Work Pack - Guide for Reviewing Mechanical Engineering Work Packs_Rev1

Engineering Work Pack Engineering Project Work Work Order/Project Code no: Work Pack Title/Description: Work Pack no: Unique (registered) number and associated revision number

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MANAGEMENT OF CHANGE MOC Approval to proceed or EHSMS 12 Appendix A MOC Form Part B checklist signed and attached? Yes

No

MOC#:

Date:

WORK PACK PURPOSE

This section must clearly describe the purpose of the work pack and be written on the basis that the target audience may have little or no prior knowledge of the job.

QA/QC REQUIREMENTS List relevant special conditions, testing requirements, and NDT requirements.

This section must list all the documentation required to ensure the work meets the minimum technical and regulatory standards. Santos Engineering or Maintenance FIC sheets and Technical Instructions relevant to the Work Pack are to be listed in this section and copies attached to the Work Pack. If specialist equipment or personnel (i.e. vendor commissioning engineer) are required they must be listed in this section. Approved Weld Procedure Specification(s) (WPS's) referenced Appropriate NDT specified for all welds and joints (e.g. magnetic particle indication, dye penetrant, visual, or radiography) Hydrotest pressures and hold time specified for each Santos Piping specification used in the WP Or equivalent data included for pneumatic test where approved by Principal Mechanical Engineer. Qualification of personnel executing the job. e.g. Welding Inspector as per AS1796 Cert 10 Note indicating to sign and return workpack and all other relevant documentation to the person originating this document. WORK PACK PREPARATION, REVIEW AND APPROVAL Work Pack Type:

Mechanical

Instrumentation

Title

Electrical

Structural

Print Name

Prepared:

Engineer

Person developing the WP

Reviewed:

Discipline Quality Control

Moomba QA Welding Coordinator

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Civil Signature

Piping Date

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Senior Discipline Engineer

Reviewed:

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Any Senior Discipline Engineer included in the list of Approved Reviewers (check with Principal Mechanical Engineer) If WP is developed by Service Company then the reviewer should be a Senior Discipline Engineer from this company Insert extra line for Santos Acceptance where Work Pack is prepared by a Service Company

Accepted by:

Engineering Team Leader

Approved:

Person responsible for issue of Work Pack

or Section Leader WORK PACK DISTRIBUTION Process Coordinator

Production Coordinator

Process/Production

Permit Authority

Area Planner

QC/Welding Coordinator

Supervisor

Tradesperson

Integrity Engineer

Project Manager

NDT Tech

Other:

RELEVANT SPECIFICATIONS, DRAWINGS & DOCUMENTS List all relevant documentation, including revision number and applicable Code/Standard as required. Attach a copy of all drawings and/or field sketches. Refer to ‘The Well, Engineering, Santos Standards Index’ for List of applicable Specifications/Standards and include below.

Item No

Document Type and Number.

Revision No.

SAFETY If the installation requires excavation work reference to the excavation Work Pack is to be made in this section. Reference the associated MOC (if applicable) . Include all the relevant documents required by the Work Pack reviewer, planner and construction personnel, e.g. P&ID’s, New/Modified Equipment data, etc. There is no need to attach the complete MOC document Approved lift study (i.e. for cranage) referenced and attached (where applicable per HSHS16 Appendix A)?

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Whenever piping demolition and/or Tie-Ins to existing systems are included include reference to the following procedures: - Moomba Plant: Operating Procedure 0003-60-001 (Identification and Marking of Plant Piping prior to Demolition or Tie-ins) or - Port Bonython Plant: Operating Procedure 2500-60-001 (Identification and Marking of Plant Piping for Cutting, Welding or Abrasive blasting, Mandatory in Moomba and Port Bonython plant only. Risks associated with hazardous or toxic substances (e.g. mercury per HSH08.4, asbestos) have been duly considered and MSDS(s) attached to workpack (refer Chemwatch)? If the persons executing the job might be exposed to hazardous or toxic substances (e.g. Mercury, Asbesto, etc.) then include relevant MSDS(s) (refer Chemwatch) Also include reference to the relevant Santos EHS procedures (eg. HSH08.4 for Mercury, HSHS08.1 for Asbestos, etc.) DESIGN All drawings which are required by the planning , construction and/or maintenance departments in order to complete the Work Pack are to be listed in this section and copies attached to the Work Pack. Drawings must be provided on A4 or A3 sheets. Legible Mark-Ups from the MOC documents are acceptable however preference is for back drafted drawings. Reference to Painting and appropriate coating specification (where applicable) List data sheets for Mechanical equipment covered by the Work Pack in this section. Copies of the datasheets are to be included in the Work Pack. Where sections of specifications or standards are referenced which the installer will need to refer to, the relevant section shall be copied and attached to the Work Pack. Do not attach the full document. Reference to all relevant Australian, International and Santos standards

WELDING / QAQC

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Approved Weld Procedure Specification(s) (WPS's) referenced and attached for all welds For golden welds or hot taps both approval in principle and notification / acceptance forms have been approved All necessary Inspection and Test Plans (ITP's) referenced and attached in accordance with Work Pack Build Sheet OTHERS List any Work Packs for other disciplines which are directly related to this Work Pack i.e. this Work Pack may say cover the Mechanical works for a new pump skid. The I/E Work Pack for the installation of the pump skid must be referenced in this section.

JOB INSTRUCTIONS Notes: A detailed step by step set of instructions for work execution.

Item No

Task Description

GENERAL This section is to include all the steps in logical order necessary to implement the work including the plant shutdown, isolation and permitting work which will normally be done by Santos. Workpack should cover a single engineering discipline only. In this context mechanical / piping / civil / structural may be treated as one discipline i.e. don't mix these with instrument or electrical workpacks.

Preference should be given to numbering each Job Instruction logical step as this makes work tracking and referencing easier. The use of sub-headings / sections is encouraged to maximise clarity. Typical sections are: 1. 2. 3. 4.

Pre-start Off-site works Site works Close-out

Colour photo’s should be included in the relevant steps in this section where they help to identify work scope and or location.

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References to all associated Workpacks are included in the relevant Job Instructions

SAFETY Permitting requirements (e.g. excavation, hot work, cold work) have been considered and suitably referenced in job steps Confined Space Entry (CSE) risks considered and factored into work methodology, CSE risk assessment called up where appropriate (must involve Process/Production representative) Include reference to approved lift study (i.e. for cranage) in relevant Job Instruction (if applicable) Demolitions and Tie-Ins aspects of the job are clearly described in the pack. Include instructions to mark the Tie-Ins and cut points as per the following procedures: - Moomba Plant: Operating Procedure 0003-60-001 (Identification and Marking of Plant Piping prior to Demolition or Tie-ins) or - Port Bonython Plant: Operating Procedure 2500-60-001 (Identification and Marking of Plant Piping for Cutting, Welding or Abrasive blasting) NOTE: The use of these procedures is mandatory in Moomba and Port Bonython plants only. Relevant notifications to site personnel. Either because they will be directly involve with the job or because they need to be aware that the job is taking place. WORK DESCRIPTION All piping field sketches match the relevant marked up (i.e. CDCR'd) P&ID(s)? i.e. pipe specifications, pressure rating, valve specification(s), valve orientations, line slopes, insulation, fire-proofing, venting / drainage requirements, applicable P&ID notes. All relevant lines, equipment items, instruments, data sheets, and drawings (field sketches, P&ID's, isometrics, equipment general arrangement drawings, plot plans etc) have been fully referenced in the main body of the Workpack (i.e. with tag / number) and at all appropriate job steps and attached

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This section must include steps to cover the QAQC checks as per the Piping Specs or Vessel standard requirements for the work Scaffolding requirements have been considered and suitably referenced in job steps

WorkPack includes fully specified Bill of Materials (including quantities, item descriptions, pipe schedules, flange schedules, fitting ratings, material grades or specifications, Santos valve specifications etc) for all necessary materials (whether it is on a field sketch or in main workpack body). All the material specifications should be consistent with Santos Standards, AS, ASME, ASTM or any other relevant Standard. All the Tie-In points should be appropriately identified in the P&ID, Isometric and Photos. Cross references should be made to the relevant Job Instructions. Use HOLD POINTS to highlight a decision point by a Technical Person (e.g Integrity Engineer, etc.) In case of Repairs for which further investigation is required, include HOLD POINTS with detailed explanation on how to preserve the relevant evidence. Check that Isometric field sketches use appropriate drawing symbols (as per Santos standard P&ID symbols drawing 1500-10-001)? Location and orientation (i.e. "north" arrow) of all relevant piping, instruments, and equipment are clearly referenced without any ambiguity or potential for confusion? Isometric field sketches use solid lines for items to be fabricated or constructed, and show adjacent piping or mechanical equipment (labelled with line or equipment number) in dashed lines for context / clarity (tie-in points are thus clearly indicated by the transition from solid to dashed lines) Site measured dimensions (albeit to be confirmed later by job supervisor and notwithstanding 40NB or less to be site run) shown where applicable on isometric and general arrangement field sketches? e.g. to assist checking weld spacing (i.e. 6x wall thickness or 50mm whichever is greater), requirement for pipe stressing, pipe run allowance for instruments, adequacy of pipe supports / spans, and for materials ordering.

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Uniquely numbered and registered field sketches of all relevant piping (i.e. isometrics) and mechanical equipment (i.e. general arrangement drawings) have been created as appropriate i.e. they are not merely substituted for by marked up photographs? Any referenced photographs are contained in the formal Mechanical/Photo Data Sheet or Scaffolding/Cranage/Rigging Data Sheet (where applicable - refer to QA/QC Build Sheet)

Risks associated with hazardous or toxic substances (e.g. mercury per HSH08.4, asbestos) have been duly considered and MSDS(s) attached to workpack (refer Chemwatch)? Excavation risks considered, particularly potential underground services, and Excavation Permit appropriately referenced in job steps. Any machinery aspects of workpack have been reviewed and approved in writing by a Senior Machinery Engineer? Design is suitable for future operator or maintainer access and ergonomics requirements? e.g. no tripping hazards introduced, adequate isolation blinds provided, emergency escape access ok, valve / instrument / controls / buttons height and orientation suitable, suitable drain valve outlet clearance provided, platforms and ladders provided for access where required, suitable withdrawal clearance for adjacent equipment such as filters and tube bundles, equipment / vehicle access ok for EWP's, cranes, bundle pullers etc, suitable valve operator installed where required per Design Guide 1515-50-G002. No threaded joints in hydrocarbon service (other than for instrument tubing, instrument connections, vents / drains, low pressure oil gathering systems, or GRE gathering systems)? CLOSE OUT Include a section to close all the relevant documents associated with the Workpack, such as: Work Permits, ITPs, etc. Instruction to compile all the Work Pack signed-off documentation and return it to the originator. WORKPACK COMPLETION

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YES

NO

N/A

COMMENTS

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All work has been completed to required standards/specifications MAC Tagging is complete as per the Mac Tag Procedure used on all flanged connections Materials / parts used were correct for the job An Electrical Certificate of Compliance have been completed Where alternate materials/parts have been used, the MOC been completed and approved. All plant / equipment / instruments / covers / supports removed to provide access to job have been reinstated. Site left in tidy condition. All tools, surplus materials, and waste removed. All records including ITPs, FICs etc completed as required?

NAME (PRINTED)

SIGNATURE

DATE

QC INSPECTOR JOB SUPERVISOR DISCIPLINE ENGINEER

Comments:

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Work Pack - Guide for Reviewing Mechanical Engineering Work Packs_Rev1

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