT

A ~P ~ ')'t!Y1BJiPE P,RE~~ONSIBLE MANA9J!F

Rewritten to include provision for various

DESCRIPTION REQUIREMENTS FOR GENERATING A

OFFICE OF ORIGIN BHP BILLITON IRON ORE G.A.

WRITTEN BY P G Edwards DATE 28/7/06 B.O.M.

REVIEWED BY O. Stacy DATE 28/7/06 SCOPE

TITLE OF REVIEWER MPDJV Deputy Project Director

STATUS APPROVAL BY BHPBIO RESPONSIBLE MANAGER/ENGINEER

SIGNED DATE REV

REVISE AND RESUBMIT

APPROVAL BY BHPBIO RESPONSIBLE MANAGER

No. Date Revisions By Ckd Revd BHPBIO

1.0 INTRODUCTION AND SCOPE

Appendix A - Typical MDR Structure (Structural/Mechanical Construction Works)

1.0 INTRODUCTION AND SCOPE

2.0 REFERENCE DOCUMENTS

SEP 15 – Numbering and Titling of Engineering Documents & Records

The Company shall mean the Company referred to in the contract.

“Manufacturer's Data Report” (MDR) means a volume or number of volumes compiled by

4.2.1 LIST OF CONTENTS (Index)

4.2.2 USER GUIDE

4.2.3 SECTION CONTENTS LIST

4.2.4 SUB-SECTION CONTENTS LIST

Section A : Inspection Release/Inspection and Test Plans

Section B : Material Certificates and Test Reports (TEST)

(i) Certificate/report number, line item- page number.

Section C : Certificate of Compliance

Section D : Welding Records

Section E : Welder and Welding Operator Records

Section F : Non-Destructive Testing Records.

Section G : Painting and Coating – (Refer to SPEC 000-S-0061 for report

Section H : Heat Treatment Records

Section I : Dimensional Records

Section J : Non-Conformance Reports and Concessions

Non-conformance reports, technical queries, and approved concessions registers shall be

Section K : Pressure Test Records

Section L : Mechanical and Performance Test Records

Section M : Electrical Certificates and Reports

In this section the following shall be included when relevant.

Section N : Instrumentation Certificates and Reports

In this section include the following when relevant.

Section O : Drawings – refer to SPEC 000-G-0001 paragraph A3.0

Section P : Miscellaneous Certificates, Reports and Records

Each volume shall clearly show:

• Project Name: - BHP Billiton Iron Ore - (Project Name)

4.3.3 PAPER SIZES

4.4 ATTACHMENTS AND ENCLOSURES

4.5 DUPLICATION OF DATA

4.6 PROGRESSIVE COMPILATION

4.7 VERIFICATION AND REVIEW

4.8 MDR INDEX EXAMPLES

TYPICAL MDR STRUCTURE FOR STRUCTURAL/MECHANICAL

VOLUME PART SECTION SUB DESCRIPTION