JSE Recovery Improvement Pilot Plant Supply, Fabrication, FAT, Install and Commissioning

⁠⁠⁠The Contractor will be required to perform the following services:
1. Structural, mechanical and piping (SMP)
Supply of the following:
(a) Structural
(i) The pilot plant is supplied in modular sections where each section would fit on a standard trailer bed.
(ii) All steelwork complies with AS1554.1 SP
(b) Mechanical
(i) Valves
(ii) Slurry pumps
(iii) Multotec HX5 Spirals
(iv) CAVEX hydrocyclones
(v) Sampling points and cutters
(vi) Assembly of Derrick Ultrafines Screen. Please note Ultrafines screen would be free- issued
(vii) Possibly an agitator to prevent settling in tanks
(viii) Slurry tanks (non-rubber lined)
(c) Piping
(i) Steel pipes for both water and slurry
(ii) Rubber bellows/Expansion joints on pumps
(iii) Preformed rubber elbows
(iv) Flanges and fittings
(d) Supply of critical spares such as valves and preformed elbows

2. Electrical, instrumentation and control (EIC)
EIC package includes the supply of the following:
(a) Cabling for power and instrumentation
(b) Field Incomer, MCC, Cooling systems, circuit breakers, VSD drives and distribution board
(c) Motors for pumps and Ultrafine Screen
(d) Instrumentation
(i) Flow tubes and flowmeters
(ii) Valve actuators and positioners
(iii) Density gauges
(iv) Pressure gauges
(v) Motors for pumps and Ultrafine Screen
(vi) Proxy switches for sample cutters
(vii) PLC kit. Please note programming would be done by EPC using Schneider Unity.
(e) Communication
(i) Hirschmann Switches
(ii) Fibre optic break out tray (FOBOT) Patch Leads
(iii) Fibre Optics
(iv) Ethernet
(v) Racks
(f) Determine placement of contactors and cable rack in a strategic manner to enable quick turnaround for assembly and disassembly of pilot plant modules

3. Project management
(a) Provision of a Project Manager /Engineer to oversee all stages of deliverables leading to site commissioning of pilot plant
(b) Preparation of scope of works for site installation
(c) Participate in shutdown planning and risk assessments

4. Assembly and Transport
(a) Trial fit and assemble all modules in the workshop
(b) Disassemble pilot plant into separate modules and organise transport with Matic. Costs of transport ex. vendor would be covered by RTIO

5. Factory Acceptance Testing (FAT)
(a) Preparation of manufacturer’s data report (MDR)
(b) Management of inspection test plan (ITP) for construction of each individual module and also assembly of the modules in a workshop. ITP must include all electrical works.
(c) Conduct point to point tests of all switchgear, electrical equipment and instrumentation upon assembly of pilot plant in the workshop. Testing of density gauges need to be excluded as density gauges need to be transported to site as dangerous goods. All required tests to meet Australia & RTIO Standards
(d) Conduct FAT in the workshop with water for functional testing upon assembly of all modules in the workshop

6. Mechanical Site Installation & Construction
(a) Provision of site labour to assemble modules
(b) Mechanical and Piping tie-into existing services like gland water supply, instrumentation air supply and service water supply
(c) Construction of slurry supply line from sampling point of thickener feed tank and discharge line leading to the thickener

7. Site Commissioning of Pilot Plant
Provide commissioning assistance for the duration of 8 dayshifts comprised of the following workforce:
(a) 2 x fitters
(b) 2 x coded boilermaker welders
(c) 1 x rigger

8. Operation of Pilot Plant
Provide site based operators for the entire duration of 30 dayshifts which is the expected duration of testwork comprised of the following workforce upon site commissioning of the pilot plant:
(a) 1x leading hand fitter
(b) 1 x fitter
(c) 1 x coded boilermaker welder