01-1022-000-SPC-FU-0007-IFC (02) - Spec Fuel

Temporary Central Emergency Power
Station (CEPS) Specification

Stage Two Garden Island (East)
Critical Infrastructure Recovery Program Sydney
Prepared for: Lendlease
iTWOcx Document No: 03-1022-000-SPC-FU-0007
ACOR Document No: NM150060-031
Issue No: 02
Sydney | Brisbane | Perth | Broome | Central Coast | Newcastle | Western Sydney

ACOR MCE Consultants Pty Ltd, ACN 162 450 375 ATF The ACOR WA Unit Trust ABN 24 416 114 936.
“ACOR Consultants” is a trademark licensed to ACOR MCE Consultants Pty Ltd by ACOR Consultants Pty Ltd
This report has been prepared in accordance with the scope of services described in the contract or agreement between ACOR
MCE Consultants Pty Ltd and the Client. The report relies upon data, surveys, measurements and results taken at or under the
particular times and conditions specified herein. Changes to circumstances or facts after certain information or material has been
submitted may impact on the accuracy, completeness or currency of the information or material .This report has been prepared
solely for use by the Client, ACOR MCE Consultants accepts no responsibility for its use by other parties without the specific
authorization of ACOR MCE Consultants Pty Ltd. ACOR MCE Consultants Pty Ltd reserves the right to alter, amend, discontinue,
vary or otherwise change any information, material or service at any time without subsequent notification. All access to, or use of,
the information or material is at the user's risk and ACOR MCE Consultants Pty Ltd accepts no responsibility for the results of any
actions taken on the basis of information or material provided, nor for its accuracy, completeness or currency.
Issue Date Purpose Prepared By Approved By
01 05/04/19 Issued for Construction Junelle Llorente Daniel Lay

02 21/06/19 Issued for Construction
(updated Section 10 and
Junelle Llorente Daniel Lay
removed hazardous area
references)
Review Panel
Division/Office Name
Lendlease Elie Sakr
01-1022-000-SPC-FU-0007[02].docx
Table of Contents
1 Introduction .............................................................................................................. 7
1.1 General....................................................................................................... 7
1.2 Existing Facility Description ........................................................................ 7
1.3 Hierarchy of documentation ........................................................................ 8
1.4 Proprietary Items ........................................................................................ 8
1.5 Deviations and Alternatives to Specification................................................ 8
2 Preliminaries ............................................................................................................ 9
2.1 Authority Approval .................................................................................... 10
3 Applicable Standards ............................................................................................. 10
4 Inspection of the Works and Hold Points ................................................................ 11
5 Scope of Works ...................................................................................................... 12
5.1 Temporary CEPS...................................................................................... 12
5.2 Product ..................................................................................................... 13
5.3 Excluded Works ........................................................................................ 13
5.4 Interface with Other Trades ...................................................................... 13
5.5 Removal of the Temporary CEPS System ................................................ 13
6 Functional Description ............................................................................................ 14
7 Equipment Specification ......................................................................................... 15
7.1 Temporary CEPS Bulk Fuel Tank ............................................................. 15
7.2 Pumps ...................................................................................................... 15
7.3 Overflow Tank .......................................................................................... 16
7.4 Valves ....................................................................................................... 16
8 Material Specification ............................................................................................. 16
8.1 Scope ....................................................................................................... 16
8.2 Materials Use ............................................................................................ 16
8.3 Handling of Pipes & Fittings ...................................................................... 17
8.4 Carbon Steel Pipe..................................................................................... 17
8.5 Carbon Steel Pipe Fittings ........................................................................ 17
8.6 Pipe Branch Connection Sizing Table ....................................................... 17
8.7 Flanges & Flanged Joints ......................................................................... 18
8.8 Flange Guards .......................................................................................... 19
01-1022-000-SPC-FU-0007[02].docx Page 3 of 50
8.9 Underground Piping .................................................................................. 19
8.10 Trenching ................................................................................................. 19
8.11 Tie In Point ............................................................................................... 20
8.12 Penetrations ............................................................................................. 20
8.13 Pipe Welding Consumables ...................................................................... 21
8.14 Pipe Support System ................................................................................ 21
8.15 Quarantine, Storage & Segregation .......................................................... 21
9 Mechanical Installation and Piping Specification .................................................... 22
9.1 Scope ....................................................................................................... 22
9.1 Operation Procedures ............................................................................... 22
9.2 Piping Systems Performances .................................................................. 22
9.3 Design & Fabrication ................................................................................ 23
9.4 Arrangement ............................................................................................. 23
9.5 Vents and Drains ...................................................................................... 23
9.6 Identification ............................................................................................. 23
9.7 Equipment Tagging................................................................................... 24
9.8 Paint scheme ............................................................................................ 25
9.9 Pipe Spacing ............................................................................................ 25
9.10 Pipe Cleaning ........................................................................................... 26
9.11 Welding .................................................................................................... 26
9.12 Sustainability Requirements ..................................................................... 29
10 Electrical Specification............................................................................................ 29
10.1 E&IC Installation ....................................................................................... 29
10.2 Equipment Selection and Installation ........................................................ 29
10.3 Equipment Inspection and Tests ............................................................... 30
10.4 Lightning Protection System, Earthing and Bonding ................................. 30
10.5 General Construction ................................................................................ 30
10.6 Local Control Panels................................................................................. 33
10.7 Instrument Junction Box ........................................................................... 34
10.8 Automatic Tank Gauging .......................................................................... 34
10.9 Cables ...................................................................................................... 34
10.10 Conduits and Cable Ladder ...................................................................... 35
10.11 Underground Cabling ................................................................................ 35
11 Commissioning ....................................................................................................... 36
11.1 General..................................................................................................... 36
11.2 Scope of Commissioning .......................................................................... 36
11.3 Commissioning Plan ................................................................................. 36
11.4 Pre-Commissioning .................................................................................. 37
11.5 Testing Medium for Pipework ................................................................... 38
11.6 Pre-commissioning Tests.......................................................................... 38
11.7 Acceptance Tests ..................................................................................... 40
11.8 Handover .................................................................................................. 41
11.9 Review of documentation .......................................................................... 41
11.10 Performance ............................................................................................. 41
12 Deliverables ........................................................................................................... 42
12.1 Work Plan ................................................................................................. 42
12.2 Workshop Drawings.................................................................................. 43
12.3 Specification Details ................................................................................. 43
12.4 Commissioning Plan ................................................................................. 43
12.5 As Constructed Documentation (General) ................................................ 43
12.6 Work-as-Executed Drawings .................................................................... 44
12.7 As Constructed Drawings ......................................................................... 45
12.8 Operation and Maintenance Manuals ....................................................... 45
12.9 Manufacturer’s Data Record (MDR) .......................................................... 45
12.10 Spare Parts List ........................................................................................ 46
13 Defects Liability Period ........................................................................................... 46
13.1 Planned Maintenance ............................................................................... 46
13.2 Unplanned Maintenance ........................................................................... 46
14 Commonwealth Personnel Training ........................................................................ 48
Abbreviations, Acronyms and Definitions
Abbreviation Definition
ACOR ACOR Consultants
AS Australian Standard
AS/NZS Australian/ New Zealand Standard
GI S2 Garden Island Stage 2
CEPS Central Emergency Power Station
Client Lend Lease
CP Cathodic Protection
FF Fuel Farm
HMI Human Machine Interface
kL Kilolitre
LEL Lower Explosive Limit
LL Lend Lease
PLC Primary Logic Controller
UPP Universal Polyethylene Pipework
VFD Variable Frequency Drive
VST Vertical Storage Tank
1 Introduction
This specification describes the minimum technical requirements for supply, fabrication and testing of the fuel
system associated with the Temporary Central Emergency Power Station (CEPS) system located adjacent to
the Museum building outside Building 10 at Garden Island East.
Temporary CEPS is a standby power station that will be utilised to supply fuel to the generators in Building 10
during the decommissioning of the existing CEPS tank and construction of the new tank.
1.1 General
This Specification applies to all Works associated with the new Temporary CEPS fuel system at Garden Island
(East) NSW.
All works shall be constructed complete and serviceable, including all necessary accessories and
miscellaneous material, minor parts and other such items, whether or not indicated in the Contract drawings
or the Specification, where it is clearly the intention that they should be installed or obviously required and
necessary to complete the work.
The Temporary CEPS fuel system shall provide a safe working environment complying with legislation,
Defence regulations, relevant Codes of Practice, Australian Standards and proven Industrial Practices,
including but not limited to fuel spill prevention, environmental protection, dangerous goods storage, fire
protection; electrical safety and worksite practices.
The installation shall deliver high quality fuel, deliver fuel efficiently in service and be easy to operate.
The Temporary CEPS system is expected to operate for at least two years, during which the new CEPS 10
system will be constructed.
1.1.1 Definitions
Managing Contractor: Lendlease
Consultant: ACOR Consultants
Contractor: A person or organisation undertaking the construction phase
Sub-Contractor: Person or organisation as engaged by the contractor
Specification: This document
Suppliers: Individual or organisation supplying any equipment as part of this specification
1.2 Existing Facility Description

Garden Island Defence Precinct (GIDP) is located approximately 3 kilometres from the Sydney Central
Business District (CBD) and in the Local Government Area of the City of Sydney Council.
GIDP is a key operational and support base for the Royal Australian Navy (Navy). It is the major fleet base on
the East Coast of Australia and its primary role is to support home-ported and visiting Navy ships, as well as
those ships belonging to foreign naval partners. As such, the base has an extensive fuel infrastructure in the
form of fuel reticulation network and cope points to support refuelling and defueling of ships.
Located within the main bund of the bulk fuel tank is a 20,000 L tank that provides dedicated diesel supply to
CEPS in Building 10. A fill line is connected from the top of the tank to the road above. The discharge line
penetrates the main tank excavation wall towards Building 10 and connected to two (2) day tanks to support
the existing diesel generators in Building 10. The existing CEPS fuel system is non-compliant and will be
decommissioned as part of this project. The existing system will be replaced by a separate, dedicated and
compliant fuel system with greater capacity for CEPS in Building 10.
During the decommissioning of the existing CEPS fuel system and the construction of the new tank, the
Temporary CEPS system will supply fuel to the existing generators in Building 10.
1.3 Hierarchy of documentation

This document should be read in conjunction with all the other documentation, including the Process and
Instrumentation Diagrams (P&ID), Basis of Design document and all relevant documents from other
disciplines including but not limited to Civil, Structural, Electrical and Hydraulics as if any interfaces. In such
case relevant drawings and documents from other contractors to be consulted. In case of any discrepancy
between the documentation the fuel consultant (ACOR) shall be consulted via the managing contractor. In
any case, documents shall follow the hierarchy below:
1. Process and Instrumentation Diagrams (P&ID) including all the notes
2. Fuel Specification & HAC report
3. 2-D drawings
4. 3-D model
5. Basis of Design
1.4 Proprietary Items

Unless otherwise stated, where the Specification refers to a specific manufacturer and/or by proprietary name
and the phrase 'or equivalent' is not included, it is deemed included. Suppliers nominated in the Specification
are for reference only; the Contractor will not be bound to use these suppliers. The Commonwealth will not
be responsible for any matter in relation to the engagement between the Contractor and their suppliers.
Equivalency must be demonstrated by the Contractor where any such equipment is proposed for use.
However, it is strongly recommended to seek the Consultant’s advice and approval prior to procurement.
1.5 Deviations and Alternatives to Specification

Any request to consider alterations to the requirements of the Specification shall be formally communicated
to Lendlease. The communication request should include the following to facilitate consideration:
 Detailed references from (all) the specified / contracted requirements which are relevant to the
deviation;
 Reason for proposed consideration to deviation;
 Details of proposed deviation, with supporting information and justification;
 Statement of the extent of revisions to the contract documents;
 Statement to the extent of revisions to the construction program;
 Statement of cost implications including costs outside the contract (where relevant);
 Statement of consequent alterations to other parts of the works;
 Statement that the proposed deviation will not necessitate alteration to other parts of the works. Note
which other part of the works had been considered relevant in the assessment; and
 Advice to be provided at what cost benefit proposed changes or substitution would be to the client.
If alternatives to the identified proprietary items are proposed, the Contractor shall submit sufficient information
to permit evaluation of the proposed alternatives including the following:
 Samples (where relevant);
 Essential technical information, in English;
 Product Data sheets and Brochures, in English;
 Examples of past applications / installation / performance;
 Reasons for the proposed substitutions;
 Installation Details and requirements;
 Maintenance Details and Requirements;
 Statement of the extent of revisions to the contract documents;
 Statement to the extent of revisions to the construction program;
 Statement of cost implications including costs outside the contract;
 Statement of consequent alterations to other parts of the works;
 Verification statement that proposed alternative has been reviewed and deemed same or better than
that specified;
 Statement that the proposed alternative will not necessitate alteration to other parts of the
works. Note which other part of the works had been considered in the assessment; and
 Advice to be provided at what cost benefit proposed changes or substitution would be to the client.
If the identified proprietary item is unavailable, the Contractor shall submit evidence to the fact. If the
substitution covers unavailability or is for any other reason, the Contractor shall submit evidence that the
substitution:
 Is of net enhanced value to the proprietor; and
 Is consistent with the contract documents and is as effectual as the identified proprietary item.
Equivalency must be demonstrated by the Contractor where any such equipment is proposed for use.
2 Preliminaries
This Specification shall be read in conjunction with the drawings, general and special conditions of the contract
and all other parts of the document. Unless varied or modified by this specification, the general and specific
conditions shall apply in full.
The Contractor is responsible for all construction related facilities and site offices and is to allow for the
following items as deemed necessary for the completion of specified work scope:
 Site Inductions and access approvals (e.g. confined space, working around wharves etc);
 Obtain security clearance and Base access passes for all required personnel;
 Provision of all plans, checklists, clearances, certificates and approvals necessary to carry out the
work (such as but not limited to Quality Plans, Method of Works Plan, ITPs, Safe Work Method
Statements, personnel background checks and qualifications);
 Mobilisation and site establishment including the provision of all site labour, supervision, tools,
equipment, power, temporary buildings and facilities necessary for performance of the work on site;
 Provision of lighting, telephone, water, sewer and other services to site offices as required by this
specification and/or by building and regulatory authorities;
 Provision and installation of erosion and pollution control, etc. as required by the statutory
authorities, and/or the Commonwealth;
 Removal of erosion and pollution control, etc. as required by the statutory authorities, and/or the
Commonwealth upon completion of the Works;
 Provision of Toilet facilities for personnel;
 Provision of safety shower facilities for personnel;
 Provision of PPE as required for works and required inspections;
 Provision of Container or workshop facilities as required;
 Security of Contractors facilities;
 Maintenance of all working areas in a clean and tidy state;
 Undertake an extensive clean-up of the Site upon completion and make good any damage to the
existing facilities which has occurred as a consequence of the construction;
 Maintenance of all areas in a safe working condition;
 Minimise disruption to the base; and
 Minimise disruption and ensure coordination with other projects on base.
During construction works, temporary fencing and barricading will be required to prevent unauthorised access
to certain areas. This fencing/barricading shall be provided by the Contractor.
As a minimum fencing/barricading shall include: all excavations, areas where welding and hot-works are
underway, confined space entry and other areas as required.
2.1 Authority Approval

The following shall be submitted as documented:
 Notes of meetings with authorities whose requirements apply to the work; and
 Evidence that notices, fees and permits have been sought and paid, that authority connections are
complete and that statutory approvals by the authorities whose requirements apply to the work have
been received.
3 Applicable Standards
The Contractor shall adopt the following list of standards, regulations and guidelines as a minimum, where
each standard, regulation and guideline is the most recent edition. All equipment shall be designed,
constructed and tested to the following standards. Where a conflict occurs between this document and an
Australian Standard or other referenced document, then the ‘higher’ requirement or standard shall prevail
(advice shall be sought from the Lendlease).
 AS 1940-2017: The storage and handling of flammable and combustible liquids;
 Department of Defence: DFI-Design Practices Manual (DFI-DPM);
 Department of Defence: Manual of Infrastructure Engineering – Electrical (MIEE);
 Department of Defence: DFI Hazardous Area Guide;
 AS 1692: Steel Tanks for Flammable and Combustible Liquids;
 AS 4041: Pressure Piping;
 AS 4977-2008: Petroleum Products – Pipeline, road tanker compartment and underground tank
identification;
 API 2000: Venting Atmospheric and Low-pressure Storage Tanks;
 API RP 2350: Overfill Protection for Storage Tanks in Petroleum Facilities;
 AS/NZS 3000 Electrical Installations (Known as the Australian/New Zealand Wiring Rules);
 ASME B31.3 Process Piping;
 API Spec 6D Pipeline Valves (Gate, Plug, Ball, and Check Valves);
 API Spec 6FA Fire Test for Valves;
 API Std 607 Fire Test for Soft-Seated Quarter-turn Valves;
 API Std 608 Metal Ball Valves – Flanged, Threaded and Butt-welding Ends;
 ASME B16.10-2009 Face-to-face and End-to-end Dimensions Of Valves; and
 ASME B16.34-2013 Valves - Flanged, Threaded, And Welding End.
4 Inspection of the Works and Hold Points

Before commencement of any site works or procurement, the Contractor shall complete a consolidated
Inspection, Test and Hold Point Plan for each equipment, component and construction activities in a form
acceptable to Lendlease. This Inspection, Test and Hold Point Plan shall be reviewed and approved by the
Consultant prior to any procurement or construction activities it may, with the approval of Lendlease, be
incorporated with the Work Plan (WP) to be prepared by the Contractor.
This plan shall refer to the requirements of the specification for submission of samples, for inspections or other
approvals, testing etc. including the number of tests and samples required in each area of work. The plan
shall record completion of action by the Contractor and nominate "Hold Points".
The Contractor shall not progress with works until Lendlease’s Representative inspects or rejects as
acceptable the following hold point items as a minimum:
 Inspection of placement of all buried services prior to backfilling;
 Witness of internal inspection of pipelines prior to sealing;
 Witness of alignment of critical equipment items (pumps, filters, valves, flanges, anchored pipe
sections) prior to connection of closing pipe spool. Documented laser alignment required;
 Inspection/witness of all hydrostatic testing;
 All Weld/ Welder Specifications, Procedures and Qualifications;
 Witness of non-destructive examination results of welds;
 Review of paint/ coating procedures
 Witness of painting activities by a qualified Coating Inspector
 Application and test results of all coating and lining systems (including primers);
 Survey levels of pipeline falls;
 Flushing and/or pigging as part of pre-commissioning
 Factory Acceptance Testing (FAT) of electrical control systems;
 Written confirmation that the required checks have been undertaken and that the installation is in a
suitable, safe condition to accept fuel;
 Witness of commissioning of systems; and
 Other specific Witness points as identified in this document.
Note that a minimum notification period of five (5) working days shall be provided prior to any hold point.
All supporting Inspection Test Records and associated documentation references included in the ITP shall be
listed in a register and provided to Lendlease.
ITP progression shall be documented and incorporated in the Contractor’s Quality Control Plan. The
completed form shall be handed over to Lendlease on completion of project.
5 Scope of Works
The Works included in this Contract shall comprise of the provision for all materials, plant, labour, and the
performance of all operations for the complete and proper construction of the Works specified.
All Works will be in accordance with this scope of work and the Tender specification, which shall form the
basis of the minimum installation practices to be carried out at the site, with the drawings and shall be to the
entire satisfaction of Lendlease.
This Specification also forms part of the mechanical, hydraulic and electrical works as applicable and is to be
read in conjunction with the Mechanical, Hydraulic and Electrical drawings.
The Contractor shall be responsible for the following:
5.1 Temporary CEPS

 Hire of 1 x 30,000 L aboveground, double walled carbon steel diesel tanks;
 Aboveground tank to be fitted with the required nozzles, vents, tank gauging, alarms and other
necessary electrical equipment;
 DN 63/50 doubled-walled UPP underground piping from the tank (fuel transition pit) to the Zone 1
tunnel as described in this Specification and in the design drawings;
 DN 50 Carbon Steel, Schedule 40 piping within the Zone 1 tunnel and above ground (from the tank
to the fuel transition pit);
 1x submersible dispensing pump (included as part of the tank package);
 Hire of diesel generator to power the dispensing pump (FG Wilson P22.6 20kVA or equivalent);
 Pre-fabricated fuel transition pit with cover (762 mm x 762 mm x 500 mm)
 Offloading point with Camlock connection, breakaway valve, dust cap and chain;
 Installation of piping, valves, fittings and vents to the three day tanks;
 Installation of the overflow tank, vents, valves and piping;
 Emergency stops (included as part of the tank package);
 Fuel control system for the Temporary CEPS tank and the day tanks inclusive of local control panels
and instrument junction box;
 Electrical cabling, trays and conduits as required to complete the fuel system controls, emergency
stops and instruments;
 Flange guards;
 Earthing and bonding requirements;
 Signage;
 Security fencing - 2.4 m chainmesh fence with 600 mm barbed wire (Class 2 fence);
 Spill kit and temporary bunding (around the fuel tanker and adjacent drains);
 2 x powder-type fire extinguishers within 10 m from the fuel tank;
 Commissioning of the system;
 Documentation (such as but not limited to O&M manuals, MDR, inspection and test certificates);
 Any other items identified in this document and necessary to make the system function as intended;
and
 Removal of the temporary CEPS fuel system at the completion of construction works.
5.2 Product
The proposed fuel system is based on following product which will be received and dispensed at the site:
 Diesel: has a flash point greater than 61.5oC and therefore, based on AS 1940, is classified as
combustible liquid.
5.3 Excluded Works

The following items are specifically excluded from the scope of works:
 Provision of mains power to the Temporary CEPS site;
 Lighting; and
 Hydraulic works (such as safety showers).
In the event there is any ambiguity or conflict, the Contractor shall notify Lendlease, who will provide
clarification.
5.4 Interface with Other Trades

At all times, the Contractor shall co-operate, coordinate and interface with all other trade Contractors on the
site.
In particular, the Contractor shall interface with all other Contractors to ensure that services laid within
trenches do not conflict with proposed works timing, do not cause damage to completed works, and will not
compromise the integrity or compliance of the works completed under this Specification.
5.5 Removal of the Temporary CEPS System

At the completion of construction works and when deemed no longer required by Lendlease, the temporary
CEPS fuel compound shall be removed and made good.
The following items shall be removed:
 Bulk 30,000L diesel tank inclusive of pump and instruments;
 Generator for temporary CEPS dispensing pump and control panel;
 Relay based local control panel within the temporary CEPS area used for controlling the system;
 Aboveground mechanical piping terminating at a blank flange and ball valve within the Zone 1 tunnel;
 Transition pit;
 Underground UPP piping;
 Electrical cabling for the control system terminating at the instrument junction box (IJB004);
 Electrical services serving the temporary CEPS area;
 Hydraulic services serving the temporary CEPS area;
 Safety shower;
 Fencing;
 Lighting;
 Fire extinguishers;
 Spill kit;
 Any ancillary items as deemed not required by Lendlease.
The area shall be made good with any excavations, holes or openings appropriately filled and sealed.
6 Functional Description
The Temporary CEPS fuel system is comprised of 1 x 30 kL double walled above ground tank. The tank will
provide fuel to the generators in Building 10 via two (2) 1000 L day tanks during decommissioning of the
existing CEPS tank and construction of the new one. The day tank controls and instrumentation are connected
to both the existing generator control panel and to the future generator control system. These connections will
be undertaken by the Electrical trade. The Temporary CEPS system shall be located adjacent to the Museum
building outside Building 10. The tank will be filled by road tankers utilising the tanker’s on-board pump.
The Temporary CEPS tank shall include a submersible dispensing pump, local control panels, instrument
junction box and emergency stops.
The system shall have the following functionality:
 Allow for tanker to offload into the bulk tank using its own onboard pump;
 Display tank level readouts via the Automatic Tank Gauge (ATG) system;
 Provide an audible alarm when high level in the bulk tank has been reached via the overfill alarm;
 Allow an operator the ability to energise the fuel system to prepare it for automatic control;
 Automatically dispense fuel to either of the two day tanks when either tank has reached low level;
 Automatically stop dispensing fuel when both day tanks have reached high level;
 Have a switch to allow electrical power for the system to be selected from either the local generator
or Building 10 mains power;
 Allow an operator to de-energise the system.
As part of operating the system, the operator shall check all valves within the system and ensure that they are
in the correct position. The operator shall then begin operations using the local control panel located within
the fenced area adjacent to the 30,000L bulk tank. Once operations have begun, fuel dispensing and control
shall be automatically and be regulated via the day tank levels. The control system shall be relay based.
7 Equipment Specification
7.1 Temporary CEPS Bulk Fuel Tank
The Temporary CEPS storage tank system shall be capable of storing 30 kL of diesel fuel and be completed
with the following:
 1 x 30 kL double walled above ground storage tank (FES Grande or equivalent)
 The tank shall be designed and tested in accordance with the latest revision of AS 1692 and AS
1940 and shall meet all the requirements of these standards. This shall include:
- Production testing
- Factory acceptance testing
- Inspection and certification
- Quality records
- Installation requirements
- Plinth and footings
- Certified lifting points
- Labelling
- Protective coatings
 Tank inlet nozzle
 Outlet Nozzle
 Dip point with lockable seal cap
 Free vent
 Manway
 Automatic tank gauge
 Overfill alarm
 Tanks shall have supports as supplied by the manufacturer and shall be compliant with AS 1692.
 Tanks shall have earthing boss fitted.
Tanks shall be off the shelf FES Grande 30,000 double walled tanks or equivalent.
7.2 Pumps
An overflow collection tank shall be provided which collects fuel overflow from the day tanks. The tank shall
be a 1,200 L doubled walled carbon steel tank compliant to AS1692 and shall be located in Building 10. Fuel
shall be gravity drained from the day tanks to the overflow tank.
Level gauge shall be provided to monitor the level in the overflow tank. A hard wire high level switch shall also
be provided to isolate the pump power supply. ANSI 150 flanges and fittings shall be provided in accordance
with the P&ID.
The tank shall be painted with the same colour scheme as the CEPS10 bulk tanks.
The tank is to be emptied via a waste removal vehicle for disposal off site.
7.3 Overflow Tank
An overflow collection tank shall be provided which collects fuel overflow from the day tanks. The tank shall
be a 1,200 L doubled walled carbon steel tank compliant to AS1692 and shall be located in Building 10. Fuel
shall be gravity drained from the day tanks to the overflow tank.
Level gauge shall be provided to monitor the level in the overflow tank. A hard wire high level switch shall also
be provided to isolate the pump power supply.
The tank is to be emptied via a waste removal vehicle for disposal off site.
7.4 Valves
All valve body material of construction shall be carbon steel.
All valves to be fire safe according to API 607 and API 598
7.4.1 Ball Valves

 Ball valves shall comply with API STD 607, API 608 and API 6D.
 Full bore ball valves shall be used for open/shut service and/or when a quick shut off is required and
must be ANSI 150 flanged.
 Ball Valves must be non-lubricated and operate from fully open to fully closed with a 90-degree
rotation of the ball and must be serviceable.
 All ball valves used must be fire safe rated.
7.4.2 Check Valves

 Check valves shall be used to prevent backflow through branch lines, meters, pumps or other
locations where runback or reverse flow must be avoided.
 Check valves must conform to API Spec 6D.
 All check valves used must be fire safe rated and ANSI 150 flanged.
 Check valves shall be selected to ensure losses are minimised through the system.
8 Material Specification
8.1 Scope
This specification details the technical and material requirements for pipe, piping components and associated
performance criteria for the Temporary CEPS system at Garden Island (East) NSW. The Contractor shall
ensure that that all materials and piping materials used for the proposed project are consistent, are fit for
purpose, perform as designed, provide a safe working environment and meet all regulatory standards and
requirements
8.2 Materials Use

Materials and components which are to be used for piping shall be:
 Suitable and safe for fabrication and the service conditions under which they are used; and
 Qualified for the conditions of their use by compliance with nominated and any additional
requirements of this Standard.
8.3 Handling of Pipes & Fittings
Pipes & fittings shall be handled at all times with equipment designed to prevent damage. Pinch bars, chains
or cable slings or other pipe handling equipment that may be injurious to the pipe or coatings shall not be
used. Suitable padding (submitted for review or rejection in advance by the Contractor) shall be used between
the pipe and the skid to prevent damage during laying operations. Any loss or damage to piping and other
materials, as a result of their movement at the work site, shall be made good by the Contractor, at his/her
expense.
8.4 Carbon Steel Pipe

All above ground pipe shall be Carbon Steel, Schedule 40 and shall be designed as per AS 4041.
Carbon steel pipe shall be supplied as per dimensional specification ANSI/ASME B36.10 and materials
specification shall be in accordance with API 5L GR B or ASTM A53 GR B.
Pipe sizes DN50 & above shall be seamless and welded (ERW) pipe supplied to schedule 40. Pipe sizes
DN40 & below shall be seamless and welded (ERW) pipe supplied to schedule 80.
All weld procedures should ensure that the corrosion resistance of the weld material and the HAZ are equal
to or better than the parent material.
All diesel fuel pipeline shall be in accordance with piping class C1. For further details refer to Appendix B for
carbon steel piping specification C1. All Carbon Steel pipe shall be painted in accordance with Section 9.9.
Sample piping shall be maintained and submitted per manufacturing batch.
8.5 Carbon Steel Pipe Fittings

Dimensions and tolerance of carbon steel butt-weld pipe fittings shall be as per ANSI/ASME B16.9 and
material specification as per ASTM A234/A 234M GR WPA, WPB or WPC.
All carbon steel socket weld and threaded fittings sizes (DN40 & below) shall be made to the dimensional
specification ANSI B16.11 and material specification as per ASTM A105.
Threaded connections shall be NPT unless otherwise specified. Variations to pipe selection (wall thickness)
for threaded pipe shall be submitted to Lendlease for review or rejection. Threaded pipeline connectors will
generally be restricted to relatively small line sizes (e.g. less than DN 25). Particular attention is required to
ensure that threads are correctly sealed to minimise leakage and long-term seepage and potential
contamination of the product. Site and hand cut threads are not permitted; factory cut threads in accordance
with the relevant piping code are required. Refer to Appendix B for pipe specification.
All fuel pipe fittings shall be in accordance with piping class C1. For further details refer Appendix B for carbon
steel piping specification C1. Sample pipe fitting shall be maintained and submitted per manufacturing batch.
8.6 Pipe Branch Connection Sizing Table
15 SWT
20 SRT SWT
25 SRT SRT SWT
H 40 SRT SRT SRT SWT
E 50 SOL SOL SOL SOL BWT
A 80 SOL SOL SOL SOL BRT BWT
D 100 SOL SOL SOL SOL BRT BRT BWT
E 150 SOL SOL SOL SOL URB BRT BRT BWT
R 200 SOL SOL SOL SOL URB URB BRT BRT BWT
250 SOL SOL SOL SOL URB URB URB BRT BRT BWT
D 300 SOL SOL SOL SOL URB URB URB URB BRT BRT BWT
N 350 SOL SOL SOL SOL URB URB URB URB URB BRT BRT BWT
400 SOL SOL SOL SOL URB URB URB URB URB URB BRT BRT BWT
450 SOL SOL SOL SOL RB RB RB RB RB RB RB BRT BRT BWT
15 20 25 40 50 80 100 150 200 250 300 350 400 450
B R A N C H D N
LEGEND
 SWT Socket Weld Tee
 SRT Socket Weld Reducing Tee
 SOL Socket Weld O-let Fitting
 BWT Butt-weld Tee
 BRT Butt-weld Reducing Tee
 URB Un-reinforced Branch
 RB Reinforced Branch
All joints should be either full-penetration butt-welded or flanged. Any joint not flanged shall need to be
approved by Lendlease prior to work taking place.
The pipe shall be gradually graded towards low points. Low points shall have DN 25 low point drain valves to
prevent free water and contaminants stagnating in the pipeline.
8.7 Flanges & Flanged Joints

All flanges in butt weld (BW) piping shall be weld neck (WN) unless specific circumstances dictate otherwise.
Socket weld or weld neck flanges can be used where socket weld flanges are nominated.
Where carbon steel flanges are specified they shall conform to ASTM A105/ A105M and dimensional
specification as per ASME B16.5 as stated in piping Class C1. Carbon steel flanges shall be of normal to high
carbon content class, not low carbon content, as per ANSI/ASME B 16.5.
All flange faces shall be stock finish (raised face) and shall meet the following requirements:
 Roughness average: = 3.2 to 6.2 m Ra
 1.8-2.2 grooves per millimetre
 Continuous spiral groove or concentric serrated
Flange guards or equivalent wrapping shall be provided for all flanges.
Carbon Steel bolting shall be stud bolts in accordance with ASTM A193 GR B7 and nuts shall conform to
ASTM A194 GR 2H.
All stud bolts shall be installed with heavy hex nuts. All stud bolts and nuts shall be suitably coated with an
anti-galling compound and packaged to prevent damage during transport. Stud bolt lengths shall be in
accordance with ASME B16.5 (BS1560) for use with raised face flanges size DN15-DN600. Material
Certification is required for use of all stud bolts used throughout construction.
All flange joints shall use spiral wound gaskets (unless stated otherwise) and will be defined to the following
specification:
 4.5mm nominal thickness;
 Graphite filled material, outer stainless steel for C1;
 PTFE filler low stress seating, inner/outer ring stainless steel 316 LL for S1; and
 Designed to ASME B16.20
Material and construction certificates are required for use of all spiral (or otherwise) gaskets used throughout
construction.
Refer to Appendix B for Project piping specification.
8.8 Flange Guards

Flange guards shall be provided for all mechanical piping to prevent mists leaking. Flange guards shall be
316 stainless steel and sized to appropriately fit over the flanges. Product shall be Flange Guards Sureband
or equivalent.
8.9 Underground Piping

All buried underground piping shall be double walled polyethylene with provision for leak detection in the void
space between inner layer and outer layer. The underground piping shall have design pressure greater than
the Maximum Allowable Working Pressure for the pump (Franklin Fuelling Systems UPP EL14125 with a
pressure rating of 1000 kPa for Primary pipe or equivalent).
Transition between underground UPP piping and aboveground carbon steel piping shall be made in the tunnel
and transition pit.
8.10 Trenching
The trenching methodology applies to all services trenching (internal and external of the building footprint)
and includes mechanical and electrical services. This following applies for the trenching requirements for
temporary CEPS enabling works.
 The Fuel contractor is to excavate all fuel trenches in accordance with the drawings and
specifications whilst at all times coordinating the works with other Contractors.
 The Fuel contractor must place excavated trench material adjacent to the trench or in a location
agreed with Lendlease and the Environmental consultant to allow testing and classification of the
excavated material by the Environmental Consultant. Excavated material may be reused for
backfilling of trenches if an acceptable classification for the material is determined by the
Environmental consultant and the material complies with the requirements of the Civil Specification
for services trenches backfill as determined by the Civil consultant. The Fuel contractor is
responsible for all costs associated with the testing and certification to confirm compliance with the
civil specification of reused backfill material. Any excavated trench material tested and classified as
contaminated is to be stockpiled in a location agreed with the Contractor. The Fuel contractor is
responsible for all costs associated with the disposal of any unused trench material including
material deemed contaminated.
 The services contractors will verify the trench depth and/or grades & provide acceptance prior to
installing their bedding layer, the service(s) and subsequent initial backfilling around the service(s).
Initial backfilling shall extend a minimum of 100mm above the top of the service(s). Initial backfilling
material must be in accordance with the civil specification i.e. cement stabilized natural sand under
building pads and pavements and select fill in landscape and other areas (or equivalent) and
compacted to the requirements of the specifications and standards. The services contractors are to
submit bedding material sample for approval prior to ordering and placing. If services are required
to be concrete encased, the supply, placement and compaction of the concrete will the responsibility
of the services contractor.
 The services contractor must supply and place tracer strips or identification tape/barrier for every
service installed. Buried marker tape shall comply with the following as a minimum:
- Tape shall be located a minimum of 300mm above the pipeline;
- Tape shall be permanently coloured with a high visibility colour;
- Tape shall identify the nature of the buried pipeline;
- Tape shall have a sufficient strength, ductility and slack to prevent it breaking before
it becomes visible; and
- Tape shall have a lifespan not less than the design life.
 The Fuel contractor must supply, place and compact suitable backfill material to haunch (side
support zone) to at least 300mm above service and to the top of the trench in accordance with the
drawings and specification or as instructed by Lendlease.
 The Fuel contractor must undertake compaction testing and certify compliance in accordance with
the specification.
 All compaction test result must be approved by the relevant services trade and also submitted to
Lendlease.
 If redundant services are encountered during the services trenching works the Fuel contractor must
remove the redundant service affecting the installation of new works.
 All excavation activities shall be undertaken in accordance with the Lendlease permit to work
system. An approved excavation permit is required prior to commencement of excavation and all
required control measures are to be implemented prior to commencement of excavation.
8.11 Tie In Point

A valving arrangement has been provided within the Zone 1 tunnel to facilitate disconnection of the temporary
CEPS fuel system at the completion of construction works and to allow tie in of the final CEPS fuel system
(delivered under a separate scope).
Tie in of the final CEPS fuel system to the temporary CEPS fuel system shall occur at a double block and
bleed valve. The Contractor shall provide a UPP to carbon steel transition within the Zone 1 tunnel. Following
disconnection of the temporary CEPS system, the line from the temporary CEPS into the Zone 1 tunnel shall
be terminated and blanked off at a ball valve within the tunnel.
Refer to the P&ID (01-1022-010-DRG-FU2123) for further details.
8.12 Penetrations
All penetrations in the tunnel are to be fire rated and water tight with adequate flexibility.
Penetrations through all structures shall be sealed and water tight. Additionally, penetrations through fire rated
walls shall be sealed with a suitable sealant around the pipe such as 3M Fire Barrier Sealant FD 150+ TDS
or HB Fuller to provide enough flexibility and movement for the pipe. This shall be followed by adding in
additional sealing such as Promastop Cement or equivalent where required in order to maintain the fire rating
of the wall. Cement shall carry a fire rating equal or better than that of the wall being sealed. Contractor shall
provide fire test certificates and reports for sealant product.
All penetrations shall comply with BCA Part C3.15 and fire rated penetrations shall comply with AS
4072.1:2005.
8.13 Pipe Welding Consumables

All materials used for construction of welded pipe systems shall be stored and managed in accordance with
procedures set out in the applicable weld procedure specification or associated construction standard.
Documented evidence of purchase and material certification of all weld consumables used for production
welds generated by the Contractor shall be available at all times throughout the construction period and form
part of the construction (welding) deliverables at the completion of the contract.
8.14 Pipe Support System

The above ground carbon steel piping from the tank to the fuel transition pit shall be suitably supported by
pipe supports from the concrete pathway.
The design and installation of structural pipe supports shall comply with the requirements of AS 3990 and AS
4041, applicable structural standards and standards for manufacture of the appropriate support system and/or
as indicated on drawings provided by the Managing Contractor.
Where not specified by the design drawings, the maximum recommended spacing between supports for steel
pipe Schedule 40 or greater carrying a fluid SG of 1.0 shall be as follows:
DN 15 20 25 50 80 100 150 200 250 300
Span (m) 1.5 2.0 3.0 4.0 4.8 5.4 6.4 6 8.0 8.6
All supports shall be hot dipped galvanised and as per the details in the design drawings.
Separate considerations relating to material compatibility of piping (i.e. carbon steel and galvanised supports)
and their exposure to fuel should be paramount. Additionally, these products will be exposed to weather and
the grade of material shall not degrade or deform under the design temperatures and parameters indicated in
the piping construction standards and scope of works. In accordance with DFI-DPM Section 6.11, where all
pipelines are mounted on supports other than that of the pipeline material, polymeric insulators shall be
installed to isolate the sections.
Pipe supports shall be laid based on the weight and forces imposed by the fuel pipeline as detailed in drawings
to protect equipment, such as pumps, tanks and valves from excess mechanical loading.
Anchor structures and pipe supports shall be constructed to prevent wear and corrosion of the piping and
should allow for adjustment of the support.
8.15 Quarantine, Storage & Segregation
8.15.1 Quarantine & Segregation

All materials deemed construction materials for the construction of piping systems, including piping material,
piping consumables, valving and instrumentation, welding consumables and pipe supports systems shall be
segregated from other construction materials and activities where such exposure may cause damage or
deterioration of those materials.
8.15.2 Storage of Materials
Where all materials, goods and equipment for use in construction are stored on site, the type of storage
facilities and location of these facilities shall be agreed to by the Contractor as to their suitability before any
construction begins.
The Contractor is to provide details of their intentions regarding this clause in the tender proposal.
Any materials that become contaminated, may at the discretion of Lendlease, be removed, repaired and/or
replaced. The costs of such replacement or repair shall be at the Contractor’s expense.
8.15.3 Material Certification & Markings

All materials used throughout the construction of fuel piping systems shall bear an appropriate marking upon
the item as deemed applicable by any standards associated with the construction of the piping system, i.e.
material identity markings for flanges (ANSI 150) and schedule/class markings of pipe & fittings for butt welded
pipe.
Valving or equipment provided for use in the piping construction shall, were appropriate, have the material
classification, model number and /or compliance number marked upon the body of the item or label attached
to the item, which shall not, other than by mechanical means be removable.
Documented certification shall be provided for all carbon steel materials and equipment used in the
construction of fuel piping systems. This documentation shall be in the form of mill certification giving details
(but not limited to) of alloy contents, material heat numbers, material descriptions and sizing. Letters of
conformity shall not be acceptable were such letters of conformity do not bear the details of the original end
manufacturer, the applicable construction standard and do not provide sufficient detail of the item’s true
origins.
8.15.4 Quality Assurance

The Contractor shall have in place a validated quality assurance program which meets the requirements of
this document and AS/NZS ISO 9001. The Contractor shall provide a quality plan giving details of personnel
and their responsibilities for critical requirements and associated tasks within the plan.
9 Mechanical Installation and Piping Specification

9.1 Scope
This specification together with the tender and the reference codes and standards, define the minimum
requirements for the design, fabrication, installation and testing of fuel facility pipe work and connections to
its associated tanks, vessels and drainage networks on the Project. This specification shall be read in
conjunction with associated project drawings, pipe and instrument drawings and other associated
specifications (materials etc).
9.1 Operation Procedures

All fabrication shall be performed in a clean and orderly area conducive to the construction, welding and
assembly of fuel quality piping systems and equipment. Precautions shall be taken to preclude system
contamination during welding and assembly.
9.2 Piping Systems Performances

 In general, the following requirements for performance shall be a guide for qualification of materials
and equipment supplied for construction of the CEPS facility.
Facility Product Requirements
Dispensing Diesel fuel Design Pressure – 1000kPa

Flow Rate – 400 L/min
9.3 Design & Fabrication

All the requirements applicable to the design and fabrication of fuel system piping and equipment shall be as
prescribed by standard (latest edition). In particular, the requirements relating to aspects of:
 AS 4041 Pressure Piping
And additional reference, where required to:
 AS 2885.1 Pipelines - Gas and Liquid Petroleum Design and Construction
 AS 2885.2 Pipelines - Gas and Liquid Petroleum – Welding,
 ASME B31.3 - Process Piping
 API 5L - Specification for Line Pipe
Piping design shall be in accordance with the Works Description and issued as workshop drawings for the
review or rejection by Lendlease. All work shall be in accordance with this specification and shall form the
basis of the minimum installation practices to be carried out at the site.
If the Contractor wishes to make any variations to the specification, this must be submitted to Lendlease for
review or rejection prior to any work being carried out. The Contractor must ensure that as part of the tender
proposal, all queries are nominated and submitted for a response by Lendlease before award of contract.
9.4 Arrangement
Pipe work shall be arranged as simply as possible with a minimal number of runs.
Where required, pipes shall be arranged to provide for expansion and contraction caused by changes in
ambient temperature.
9.5 Vents and Drains

Manual high point vents and low point drains shall be provided to ensure the pipeline can be drained and
reprimed. These points shall have dust caps with captive chains. Access shall be allowed for a 500mm high
sampling bucket to be placed under a fuel sampling point or drain point.
9.6 Identification
The Temporary CEPS tank and corresponding piping shall be identified as per AS 1940 and AS 1345 to
ensure markers, colour codes, etc are consistent.
Tagging for all instrumentation and valving shall be a carbon steel/stainless steel label engraved with the tag
number of the instrument or valve and back painted with a black or white UV stable epoxy paint. The tag shall
be approximately 50mm x 12mm x 1.2 thicknesses (min). Lettering shall be approximately 10mm high. The
tag shall be connected to the instrument or valve be means of a carbon steel/stainless steel wire cable and
crimped permanently to avoid unnecessary or inadvertent removal.
9.6.1 Tank Markings

All above ground tanks shall have following provisions for markings and identification.
 Contractor shall consult the Dangerous Goods Report (00-1022-000-REP-DG-0001) for detail on
signage;
 Markings shall be displayed on the outside wall of the tanks and shall be not less than 150 mm in
height.
 All markings shall be of a colour contrasting with that of the tank.
 All recommendations as outlined in AS 1940 shall be followed.
 All tanks shall be marked with appropriate warning placard as required by WHS or relevant
regulation.
9.6.2 Pipe Labelling and Marking

The pipes in the installation are to be marked as per AS 1345 to indicate the product to be carried or stored.
This is to prevent inadvertent mixing of different fuels (such as product contamination) within the installation.
The facility shall be provided with adequate signage in accordance with Workplace Health and Safety Act and
Regulation 2017.
9.7 Equipment Tagging

All equipment if designed as per API or ASME or any of other standard shall have the name tag as stated in
the standard otherwise manufacturer standard shall apply subject to approval. All equipment tags shall be
submitted to Lendlease for final approval.
All equipment tags shall have minimum of:
 Name plate identifying the type, size, capacity, flow
 All equipment to be labelled / numbered and referenced on the as-built and O&M Manuals.
9.7.1 Valve Tagging

Tagging for all instrumentation and valving shall be a carbon steel/stainless steel label engraved with the tag
number of the instrument or valve and back painted with a black or white UV stable epoxy paint. The tag shall
be approximately 50mm x 12mm x 1.2 thicknesses (min). Lettering shall be approximately 10mm high. The
tag shall be connected to the instrument or valve be means of a carbon steel/stainless steel wire cable and
crimped permanently to avoid unnecessary or inadvertent removal.
A permanently attached stainless steel tag(s) shall be provided as per the following dimensions stamped with
the following information in lettering as sized below for each valve. Valve number and size/class shall be as
per P&IDs.
Figure 1: Valve Tags
9.8 Paint scheme

All above ground tanks and piping shall be Carbon steel externally painted. The painting system shall be
suitable for extreme marine and industrial petrochemical environments.
Surface Treatment for Carbon Steel Pipework shall be:
 Abrasive blast to Class 2.5 finish
 75 microns of amine cured epoxy coating (Jotun Penguard Express Zp)
 400 microns high build epoxy paint (Jotun Marathon 500)
 75 microns finish painting (Jotun Hard Top Ultra As)
 Top coat colour to be in accordance with AS1345 (X55 Nut Brown for Fuel service)
An ITP for painting/ coating of piping and equipment shall be submitted for review and approval.
In minimum, painting of pipeline and tanks shall be as per manufacturer’s recommendations and reference
shall be made to DFI-DPM Section 6.17.
Potential paint systems include:

Two pack high build epoxy Intergard 475
High Build Epoxy amine or polyamide cured, tar Amerlock 400/2K
free, designed for single Epinamel HSE 707
(<200micron) or multiple coat Jotun Jotacote 418
application for new or existing
steelwork. Minimum 80%
volume of solids.
High Build Phenolic Epoxy Two pack high build phenolic
epoxy designed for tank and Interline 850
pipe lining.
9.9 Pipe Spacing

Minimum spacing between adjacent pipe flanges shall be 25mm. Minimum pipe ground clearance shall be
450mm where practical. Where low point drains are located, access for a 500 mm sampling bucket to be
placed below the pipeline or a sample extension riser and valve shall be provided.
Sufficient clearance shall be accommodated for servicing and maintenance purposes, specifically around
flanges in pits.
9.10 Pipe Cleaning

Each joint of pipe shall be thoroughly swabbed to remove all dirt and foreign matter from the inside of the pipe
before the joints are lined up and welded. Where the pipeline is welded in long sections by the firing line
method, the ends of the long sections shall be closed with night caps and kept closed until the long sections
are finally tied-in. During the laying operation, close attention shall be given to open ends to ensure a clean
pipeline free of any obstructions. All precautions shall be taken to prevent water from entering the pipeline.
The open end of the pipeline shall be securely closed at all times (unless required directly for the progress of
the works), by use of night caps or approved expanding rubber rings, to prevent entrance of small animals or
the introduction of foreign matter of any nature, when not required open for construction or testing. Special
attention should be given to ensuring that this requirement is adhered to at the end of each day's work. Any
obstructions remaining in the pipeline after completion shall be removed at the expense of the Contractor. All
work shall be finished with a neat, clean appearance and shall be in accordance with AS 4041.
9.11 Welding
9.11.1 Qualification
Welded joints done offsite (i.e. in the workshop) and onsite shall comply with AS 4041 Pressure Piping.
Qualification of alternative weld procedures may be considered and shall be provided for review or rejection
of Lendlease.
As a minimum, the following shall be submitted prior to any production welding being reviewed or rejected:
 Weld Procedure Specification
 Weld Procedure Qualification Record (with welder details)
 Welder Qualifications
 Weld Inspection & Testing Quality Procedures
 Inspection & Test Plan (Procedures)
Detailed inspection and test plans outlining construction procedures for fabrication and production welds shall
also be submitted for review or rejection. The Contractor shall submit welding procedures for review or
rejection and these procedures must be qualified. The qualifying of the procedures and the welders shall be
at the cost of the Contractor.
9.11.2 Qualification of Welders

The Contractor shall use only skilled workmen/women for welding. Each welder employed by the Contractor
shall be required to pass a welding test for the type and methods of welding he/she will do. No welder shall
do any phase of welding on the pipeline for which he/she has not been tested and accepted as qualified by
the Lendlease. Each welder shall be given a unique number for use during the project. The qualifying tests
shall be made in accordance with the requirements of Australian Standard AS 4041. The Contractor shall
furnish welding coupons (if required), mechanical testing records, and NDT reports for final qualification of
welders.
9.11.3 Radiographic Inspection of Welds

Radiographic testing shall be used for the non-destructive testing (NDT) of welds. Radiographic inspections
shall be as specified in AS 4041.
Weld radiography, examination, acceptance and repair of defective welds shall be in accordance with AS
4041.
If radiographic testing is not possible and suitable reasoning and qualification is submitted to and approved
by Lendlease, dye-penetrant testing in accordance with AS 2062 and AS 4041 can be conducted.
At least one weld must be radiographed for each welder. NATA registered personnel shall carry out
radiographic inspections. Weld repairs and repeat NDT shall be at the cost of the Contractor. Re-testing shall
only be done once and if the additional test specimen fails, the welding procedure shall be deemed non-
compliant to the standard.
The Contractor shall nominate the personnel, methods (i.e. radiographic) and equipment for inspection of
welds during the tender submission. The Contractor is also to prepare a Weld Testing Plan for submission
and approval by Lendlease.
A clearance of 450 mm minimum, or greater if required by an inspecting radiographer, shall be provided at all
points around joints to permit ease of radiographing of the welded joint. A similar clearance shall be provided
around closing welds in the trench.
The Contractor, at their own expense, shall repair all defective welds.
100% visual inspections shall be undertaken for all welds by a qualified Welding Inspector.
The nominated NDT level will be 10% (radiographic inspection weld tests) for butt welded pipe joints.
9.11.4 Permanent Records of Pipe Installations

A permanent record of each weld shall be maintained by the Contractor, detailing joint identification, date,
welder, test record reference (including visual inspection records and weld material certificates), comments
and remarks to the satisfaction of Lendlease. The location of each weld joint shall be marked on the "as built"
drawings and submitted as part of the handover documentation.
9.11.5 Cleaning Welds

All slag, knots of filler metal, and surface defects shall be removed between passes. Cleaning may be done
with either hand or power tools. Flame gouging is prohibited.
9.11.6 Marking Welds

All welds shall be marked with waterproof crayon or paint stick by the welders according to numbers assigned
to them by the Inspector at the time they qualify. Should any welder leave prior to completion of the project,
their number shall be voided and not duplicated on this project. No punch or steel stencilling will be permitted.
Markings on painted section shall not be painted over.
Weld numbering and testing shall be documented and retained on site for the information of the Contractor
and Lendlease as a part of the Contractor’s quality assurance system.
9.11.7 Welding During Inclement Weather

Welding shall not be carried on when the weather conditions are unsatisfactory and impair the quality of the
welds. The Contractor shall provide umbrellas, tents, insulation covering, windbreaks and shields and welders'
platforms when conditions warrant their use.
9.11.8 Fabrication General

All fabrication of welded pipework will be managed in accordance with this specification and those
requirements outlined in other sections of this specification.
 No fabrication shall occur until all fabrication procedures have been reviewed or rejected by
Lendlease;
 Identification of all materials shall remain throughout the fabrication process;
 Spool fabrication numbers shall be assigned by the fabricator and should be in accordance with the
pipe drawings schedule. These numbers shall be marked on the pipework using an approved marker
pen during construction and on the spool fabrication (workshop) drawings;
 Only consumable items designated for use with carbon steel may be used (silicon carbide, iron free
cutting and grinding discs, wire brushes etc.);
 Covering of open ended piping spools, piping construction materials and equipment shall occur at
the completion of daily work procedures or when the constructed item is not being worked on to
ensure that no contamination occurs;
 All seam welded piping shall be staggered longitudinally;
 Unless otherwise stated, flange boltholes shall straddle the natural vertical and horizontal centrelines
of pipework;
 All machined faces of piping flanges and proprietary items (valves) shall be checked for damage
before installation. If any item is damaged it will be removed and replaced at the Contractor’s
expense;
 Internal butt-weld surfaces of orifice flanges and other flow equipment are to be ground flush;
 All butt-weld connections shall be bevel-cut using machining or grinding processes. All preparations
should reflect the procedure outlined in the weld procedure specification. It is recommended that all
field weld preparations in areas classified as hazardous areas (especially for tie-in welds) be
performed by cold cutting machines, as these devices provide quality in position preparation;
 On socket weld piping a gap of 1.5 mm should be left between the bottom of the pipe and the fitting
to ensure that “Bottoming” of the joint does not occur;
 Welders making branch connections, socket weld or weldolet connections shall be qualified
accordingly and a procedure for the connections provided. Weldolet connections shall be performed
as per manufacturers recommendations;
 The minimum distance between full penetration butt welds shall be minimum 100 mm or 6 times the
pipe wall thickness (whichever is the greater). Any weld that contradicts this clause will be brought
to the attention of Lendlease for assessment;
 Line heating for correction to distortion or for correction of flange position is not permitted;
 Cold springing or forcing of pipework for alignment or making a joint is not permitted;
 All pipe fabrication shall be performed using the appropriate use of pipe supports during the tacking
phase and the practices of dogging into alignment the pipe or fitting is not permitted. If pipe clamps
are used they must be stainless steel or be appropriately insulated for use with stainless alloys;
 The alignment of flanges across the perpendicular plane shall be plus or minus 5mm/m (1/4 Degree)
of the theoretical centreline of the joint;
 Deviation of bolt hole alignment shall be +/- 1.5mm; and
 Alignment of Bore:
- Piping above 6.0 mm wall thickness +/- 1.5mm.
- Piping below 6.0 mm wall thickness +/- 25% wall thickness.
 Installation of UPP piping shall be in accordance with the manufacturer’s instructions.
9.11.9 Weld Repairs
All weld repairs should be performed in accordance to a weld repair procedure, and the weld procedure
specification for the repair must be qualified and approved by Lendlease before use. The Contractor shall
inform Lendlease of all weld failures as part of their ITP quality assurance plan.
9.12 Sustainability Requirements

The following specification clauses outline the sustainability requirements for the project. It is both the
Managing Contractor and sub-contractor’s responsibility to ensure these sustainability objectives are met for
the project in accordance with this specification and any supporting documentation.
The project has been designed documented to comply where applicable the requirements of the Defence
Smart Infrastructure Manual (SmartIM) and the Building Energy Performance Manual (BEPM).
9.12.1 Construction and Demolition Waste

It shall be demonstrated that 70% of the waste generated during construction and demolition has been
diverted from landfill.
To calculate the amount of waste diverted from landfill, the project is required to report the total amount of
waste generated (kg), and the total amount of waste diverted from landfill (kg), and report on the proportion
diverted as a percentage.
9.12.2 Excluded Waste

Special waste and excavation waste are to be excluded from consideration in this credit. However, soil
generated from site clean-up works which incorporates soil leaving the site mixed with general construction
and demolition waste, must be included in the waste-to-landfill calculations, as it forms part of the building
site’s general waste profile.
Special Waste includes asbestos waste and asbestos containing material, or other hazardous waste and
restricted solid waste as defined by the NSW Environment Protection Authority Environmental Guidelines and
Policies for Waste.
Excavation waste includes unwanted material resulting from excavation activities such as a reduced level dig
and site preparation and levelling, and the excavation of foundations, basements, tunnels and service
trenches typically consisting of soil and stones.
9.12.3 Volume to Weight Conversion

Waste contractors are often required to determine the weight of particular waste material streams from visual
inspections of a load's volume for the purpose of reporting the estimated weights of material types removed
from site (e.g. timber, steel, plasterboard, concrete, carpet). This is acceptable as a means to calculate weight.
10 Electrical Specification
10.1 E&IC Installation
All E&IC installations shall conform to the wiring rules (AS/NZS 3000) and to requirements in the Defence
MIEE.
10.2 Equipment Selection and Installation

The Contractor shall ensure that all electrical equipment and associated materials are to be selected and
installed for their intended use in accordance with the design intent.
The ambient temperature range for all electrical/instrumentation equipment associated with the installation is:
-10°C to +50°C.
All electrical equipment shall meet or exceed this ambient temperature range.
The Contractor shall ensure that all field electrical/ instrumentation equipment to be installed in an area not
protected by a dedicated structure against the effects of solar radiation is installed with a suitable protective
cover suited to the equipment.
The equipment shall be installed so that there is ease of access for future inspection and maintenance
activities.
All power and controls wiring to the fuel installation shall be protected from overcurrent, short circuit and earth
fault conditions. To comply with this the Contractor shall test all power circuits in accordance with the
mandatory tests stipulated in Clause 8.3.2 of AS/NZS3000.
The Contractor shall arrange to have all necessary testing completed prior to the completion of the
construction period.
All electrical equipment and related fittings (e.g. cable glands, bushings, plugs, etc.) shall be certified to comply
with the requirements of the equipment protection technique.
The Contractor shall ensure that all conduits shall have a suitable seal to stop the accumulation of dust, insect
nests, debris etc.
10.3 Equipment Inspection and Tests

The Contractor shall allow for the Managing Contractor to review and approving each piece of equipment
before it is procured. The procurement shall be based on the instrument and equipment noted in the design.
The Contractor shall undertake verification of the works in accordance with applicable electrical Australian
standards for electrical equipment/instruments once the installation has been completed and prior to
energisation. Verification will encompass opening of enclosures via use of tools to inspect for defects such as
loose terminals, unterminated cores or incorrect terminations. The Contractor shall develop suitable
inspections and test plan (ITP) and Inspection test Registers (ITR) to document the verification process.
The Contractor shall allow for the Managing Contractor after the verification process has been undertaken to
undertake a visual inspection of all the equipment/ instruments including all associated control panels and
switchboards.
Site certification shall not be provided until all ITPs have been included in the MDR for review by the Managing
Contractor and the Contractor has completed all the verification works as detailed above.
10.4 Lightning Protection System, Earthing and Bonding

Earthing and bonding requirements shall be in accordance with AS/NZS 3000, AS/NZS 1768, AS/NZS 1940,
AS/NZS 1020.
10.5 General Construction

The Contractor shall submit switchboard Shop Drawings detailing arrangement, construction and component
details for approval by Lendlease prior to the commencement of fabrication/construction.
The Shop Drawings shall include metal work construction Drawings and a complete Bill of Materials and
Components.
Main switchboards shall be suitable for operation on a three phase and neutral 415 / 240V, 50Hz, solidly
earthed system.
Switchboard shall be designed as per site conditions and applicable Australian/ Defence standards for
electrical installations.
Switchboards shall be rated for the wind loading for the appropriate region and terrain category as per AS
1170.2.
An adequate number of suitably sized eye bolts shall be provided to facilitate handling. Eye bolts shall be
located so that no distortion or fatigue will result from lifting. It should be possible to remove all lifting
accessories without needing access to any internal section of the enclosure.
Rivets in the assembly of all enclosures shall not be used. All metallic non-current-carrying parts of the
switchboard shall be electrically bonded to the main earth bar.
All electrically conductive doors shall have a flexible 6 mm2 earth connection to the enclosure frame.
Hinged internal panels are preferred over removable panels.
Water shedding feature on doors, door restraints with auto latch/unlatch feature shall be provided.
10.5.1 Degree of Protection

The equipment should have the following minimum degree of protection in accordance with AS/NZS 60529:
 Indoor – IP42, and
 Outdoor – IP66 or as per Defence standards
10.5.2 Form of Segregation

Switchboards shall be constructed with minimum Form 2bi segregation in accordance with AS/NZS 3439.1
(except for board with more than 800A nominal current per phase which need to be Form 3 or higher
segregation refer to AS/NZS 3439.1). Control Panel shall be Form 1 or Managing Contractor approved Form
rating (the Form rating shall be clarified in the shop drawings as part of the approval before manufacturing).
10.5.3 Enclosure Material

Distribution boards for outdoor service shall be fabricated using either:
 316 grade stainless steel with a minimum thickness of 1.6mm, or
 Marine grade aluminium with a minimum thickness of 2mm.
The enclosure shall be formed by folding and welding. All welds shall be continuous.
10.5.4 Doors
Door openings shall be of sufficient size as to permit the easy removal of equipment mounting panels and
components without interference to the construction and service entries.
Hinged doors should be mounted on heavy duty hinges and shall be capable of swinging through an angle of
not less than 120° from the closed position.
Lift-off hinges shall have unequal length pins to enable the door to be refitted with ease.
For outdoor switchboard, all hinges, handles and locks shall be stainless steel. Switchboards with a door
greater than 1000 mm high shall have a door stay fitted to the bottom of the door. Door stays and struts shall
be selected as heavy duty and suitable for high winds.
All doors shall be earthed.
All doors shall be fitted with pinchweld or neoprene rubber seals.
All doors shall have a Perspex holder for an A3 drawing or circuit schedule, mounted on the inside.
All doors should be padlockable.
10.5.5 Roof
All outdoor enclosures shall have a sloping rain / sun hood (at least 10° from the front to rear) and guttering
directing water away from doors. The enclosure roof shall be fitted with water shedding lip or gutter at the front
to prevent water running back under the roof.
10.5.6 Spare Capacity

Where appropriate, space to accommodate spare capacity of 25% shall be provided within the switchboard
as per MIEE.
10.5.7 Ventilation
Enclosures shall generally be non-ventilated except where resistors, electronic power devices or transformers
are enclosed. However, where heating from control devices results in a temperature rise detrimental to the
enclosed equipment or its operation, natural or forced ventilation shall be used. Any ventilating opening shall
be so designed as to minimise the entry of dust/ moisture.
10.5.8 Cable Access and Glanding

Enclosures should be designed for bottom cable access.
Gland plates shall be of sufficient thickness to resist bending during installation of cables and through the life
of the enclosure. Gland plates shall be minimum 5mm aluminium or stainless steel.
Gland plates shall be bolted to the floor of each enclosure. Enough gland plates shall be provided to
accommodate all cables plus 25% spare.
Cable glands shall be used for all cable entries including earth cables.
10.5.9 Nuts and Bolts

All nuts and bolts used in the assembly and fixing of enclosures shall be to AS/NZS 1111 and AS/NZS 1112.
All nuts and bolt heads should be hexagonal. Washers shall be provided with locknuts, spring washers or
other similar means of locking.
The fixing of components to the equipment pans shall only be by hexagonal or rounded head machine screws
into a tapped hole. Under no circumstances shall self-tapping or thread forming screws be used.
10.5.10 Finish
Grade 316 stainless steel or aluminium enclosures shall be unpainted, matte finish, orbital sanded or similar.
Powder coating or painting may also be considered and approval shall be sought from Lendlease prior to
manufacturing.
10.5.11 Wiring
All control wiring within electrical equipment enclosures shall be installed in horizontal or vertical duct
(enclosed wiring/cable run) system. Wiring diagonally is not acceptable.
Where PVC insulated conductors are laid or secured to steel supports, they shall be covered over their entire
length with an insulating material (e.g. split PVC spiral sleeving or similar). Where wiring is to pass through
cut-outs in panelling, the hole shall be bushed with a PVC grommet or similar. All cabling shall comply with
AS/NZS 3000 and AS/NZS 3191, as applicable.
Where colours are used for identification purposes they shall comply with AS/NZS 2700 or Defence electrical
standard.
Low voltage and extra low voltage wiring within control panels should be kept separate.
AC and DC wiring within control panels shall be clearly labelled as such.
All low level signal wiring shall use screened pairs. A minimum of two pair of Dekoron type cabling shall be
used with a minimum cross-sectional area of 1.5mm².
Profibus, Ethernet, and Modbus wiring should be carefully routed away from mains and 24V DC cables.
AC wiring and DC wiring within Switchboard, where practicable, be kept separate. All equipment shall remain
fully accessible with labels and ferrules visible, after wiring and cabling has been completed.
Every wire shall be identified at both ends with an approved wire labelling system. Wire markers shall be
installed such that they may be read from the left to the right for horizontal runs when facing them and from
the bottom up for vertical markings. All markers shall be fully visible without removing equipment or ducting
covers.
10.5.12 Minimum Cable Sizes

The minimum power cable size should be 2.5 mm².
The minimum control cable size should be 1.5 mm².
The minimum instrument cable size should be 1.5 mm².
The minimum cable size for low-level signal wiring should be 1.5 mm 2.
The minimum cable size for PLC Patch Wiring shall be 0.5 mm 2
Reference shall be made to MIEE for further details.
10.5.13 Labels
Each switchboard shall have a nameplate in accordance with the requirements of AS/NZS 3439.1. In addition,
the nameplate shall indicate the switchboard internal arcing-fault tested value and time according to AS/NZS
3439.1 ZD.
Switchboard shall have a main label bearing the name or number of the switchboard in letters at least 25mm
high fixed to the door and the number and location of the source it is fed from.
Main labels for outdoor switchboards shall be stainless steel or anodised aluminium, engraved letters.
All equipment and devices inside switchboards should be identified with engraved traffolyte labels with black
letters and white surfaces.
Nameplates and labels shall be fixed by screws in slotted holes. Adhesive labels shall not be used.
Screws shall be stainless steel for all external labels on external switchboards and nickel plated for all other
labels. Labels larger than 100mm x 40mm shall have four fixing points.
All components shall be labelled in accordance with the related design drawings, indicating where necessary
their functions and ‘ON’ and ‘OFF’ positions. Labels shall not be fixed to removable equipment such as duct
covers and switchgear. External and internal labels shall be provided to identify equipment that is accessible
externally and internally, e.g. switches. Danger and warning signs shall have white letters on a red
background.
10.6 Local Control Panels
The Contractor shall supply, install and commission three Local Control Panels (LCP). One of the LCPs shall
contain relays to control the temporary CEPS fuel system. The LCP shall be mounted on a suitable pedestal
within the Temporary CEPS fenced area. Specific reference shall be made to Section 10.8.
Two local control panels (LCP022 and LCP023) shall be provided within Building 10 for use in the final CEPS
fuel system.
For local control panel details refer to drawing 01-1022-010-DRG-FU-6078.
10.7 Instrument Junction Box

An instrument junction box (IJB004) shall be provided within the Zone 1 tunnel to allow for termination of
cabling. The instrument junction box shall be used to facilitate connection between the Building 10 electrical
equipment to the Temporary CEPS electrical control system. The Instrument junction box shall also allow for
connection to the final CEPS fuel electrical control system being delivered under a separate scope.
The instrument junction box shall be a stainless steel 316L enclosure and appropriately sized for all required
cabling as shown on the design drawings.
For local control panel details refer to drawing 01-1022-010-DRG-FU-6078.
10.8 Automatic Tank Gauging

An automatic tank gauging system shall be installed for Temporary CEPS fuel tank. The tank probe shall be
suitable for diesel.
The Contractor is responsible to supply, install, test and commission all the instrumentation.
10.9 Cables
The Contractor shall supply, install and commission all the electrical and control including communications
cables (if required) as per the design documentation. All cable installations shall comply with the requirements
of AS/NZS 3000.
The Contractor shall supply, install and terminate all electrical and instrument cabling, glands and associated
labels (contractor to prepare the electrical termination drawings and compile a final cable schedule).
All cable ties exposed to direct sunlight are to be stainless steel type. Nylon type is acceptable within cable
tray.
Analogue signal cables shall be segregated from power cables to avoid interference.
Intrinsically safe (I.S.) circuits and non-intrinsically (I.S.) safe circuits shall not be mixed within multi-core
cables and shall also be physically segregated from power cables.
Cables shall be terminated at each device or junction box using cable glands.
All external glands exposed to weather shall have PVC shrouds fitted.
All cables shall be in a continuous run unless the Managing Contractor approves otherwise in writing. Prior to
commencing the pulling or laying of cables the actual route length shall be checked by the Contractor to
ensure sufficient cable is available to meet the run without having to join the cable. The Contractor shall be
responsible for cutting cable to the correct length.
The outer sheaths of cables shall be coloured as follows:
 Power Cables Orange or Black,
 Control Cables Orange or Black, and
 Intrinsically Safe Circuit Cables Blue.
All cables shall be identified at each end with stainless steel cable markers and carrier straps (or approved
equal).
10.10 Conduits and Cable Ladder

The Contractor shall supply and install all the cable carriers (cable ladders, conduits, etc.) and associated
supports as required. Where cable ladder and/or Unistrut (or equivalent) cannot be supported off pipe supports
or other infrastructure then the Contractor shall install separate supporting structure(s) to enable cable
installation with prior approval from the Managing Contractor.
Cable trays/ladders shall be galvanised steel fixed to walls and support columns using a Unistrut (or
equivalent) type support system.
Cable runs of one or two cables shall be protected via galvanised steel conduit, securely fixed to equipment
structural members using galvanised Unistrut (or equivalent).
Cable runs with more than two cables shall generally be supported by cable ladder.
All underground conduits used shall be fitted with draw wires including those with cables installed.
Following installation of all cables, seal all conduits enclosures with a suitable waterproof barrier to prevent
ingress of water into and out of conduits.
Cable ladders shall be heavy duty hot-dip galvanised manufactured from steel unless noted otherwise,
galvanised after manufacture to AS/NZS 4680.
Seal end of conduits to prevent mitigation of vapours, accumulation of debris, dust and insect nests etc.
Provide covers to all external ladders, ducts and trays including bends, tees and other connection pieces.
Covers are to be of the same material, of an adequate strength and rigidity, and preferably from the same
manufacturer as the cable support system.
All cable ladders shall have a minimum load rating of NEMA 12.
All bends and other changes in direction of cable support systems are to be made with standard catalogue
manufactured accessories matching the cable support system used.
No other form of bend or change in direction of cable support system is acceptable. Bends shall have a
minimum inside radius of not less than twelve times the outside diameter of the largest diameter cable carried.
Position the support system to give adequate access for inspecting, replacing, or adding cable.
Fix cable to the support system by proprietary nylon ties, straps or saddles, at 1000 mm centres for vertical
runs and 2000 mm centres for horizontal runs.
Provide a slightly curved support surface under cables leaving the tray or cable ladder to protect the cable
sheath from impingement by the tray or ladder edge.
Earth the complete support system including barriers.
10.11 Underground Cabling

The route of all below ground electric cables shall be recorded on the “As-Constructed” site plan as accurately
as practicable within a margin of error not exceeding 200 millimetres.
All below ground cables shall be installed in below ground conduit in accordance with the requirements of
AS/NZS 3000. Underground conduits shall be rigid uPVC heavy-duty orange conduit. Provide sufficient below
ground conduits to set out the cables for maximum current carrying capacity as indicated in AS/NZ 3008.
Provide polypropylene draw cords in all conduits including those with cabling installed.
Seal the buried entries to ducts and conduits with a pliable non-setting waterproof compound. Seal spare
ducts or conduits immediately after installation, and seal the others after the cable installation. Once cables
are installed, install warning tape as per AS/NZS 3000.
All pits installed in trafficable areas (including for maintenance purposes) shall be appropriately load rated and
approved before installation. Electrical pits shall be Class D, precast type and shall be lockable with a common
key.
11 Commissioning
11.1 General
Commissioning refers to operation of all the constituent functions of the completed works using fuels and all
other working media, as far as possible, under actual working conditions.
The Contractor shall ensure all the relevant pre-commissioning activities are undertaken, including completion
of FSB Commissioning Check Forms and the Pre-Start Up Safety Review (PSSR) and/or any Thales forms
(if applicable).
The Contractor shall take all steps necessary during commissioning to avoid accidental loss of fuel or other
oils to a minimum and contain any such leakage. The Contractor shall be responsible for any spills of fuel or
oil that shall be cleaned up immediately they occur and any remediation of the ground that may be required.
The Contractor shall be responsible for the disposal of spilled or leaked fuel after commissioning in
accordance with legislation and the Contractor’s CEMP.
During commissioning, the Contractor shall ensure that:
 The operation of all the constituent functions of the completed works are satisfactory;
 The integrity of the completed works is satisfactory; and
 The fuel to be dispensed from the completed works must be of a very high standard of cleanliness.
11.2 Scope of Commissioning

Commissioning refers to operation of all the constituent functions of the completed works using fuels and all
other working media, as far as possible, under working conditions. Commissioning shall be undertaken as
required by legislation; relevant Australian standards, international standards and military standards; codes
of practice; manufacturer’s written instructions and industries best practices.
Commissioning activities shall include, but is not limited to the following:
 Confirming operation of all tank mechanical components (drains, fill point, dip stick, hatches);
 Ensuring no leaks from piping;
 Confirming operation of mechanical equipment;
 Confirming operation of electrical equipment:
- Level gauges and ATG;
- Local control panel;
- Emergency stops;
 Confirming operation of interlocks; and
 Confirming the fuel dispensed from the facility is of a high standard of cleanliness and quality
11.3 Commissioning Plan
The Contractor shall prepare a Commissioning Plan for Submission to Lendlease, a minimum of sixty [60]
days prior to any commissioning activities taking place. The Contractor shall update this document with
comments issued by Lendlease following review or rejection of the commissioning plan.
The Contractor shall also include in the commissioning plan details on the following:
 A schedule of service shutdowns (if required);
 Duration of shutdown periods; and
 Contingency in the event of shutdown period overrun (at the expense of the Contractor).
The Contractor shall liaise with Lendlease and the Base to ensure that shutdown periods do not occur during
high activity periods.
11.4 Pre-Commissioning
Reference shall also be given to Installation Qualification Training detailed below.
The Contractor shall complete all works covered by the project and any other associated works that can be
completed prior to the introduction of fuel into the system.
The Contractor shall prepare commissioning plans detailing the tests to be carried out and the program and
procedures. Reference must be made to the Commonwealth of Australia’s legislation. This must incorporate
procedures for the works and the proposed emergency procedures that will be undertaken in the event of a
site spillage. The commissioning plans shall be submitted to Lendlease for review or rejection before
commissioning is due to commence.
Lendlease shall be notified in writing of the proposed fuel supplies for commissioning or hydrostatic testing a
minimum of thirty [30] days before they are required. The final requirement for fuel supplies shall be confirmed
to the Commonwealth before the fuel is required at the site.
The Commonwealth will be responsible for the supply of fuel in limited quantities for testing and
commissioning. The Contractor should calculate this quantity of fuel and have it agreed with by the
Commonwealth. Any excessive quantity of fuel will be supplied by the Commonwealth and shall be paid by
the Contractor. This requirement ensures that a high level of quality control in works will be maintained to
minimise fuel leakage and area contamination in testing and commissioning. The Contractor shall be
responsible for the provision of facilities and personnel to supply fuel and for the disposal of contaminated
fuel, under the supervision of the Commonwealth.
Lendlease shall advise and provide direction should the Commonwealth elect to not provide fuel for testing.
Fuel shall not be introduced into the equipment, pipelines, work or installation until the following have been
completed satisfactorily:
 All essential checks and tests have been undertaken;
 The installation is in a suitable, safe condition to accept fuel;
 All emergency and safety procedures are in place;
 The testing of all electrical installations and bonding, earthing and lightning protective systems;
 The issue to the Commonwealth, test certificates with respect to the testing referred to in the
foregoing item above;
 The execution of alignment checks on all major items of plant and equipment such as the pipeline,
and valves, and availability of certificates relating to performance and pressure test;
 The pressure testing of all piping; with certification;
 All identification markings, danger/warning notices positioned; and
 Test position indicators on valves.
 Completion of Fuel Services Branch’s Pre-Startup Safety Review forms and/or any Thales forms (if
applicable).
The Contractor shall provide Lendlease written confirmation that the above checks have been undertaken and
that the installation is in a suitable, safe condition to accept fuel. Prior to fuel being introduced to the
installation, the prior approval must be sought from Defence, Thales, Operating Authority of the fuel facility
via Lendlease. This shall be a Hold point in the ITP.
11.4.1 Installation Qualification Testing

As part of the commissioning plan for the installation of pipework and its associated systems, the Contractor
is required to provide Lendlease with sufficient evidence in the form of documented installation forms,
recording the manufacturing and installation process allowing for cross reference to validate:
 That the pipe work has been installed according the drawings and tender scope;
 That the equipment and the instrumentation is installed as required;
 That the piping systems have been systematically tested in accordance with the tender specification
and scope of work;
 That the electrical control system has undergone factory acceptance testing (FAT); and
 That the “as installed” position and operational setting of the piping equipment has been recorded.
Examples of I.Q documentation include:
 As Built Construction Drawings;

 NDT testing records;
 Pressure testing records;
 FAT records; and
 “As installed” records of setting (valve positions, relief valve setting etc) for field equipment.
11.5 Testing Medium for Pipework

All new pipework shall be hydrostatically/pressure tested prior to commissioning. Treated potable water or
demineralised water should be used as the test medium. All precautions as outlined in AS 4041 shall be taken
and the pipework shall be flushed clean and dried after the testing.
11.6 Pre-commissioning Tests

The minimum commissioning tests shall include all tests required by legislation, relevant Australian Standards,
International Standards and Military Standards, Codes of practice, manufacturers’ written instructions and
industry best practice.
Contractor shall confirm tank performance is in accordance with design intent. Contractor shall also ensure
all pre-commissioning tests have been performed and accepted.
 Acceptance criteria shall be as follows:
 Inspection test plan (ITP) signed and approved.
 Performance in accordance with agreed criteria (set pressure and time)
Minimum commissioning testing shall include, but not be limited to those in the following:
11.6.1 Pipework
The Contractor will ensure that the following is conducted with regard to Pipework:
 Tested to AS 4041;
 Welding tests - visual inspection, non-destructive testings and other necessary surveys;
 Pressure tests of leak and strength; and
 Dry film thickness and 100% holiday inspection tests for paint.
11.6.2 Hydrostatic Testing

The Contractor is to weld the longest possible piping spools for minimisation of in-trench tie-in welds. Spooling
arrangement is to be approved by the Contractor prior to commencement of any welding.
All new pipelines shall be blanked off and subjected to hydrostatic test using treated potable water or
demineralised water. Hydrostatic tests shall be performed in accordance to AS 4041 Section 6.7.
The testing shall be conducted and certified by an accredited NATA registered agency.
In the eventuality that a hydrostatic test does not pass the criteria of AS 4041 as noted, the Contractor shall
be responsible for rectification and any retesting.
The procedure shall also include full details of the proposed test report, which shall include, but not limited to:
 Date of test;
 Pipeline identification;
 Test fluid;
 Duration of test;
 Test equipment; and
 Test certification by examiner
At least twenty one [21] days’ notice shall be given prior to hydrotesting regarding attendance at the time of
testing. Testing shall only proceed on receipt of written approval by the Contractor. All items in the pipeline
such as isolating valves, strainers etc. shall be tested for correct operation prior to the test. Test gauges in
kPa accurate to 1% test pressure range shall be used.
Testing equipment will be:
 By calibrated transducer and chart recording giving a paper copy print out of test incorporating pressure
of pipe system, ambient temperature, product temperature or surface temperature; and
 Subject to total duration time of the test the Contractor should allow to conduct these tests in out–of-
hours periods.
Discharge of test water shall follow local authority requirements. Lendlease’ approval must be sought prior
to discharge.
11.6.3 Electrical Services

The Contractor will ensure the following is conducted with regard to Electrical Services:
 Inspection and testing of electrical installations, bonding, earthing and lightning protective systems
in accordance with the relevant Codes and Australian Standards including, but not be limited to -
HB 13, AS/NZS 1020, AS 1076 Series, AS/NZS 1768, AS 2381 Series, AS/NZS 3000, AS/NZS 3100
and AS/NZS 3017;
 All Fuel tanks, pipework and equipment shall be bonded by the fuel contractor.
 Factory Acceptance Testing of electrical equipment and switchboards;
 Tested to any requirements defined in the Defence Infrastructure Manual, including but not limited
to:
- Visual inspection of installation
- Full functional tests
- Insulation and continuity testing for HV and LV requirements
- Correction operation of protection relays and other protective devices
- Instrument configuration and calibration
Copies of the test records shall be incorporated in the Operations and Maintenance Manual.
 The Contractor shall provide Lendlease a copy of “Notification of Electrical Works” or equivalent,
together with all test results, particularly, the earth test results;
 All ‘Point to Point’ checks for instrumentation and equipment; and
 The Contractor shall provide logbooks with the original test results as required for equipment and
earthing systems.
11.6.4 Other Services

Other services including, but not limited to, pumping and reticulation, environmental control facilities, security,
civil works, safety and emergency systems, lighting and building services shall be tested in accordance with
legislation, relevant Codes of Practice, Australian Standards, International Standards and Military Standards,
written manufacturer instructions (both factory acceptance tests and site tests) and industry best practice.
11.7 Acceptance Tests

Full working tests of all aspects of the installations shall be carried out in accordance with the approved
commissioning plans.
The Contractor shall provide all testing equipment and obtain approval of the satisfactory completed tests and
accept this approval as a requirement for final completion of the Contract.
11.7.1 Functional Testing

Contractor shall perform functional testing of fuel system, including but not limited to:
 Offloading for Temporary CEPS using a tanker
 Dispensing from Temporary CEPS to Building 10 day tanks
Contractor shall include in the commissioning plan proposed functional testing activities for approval by
Defence, Lendlease and Consultant (ACOR).
11.7.2 Fuel Losses

The Commonwealth will supply a limited quantity of fuel at no expense to the Contractor for testing and
commissioning. The Contractor shall log the movement of all fuel in and out of the system, up to acceptance
of the installation by Defence.
Specifically, The Commonwealth will supply the initial batch of fuel for soak testing. The Contractor, prior to
any project fuel use, shall confirm this amount with Lendlease.
The fuel shall be able to be recovered for full testing and re-certification. It is not expected that any form of
contamination to be present in the system, other than particulates and small amounts of water, and therefore
it is reasonable to expect that the fuel can be recertified for use.
The supply of fuel by the Commonwealth is at their discretion. Lendlease shall advise and provide direction
should the Commonwealth elect to not provide fuel for testing.
The following costs are to be borne by the Contractor:
 Cost of fuel lost through spillages; and
 Cost of fuel that is rendered unserviceable due to contamination by the system.
11.7.3 Facility Use Prior to Completion of Acceptance Tests

If it becomes necessary to use the facility prior to completion of tests, this shall not be taken as acceptance
of the facility by The Commonwealth.
11.8 Handover
The Contractor must give Lendlease all test certificates including, but not limited to, work test certificates of
all electrical services, pressure vessels and valves, radiography records, painting tests and inspections,
pressure tests, completed commissioning plans and records and any other documents requested before
handover.
The full set of “as installed” drawings, in the required format with the correct number of copies, must be
submitted, together with operation and maintenance manuals, prior to handover. Refer to Section 12 for
deliverable requirements.
11.9 Review of documentation

The following documentation shall be maintained to ensure the construction phase of the project was
conducted in accordance with the design and tender:
 Log sheets;
 Qualifications, experience and current licenses of tradespeople, individuals or organisations
conducting any testing of construction (paint surfaces, weld thickness, weld quality, hydrostatic
testing of pressure vessels, electrical safety etc.);
 Test methods to ensure the tests carried out were documented and current, in accordance with the
appropriate standards;
 Results of the tests reported, in accordance with applicable standards for reporting or consistent
with the result format expected from the test; and
 Documentation for materials authenticity.
11.10 Performance
The Contractor is required to demonstrate the capability of the delivered product to perform to the parameters
of the design. Where there is no standard or test method published, it shall be demonstrated to Lendlease
that the delivered product performs to the design specification.
The demonstrated operation of all new or modified components, in accordance with the documented
procedures using various scenarios, including 100% design capacity and maximum effort (i.e. surge capacity)
is required by the Contractor.
Note that not less than twenty one [21] days’ notice shall be provided to Lendlease of intent to undertake
functional testing.
11.10.1 Piping and Equipment

The Contractor will provide the following to determine material properties and performance in accordance with
design:
 Material testing (samples, off-cuts, non-critical areas);
 Material certificates; and
 Hydrotest and soak test certificates.
11.10.2 Electrical Services

The Contractor will provide demonstration of full functionality of electrical systems including:
 Documentation (operators manuals, cabling diagrams etc); and
 Function of Emergency Stop Buttons, instrumentation and Local Control Panel;
Reference the Tender Specification Sections for further details and inclusions to be incorporated in Testing
and Commissioning Plan to be submitted by the Contractor.
12 Deliverables
The Contractor shall not rely solely on dimensions provided, but shall check all dimensions on site prior to
construction. The Contractor shall report any discrepancies, inconsistencies, errors and contradictions on
drawings and documentation immediately and seek Lendlease’s direction.
All equipment & fittings proposed for procurement shall be submitted to Lendlease with verification indicating
compliance with design intent and technical specification. Submissions shall be in the form of technical data
sheets and samples where relevant.
12.1 Work Plan

The Contractor shall:
 Submit a detailed Work Plan (WP) to the satisfaction of Lendlease. The WP shall be reviewed and
accepted, or rejected by Lendlease prior to the commencement of any works; and
 Submit to Lendlease a methodology and staging plan for the works, making connections and
reticulating temporary services as necessary for construction purposes, including but not limited to
fuel, water, sewer and power/communication services.
This plan will cover:
 Determination of the location and level of all existing services on site prior to the commencement of
any work;
 Demolition and removal from site of redundant existing structures;
 Protection of the works including stormwater diversion, control of runoff, dewatering, erosion and
sediment control, and grassing;
 Dust control. Any dust or sand blown from the site must be controlled at all times during the works.
The Contractor is to ensure that all dewatering is included in their contract;
 Maintenance of traffic and environmental control of construction vehicles entering and exiting the
site;
 Construction of services conduits where specified;
 Geotechnical testing, inspections and supervision as specified, with all costs associated with the
provision of Geotechnical activities borne by the Contractor;
 Inspection Test and Hold Point Plan. Refer to Section 4 for a list of minimum hold point items
 Works as executed drawings;
 Ancillary and maintenance works related to WH&S and environmental protection during the course
of this contract; and
 A consolidated register of all Works Plans (WPs), Installation and Test Records, Field Installation
Checklists, etc to be utilised by the Contractor shall be provided and included in the Quality Plan.
12.2 Workshop Drawings

The Contractor shall supply all Workshop Drawings to Lendlease for approval.
Construction and installation shall not proceed prior to the acceptance of Workshop Drawings by Lendlease.
As a minimum, Workshop Drawings shall be provided for:
 Temporary CEPS tank;
 Pipework;
 All electrical control system equipment (inclusive of local control panels and instrument junction
boxes);
 All electrical emergency stop system equipment.
12.3 Specification Details

Detailed drawings provided as part of the Works have been provided to assist the tenderer with
comprehension of the design philosophy.
It is the Contractor’s responsibility to provide a full set of Workshop Drawings to Lendlease to review or reject
as part of the construction process.
The workshop drawings set shall include but not be limited to:
 Piping, instrumentation and equipment spooling, routing, fixing and support arrangements;
 Verification of equipment selection and performance calculations; and
 Termination drawings for equipment.
12.4 Commissioning Plan

The Contractor shall supply a commissioning plan as detailed in previous section.
12.5 As Constructed Documentation (General)

As constructed documentation shall be issued in both hard copy and electronic documents in formats as
identified below.
Documentation Format
A1 or B1 Drawings AutoCAD 2007
A3 Drawings Adobe Acrobat
Colour A3 Drawings, Schematics & Impressions Adobe Acrobat
Schedules Microsoft Excel
Specifications and Sundry Text Microsoft Word
Data Projector Presentations Microsoft PowerPoint
Program Microsoft Project
3D Model Navis Works
Documentation shall be compiled and submitted in accordance with the Defence Estate Maintenance
procedures.
12.5.1 Web Based Tools

Submission of As Constructed documentation shall be on electronic media (such as WebFM/Omtrack).
12.5.2 GFIS & DEMS Information

Underground services and infrastructure information shall be compiled and recorded under the National
Spatial Infrastructure Management System (NSIMS) previously GFIS, with this documentation being included
within the as built documentation.
12.6 Work-as-Executed Drawings

Prior to completion of the works the Contractor is to provide a complete and accurate set of “as constructed”
site surveyed drawings (in accordance with the Defence Document – Survey Specification for Facility Detail
and As-constructed Site Survey) showing the installed position of all elements included in this specification.
The survey of the installed elements shall be carried out by a registered surveyor to Australian Height Datum
(AHD) and Map Grid Australia (MGA). The drawings shall be provided in hard copy (3 off copies) together
with an electronic copy (1 off) in ACAD and PDF format.
The drawings should indicate ALL features forming part of this contract including but not limited to:
 Civil and other earthworks performed;
 Hydraulic services;
 Structural components of the fuel system;
 Piping, valves, flanges, etc. layout and installation;
 Electrical drawings for conduit, cabling, terminations, etc.; and
 Other underground services.
The drawings should indicate all features forming part of this contract, should be accurately plotted on the
drawings and be indicated by measurement from permanent features or by coordinates. If stormwater, fuel
services and other underground services form part of this contract, the work-as-executed details for those
services may, with Lendlease’ approval, be shown on the same drawings. In addition, the Contractor will
supply the following data as a computer spreadsheet file using Microsoft Excel format.
 Compaction test data for each layer.
 Location of each test by co-ordinates.
 Prevailing weather conditions at the time of and 24hrs prior to subgrade preparation, including proof
rolling.
 Location of drainage pipes and other underground services, materials used, pipe class, invert levels,
backfill type and compaction, date of installation.
The Contractor shall sign the work as executed drawings on completion of the works verifying that all proposed
works have been constructed as specified.
12.7 As Constructed Drawings

The Contractor shall provide three hard copies (plus one electronic copy) of “as constructed” drawings for all
aspects of the CEPS facility in the forms as noted in previous section.
12.8 Operation and Maintenance Manuals

The Contractor shall provide an Operation and Maintenance manual inclusive of all equipment supplied for
the Contract works. Manuals shall contain all manufacturer and supplier details, equipment specifications, list
of consumables associated with equipment and associated part numbers (for replaceable items), as well as
certificates and warranties.
The Contractor shall provide three (3) hard copies and one electronic copy of Operation and Maintenance
Manuals that provide:
 The description of the systems, the method of operation and maintenance requirements of the
systems and each equipment (all information necessary for the satisfactory long-term operation and
regular maintenance of all equipment and materials); and
 All data (including manufacturers’ data) of all equipment, detailed technical description easily
understandable by a trained technician not familiar with the equipment, with performance data and
illustrations where appropriate.
The Contractor shall provide for equipment a logbook for recording separate operational and maintenance
procedures, materials used, test results, comments for future maintenance actions, notes covering the
conditions of the installation, etc. The logbook shall be sufficient in page number to receive for the defects
liability and maintenance period and for a further period of 12 months.
The operation and maintenance manuals and logbooks shall be in both hard copy and electronic format.
A draft of the Operation and Maintenance manual shall be submitted to Lendlease at least 10 weeks prior to
completion (or at the request of Lendlease).
12.9 Manufacturer’s Data Record (MDR)

A Manufacturer’s Data Record (MDR) shall be progressively compiled by the Contractor throughout the period
of works and submitted to Lendlease at the completion of the project.
A draft format of the MDR shall be submitted to Lendlease at least 10 weeks prior to completion.
The Contractor shall provide three (3) hard copies and one electronic copy of the MDR which shall contain,
but is not limited to, the following items:
 ITPs and inspection checklists;
 Equipment Certificates and traceability record;
 Material certificates (full traceability record);
 Welder records (including NDT results and qualifications);
 Weld procedure and specification;
 Permanent record of welds;
 Weld inspection results;
 Pressure Test and Soak Certificates;
 FAT and SAT records;
 File notes, records or approvals detailing any departures from the design;
 Construction and Installation certificates certifying that the installation complies with the relevant
Australian Standards, Defence policies and Acts and Regulations; and
 Any other information deemed important to the construction and commissioning of the system.
12.10 Spare Parts List

A spare parts list shall be prepared for the fuel system and submitted as part of Handover documentation.
The list should detail critical spares to be kept on site and include details such as:
 Part number;
 Part name;
 Number of spares required;
 Use (referencing equipment tags or a general description);
 Lead time; and
 Local supplier details (name, number and contact person)
 Contractor shall allow for following additional spares for:
 Capital
 Commissioning
 Installation and
 Hydro test
13 Defects Liability Period

The objective of the defects liability period (DLP) is to ensure identified defects are eliminated from works.
During this period, the Contractor is expected to perform planned and unplanned maintenance of the system.
Orders shall be issued by the Defects and Maintenance Manager. The duration of the DLP will be 12 months
from the date of practical completion.
13.1 Planned Maintenance

 The Contractor shall prepare a schedule of the scope and frequency for planned maintenance to be
carried out during the DLP. The scope and frequency shall ensure that:
 Manufacturers warranties are maintained;
 Compliance with Australian Standards and Defence policies; and
 The works remain fit for intended purpose and complies with statutory requirements and other
requirements of the Contract.
The Contractor shall allow for the preparation of Permit to Interrupt (PTI) and the engagement of Thales Safety
Officers for maintenance activities.
13.2 Unplanned Maintenance
 The Contractor shall address unplanned maintenance requirements to ensure that in an emergency
the site is made safe and secure. The response criteria shall be agreed between Lendlease and the
Contractor.
14 Commonwealth Personnel Training
Specific training for nominated Commonwealth Personnel is to be provided. As a minimum this shall include
training for all new and modified equipment and systems supplied under the Contract.
The Contractor shall provide training to ensure the Commonwealth operators and maintenance staff are
capable of operating and maintaining the CEPS facility correctly, safely and efficiently. The Contractor shall
allow training for an agreed number of operating and maintenance personnel prior to the handover of the
commissioned facility. The operating and maintenance personnel will have had previous general CEPS facility
operational and/or maintenance training and fuel product knowledge. The content of the training shall be
tailored to the level of the participants, with greater depth provided where appropriate.
The training should concentrate on the operational and maintenance requirements of the CEPS facility. The
content of the training sessions will utilise content from the O&M manuals and where applicable, will also
include an orientation tour of the facility to reinforce the locations of key plant and equipment, isolation
valves/switches etc. Training shall be coordinated with the other trade Contractors to ensure that all aspects
of the facility are covered.
Prior to training, the agreed operating and maintenance manual and a full listing of vendor equipment
information should be available. It is expected the training will be conducted by an agreed number of
specialists from the Contractor. At least, one specialist should have a full understanding of operating the CEPS
facility. Each participant should have a set of trainer notes and handouts. All presentation slides and any other
training aids (such as O&M manual) used during presentations should be handed-over to The Commonwealth.
Signed documentation by Contractor Trainers – Defence personnel who undertook the training and Lendlease
confirming all training modules have been undertaken and completed to the satisfaction of Lendlease will be
required at Commissioning/Hand-over.
Completed documentation in draft format shall be submitted to Lendlease for review or rejection prior to
commencing training. Any changes, alteration or further explanations advised by Lendlease shall be
incorporated prior to modification from ‘draft’ to ‘final release’ format of the training documentation.
Appendix A - Reference Safety Data Sheet (SDS)
SAFETY DATA SHEET
Automotive Diesel Fuel
Section 1. Identification
GHS product identifier Automotive Diesel Fuel
Other means of G10, BP 10 ppm diesel fuel,Ultra Low Sulphur diesel Fuel, Automotive Diesel Fuel
identification AD 20 , AD40, ALPINE DIESEL, Biodiesel B5
Product code 0000002718
SDS no. 0000002718
Historic SDS no. AD0K1
Relevant identified uses of the substance or mixture and uses advised against
Use of the substance/ Fuel for compression ignition diesel engines.
mixture
Manufacturer
Supplier BP Australia Pty Ltd
Level 17, 717 Bourke Street
Docklands, Victoria 3008
ABN 53 004 085 616
www.bp.com.au
Technical Helpline Number: 1300 139 700

EMERGENCY TELEPHONE 1800 638 556
NUMBER
Section 2. Hazard(s) identification

Classification of the FLAMMABLE LIQUIDS - Category 4
substance or mixture ACUTE TOXICITY (inhalation) - Category 4
SKIN CORROSION/IRRITATION - Category 2
CARCINOGENICITY - Category 2
SPECIFIC TARGET ORGAN TOXICITY (REPEATED EXPOSURE) (bone marrow,
liver and thymus) - Category 2
ASPIRATION HAZARD - Category 1
GHS label elements

Hazard pictograms
Signal word DANGER

Hazard statements H227 - Combustible liquid.
H332 - Harmful if inhaled.
H315 - Causes skin irritation.
H351 - Suspected of causing cancer.
H304 - May be fatal if swallowed and enters airways.
H373 - May cause damage to organs through prolonged or repeated exposure.
(bone marrow, liver, thymus)
Precautionary statements
General P103 - Read label before use.
P102 - Keep out of reach of children.
P101 - If medical advice is needed, have product container or label at hand.
Product name Automotive Diesel Fuel Product code 0000002718 Page: 1/13
Version 1 Date of issue 07/04/2016 Format Australia Language ENGLISH
(Australia) (ENGLISH)
Section 2. Hazard(s) identification
Prevention P201 - Obtain special instructions before use.
P260 - Do not breathe vapour.
P280 - Wear protective gloves. Wear eye or face protection. Wear protective
clothing.
P210 - Keep away from heat, hot surfaces, sparks, open flames and other ignition
sources. No smoking.
P241 - Use explosion-proof electrical, ventilating, lighting and all material-handling
equipment.
P273 -Avoid release to the environment.
Response P314 - Get medical attention if you feel unwell.
P308 + P313 - IF exposed or concerned: Get medical attention.
P304 + P340 + P312 - IF INHALED: Remove victim to fresh air and keep at rest in a
position comfortable for breathing. Call a POISON CENTER or physician if you feel
unwell.
P301 + P310 + P331 - IF SWALLOWED: Immediately call a POISON CENTER or
physician. Do NOT induce vomiting.
P302 + P352 + P362-2 + P363 - IF ON SKIN: Wash with plenty of soap and water.
Take off contaminated clothing. Wash contaminated clothing before reuse.
P332 + P313 - If skin irritation occurs: Get medical attention.
Storage P405 - Store locked up.
P403 - Store in a well-ventilated place.
P235 - Keep cool.
Disposal P501 - Dispose of contents and container in accordance with all local, regional,
national and international regulations.
Supplemental label Not applicable.
elements
Other hazards which do not This material may contain significant quantities of polycyclic aromatic hydrocarbons,
result in classification some of which have been shown by experimental studies to induce skin cancer.
Note: High Pressure Applications
Injections through the skin resulting from contact with the product at high pressure
constitute a major medical emergency.
See 'Notes to physician' under First-Aid Measures, Section 4 of this Safety Data
Sheet.
Section 3. Composition and ingredient information

Substance/mixture Mixture
May contain Fatty Acid Methyl Esters (FAME). May also contain small quantities of proprietary performance additives.
Contains small quantities of polycyclic aromatic hydrocarbons (PAHs).
Ingredient name % (w/w) CAS number
Fuels, diesel > 95 68334-30-5
Alkanes, C10-20-branched and linear 0 - 20 928771-01-1
There are no additional ingredients present which, within the current knowledge of the supplier and in the
concentrations applicable, are classified as hazardous to health or the environment and hence require
reporting in this section.
Occupational exposure limits, if available, are listed in Section 8.
Section 4. First aid measures

Description of necessary first aid measures
Eye contact In case of contact, immediately flush eyes with plenty of water for at least 15
minutes. Eyelids should be held away from the eyeball to ensure thorough rinsing.
Check for and remove any contact lenses. Get medical attention.
Inhalation If inhaled, remove to fresh air. If not breathing, if breathing is irregular or if
respiratory arrest occurs, provide artificial respiration or oxygen by trained personnel.
Get medical attention.
Section 4. First aid measures
Skin contact In case of contact, immediately flush skin with plenty of water for at least 15 minutes
while removing contaminated clothing and shoes. Clean shoes thoroughly before
reuse. Drench contaminated clothing with water before removing. This is necessary
to avoid the risk of sparks from static electricity that could ignite contaminated
clothing. Contaminated clothing is a fire hazard. Contaminated leather, particularly
footwear, must be discarded. Get medical attention.
Ingestion Do not induce vomiting. Never give anything by mouth to an unconscious person. If
unconscious, place in recovery position and get medical attention immediately.
Aspiration hazard if swallowed. Can enter lungs and cause damage. Get medical
attention immediately.
Most important symptoms/effects, acute and delayed

See Section 11 for more detailed information on health effects and symptoms.
Indication of immediate medical attention and special treatment needed, if necessary
Notes to physician Treatment should in general be symptomatic and directed to relieving any effects.
Product can be aspirated on swallowing or following regurgitation of stomach
contents, and can cause severe and potentially fatal chemical pneumonitis, which
will require urgent treatment. Because of the risk of aspiration, induction of vomiting
and gastric lavage should be avoided. Gastric lavage should be undertaken only
after endotracheal intubation. Monitor for cardiac dysrhythmias.
Note: High Pressure Applications

Injections through the skin resulting from contact with the product at high pressure
constitute a major medical emergency. Injuries may not appear serious at first but
within a few hours tissue becomes swollen, discoloured and extremely painful with
extensive subcutaneous necrosis.
Surgical exploration should be undertaken without delay. Thorough and extensive
debridement of the wound and underlying tissue is necessary to minimise tissue
loss and prevent or limit permanent damage. Note that high pressure may force the
product considerable distances along tissue planes.
Specific treatments No specific treatment.
Protection of first-aiders No action shall be taken involving any personal risk or without suitable training. If it
is suspected that fumes are still present, the rescuer should wear an appropriate
mask or self-contained breathing apparatus. It may be dangerous to the person
providing aid to give mouth-to-mouth resuscitation.
Section 5. Firefighting measures

Extinguishing media
Suitable extinguishing In case of fire, use water fog, foam, dry chemical or carbon dioxide extinguisher or
media spray.
Unsuitable extinguishing Do not use water jet.
media
Specific hazards arising Combustible liquid. Fire water contaminated with this material must be contained
from the chemical and prevented from being discharged to any waterway, sewer or drain. In a fire or if
heated, a pressure increase will occur and the container may burst, with the risk of a
subsequent explosion. Runoff to sewer may create fire or explosion hazard.
Hazardous thermal Combustion products may include the following:
decomposition products carbon dioxide
carbon monoxide
other hazardous substances.
Section 5. Firefighting measures
Special protective actions Promptly isolate the scene by removing all persons from the vicinity of the incident if
for fire-fighters there is a fire. No action shall be taken involving any personal risk or without
suitable training. Move containers from fire area if this can be done without risk.
Use water spray to keep fire-exposed containers cool.
Special protective Fire-fighters should wear positive pressure self-contained breathing apparatus
equipment for fire-fighters (SCBA) and full turnout gear.
Hazchem code 3z
Section 6. Accidental release measures

Personal precautions, protective equipment and emergency procedures
For non-emergency Immediately contact emergency personnel. No action shall be taken involving any
personnel personal risk or without suitable training. Evacuate surrounding areas. Keep
unnecessary and unprotected personnel from entering. Do not touch or walk
through spilt material. No flares, smoking or flames in hazard area. Avoid breathing
vapour or mist. Provide adequate ventilation. Put on appropriate personal
protective equipment. Floors may be slippery; use care to avoid falling. Eliminate
all ignition sources.
For emergency responders Entry into a confined space or poorly ventilated area contaminated with vapour, mist
or fume is extremely hazardous without the correct respiratory protective equipment
and a safe system of work. Wear self-contained breathing apparatus. Wear a
suitable chemical protective suit. Chemical resistant boots. See also the
information in "For non-emergency personnel".
Environmental precautions Avoid dispersal of spilt material and runoff and contact with soil, waterways, drains
and sewers. Inform the relevant authorities if the product has caused environmental
pollution (sewers, waterways, soil or air). Water polluting material. May be harmful
to the environment if released in large quantities.
Methods and material for containment and cleaning up

Small spill Eliminate all ignition sources. Stop leak if without risk. Move containers from spill
area. Absorb with an inert material and place in an appropriate waste disposal
container. Use spark-proof tools and explosion-proof equipment. Dispose of via a
licensed waste disposal contractor. The method and equipment used must be in
conformance with appropriate regulations and industry practice on explosive
atmospheres.
Large spill Eliminate all ignition sources. Stop leak if without risk. Move containers from spill
area. Approach the release from upwind. Prevent entry into sewers, water courses,
basements or confined areas. Dike spill area and do not allow product to reach
sewage system and surface or ground water. Contain and collect spillage with non-
combustible, absorbent material e.g. sand, earth, vermiculite or diatomaceous earth
and place in container for disposal according to local regulations. Use spark-proof
tools and explosion-proof equipment. Contaminated absorbent material may pose
the same hazard as the spilt product. The method and equipment used must be in
conformance with appropriate regulations and industry practice on explosive
atmospheres. Dispose of via a licensed waste disposal contractor.
Section 7. Handling and storage

Precautions for safe handling
Protective measures Put on appropriate personal protective equipment (see Section 8). Do not get in
eyes or on skin or clothing. Use only with adequate ventilation. Wear appropriate
respirator when ventilation is inadequate. Avoid contact of spilt material and runoff
with soil and surface waterways. Empty containers retain product residue and can
be hazardous. Keep in the original container or an approved alternative made from
a compatible material, kept tightly closed when not in use. Do not reuse container.
Store and use away from heat, sparks, open flame or any other ignition source. Use
explosion-proof electrical (ventilating, lighting and material handling) equipment.
Use only non-sparking tools. Do not breathe vapour or mist. Avoid exposure -
Section 7. Handling and storage
obtain special instructions before use. Do not handle until all safety precautions
have been read and understood. Do not swallow. Aspiration hazard if swallowed.
Can enter lungs and cause damage. Never siphon by mouth.
Advice on general Eating, drinking and smoking should be prohibited in areas where this material is
occupational hygiene handled, stored and processed. Wash thoroughly after handling. Remove
contaminated clothing and protective equipment before entering eating areas. See
also Section 8 for additional information on hygiene measures.
Conditions for safe storage, Store in accordance with local regulations. Store in a segregated and approved
including any area. Store in original container protected from direct sunlight in a dry, cool and well-
incompatibilities ventilated area, away from incompatible materials (see Section 10) and food and
drink. Store locked up. Eliminate all ignition sources. Separate from oxidising
materials. Keep container tightly closed and sealed until ready for use. Store and
use only in equipment/containers designed for use with this product. Containers
that have been opened must be carefully resealed and kept upright to prevent
leakage. Do not store in unlabelled containers. Use appropriate containment to
avoid environmental contamination.
As a precaution, tank headspaces should always be regarded as potentially

flammable and care should be taken to avoid static electrical discharge and all
ignition sources during filling, ullaging and sampling from storage tanks. Do not
enter storage tanks. If entry to vessels is necessary, follow permit to work
procedures. When the product is pumped (e.g. during filling, discharge or ullaging)
and when sampling, there is a risk of static discharge. Ensure equipment used is
properly earthed or bonded to the tank structure. Electrical equipment should not be
used unless it is intrinsically safe (i.e. will not produce sparks). Explosive air/vapour
mixtures may form at ambient temperature. If product comes into contact with hot
surfaces, or leaks occur from pressurised fuel pipes, the vapour or mists generated
will create a flammability or explosion hazard. Product contaminated rags, paper or
material used to absorb spillages, represent a fire hazard, and should not be
allowed to accumulate. Dispose of safely immediately after use. Entry into a
confined space or poorly ventilated area contaminated with vapour, mist or fume is
extremely hazardous without the correct respiratory protective equipment and a safe
system of work.
Section 8. Exposure controls and personal protection

Control parameters
Occupational exposure limits
Ingredient name Exposure limits
Fuels, diesel ACGIH TLV (United States). Absorbed
through skin.
TWA: 100 mg/m³, (measured as total
hydrocarbons) 8 hours. Issued/Revised:
1/2007 Form: Inhalable fraction and vapor
Appropriate engineering All activities involving chemicals should be assessed for their risks to health, to
controls ensure exposures are adequately controlled. Personal protective equipment should
only be considered after other forms of control measures (e.g. engineering controls)
have been suitably evaluated. Personal protective equipment should conform to
appropriate standards, be suitable for use, be kept in good condition and properly
maintained.
Your supplier of personal protective equipment should be consulted for advice on
selection and appropriate standards. For further information contact your national
organisation for standards.
Provide exhaust ventilation or other engineering controls to keep the relevant
airborne concentrations below their respective occupational exposure limits.
The final choice of protective equipment will depend upon a risk assessment. It is
important to ensure that all items of personal protective equipment are compatible.
Environmental exposure Emissions from ventilation or work process equipment should be checked to ensure
controls they comply with the requirements of environmental protection legislation. In some
cases, fume scrubbers, filters or engineering modifications to the process
equipment will be necessary to reduce emissions to acceptable levels.
Individual protection measures

Hygiene measures Wash hands, forearms and face thoroughly after handling chemical products, before
eating, smoking and using the lavatory and at the end of the working period.
Appropriate techniques should be used to remove potentially contaminated clothing.
Wash contaminated clothing before reusing. Ensure that eyewash stations and
safety showers are close to the workstation location.
Eye/face protection Chemical splash goggles.
Skin protection
Hand protection Wear chemical resistant gloves.
Protective gloves must give suitable protection against mechanical risks (i.e.
abrasion, blade cut and puncture). Protective gloves will deteriorate over time due
to physical and chemical damage. Inspect and replace gloves on a regular basis.
The frequency of replacement will depend upon the circumstances of use.
Recommended: Nitrile gloves.
Skin protection Use of protective clothing is good industrial practice.
Cotton or polyester/cotton overalls will only provide protection against light
superficial contamination that will not soak through to the skin. Overalls should be
laundered on a regular basis. When the risk of skin exposure is high (e.g. when
cleaning up spillages or if there is a risk of splashing) then chemical resistant aprons
and/or impervious chemical suits and boots will be required.
Wear suitable protective clothing.
Footwear highly resistant to chemicals.
When there is a risk of ignition from static electricity, wear anti-static protective
clothing. For greatest effectiveness against static electricity, overalls, boots and
gloves should all be anti-static.
When there is a risk of ignition wear inherently fire resistant protective clothes and
gloves.
Work clothing / overalls should be laundered on a regular basis. Laundering of
contaminated work clothing should only be done by professional cleaners who have
been told about the hazards of the contamination. Always keep contaminated work
clothing away from uncontaminated work clothing and uncontaminated personal
clothes.
When the risk of skin exposure is high (from experience this could apply to the
following tasks: cleaning work, maintenance and service, filling and transfer, taking
samples and cleaning up spillages) then a chemical protective suit and boots will be
required.
Personal protective equipment for the body should be selected based on the task
being performed and the risks involved and should be approved by a specialist
before handling this product.
Recommended: overall
Other skin protection Appropriate footwear and any additional skin protection measures should be
selected based on the task being performed and the risks involved and should be
approved by a specialist before handling this product.
Respiratory protection Use with adequate ventilation.
In case of insufficient ventilation, wear suitable respiratory equipment.
If there is a requirement for the use of a respiratory protective device, but the use of
breathing apparatus (independent of ambient atmosphere) is not required, then a
suitable filtering device must be worn.
The filter class must be suitable for the maximum contaminant concentration (gas/
vapour/aerosol/particulates) that may arise when handling the product.
The correct choice of respiratory protection depends upon the chemicals being
handled, the conditions of work and use, and the condition of the respiratory
equipment. Safety procedures should be developed for each intended application.
Respiratory protection equipment should therefore be chosen in consultation with
the supplier/manufacturer and with a full assessment of the working conditions.
Recommended: If ventilation is inadequate, use respirator that will protect against
organic vapour and dust/mist.
Refer to standards: Respiratory protection:AS/NZS 1715 and AS/NZS 1716
Gloves:AS/NZS 2161.1
Eye protection:AS/NZS 1336 and AS/NZS 1337
Section 9. Physical and chemical properties

Appearance
Physical state Liquid.
Colour Water white to straw including fluorescent green, blue or yellow.
Odour Mild
Odour threshold Not available.
pH Not available.
Melting point Not available.
Boiling point 180 to 380°C (356 to 716°F)
Flash point Closed cup: >61.5°C (>142.7°F) [Pensky-Martens.]
Evaporation rate Not available.
Flammability (solid, gas) Not applicable. Based on - Physical state
Lower and upper explosive Lower: 0.5%
(flammable) limits Upper: 7.5%
Vapour pressure 0.1 kPa (0.755 mm Hg)
Vapour density Not available.
Relative density 0.83
Density 820 to 850 kg/m³ (0.82 to 0.85 g/cm³) at 15°C
Solubility Not available.
Partition coefficient: n- Not available.
octanol/water
Auto-ignition temperature 240°C (464°F)
Decomposition temperature Not available.
Viscosity Kinematic: 2 to 4.5 mm2/s (2 to 4.5 cSt) at 40°C
Section 10. Stability and reactivity

Reactivity No specific test data available for this product. Refer to Conditions to avoid and
Incompatible materials for additional information.
Chemical stability The product is stable.
Possibility of hazardous Under normal conditions of storage and use, hazardous reactions will not occur.
reactions Under normal conditions of storage and use, hazardous polymerisation will not
occur.
Conditions to avoid Avoid all possible sources of ignition (spark or flame). Avoid excessive heat.
Incompatible materials Reactive or incompatible with the following materials: oxidising materials.
Hazardous decomposition Under normal conditions of storage and use, hazardous decomposition products
products should not be produced.
Section 11. Toxicological information
Information on toxicological effects
Acute toxicity
Product/ingredient name Result Species Dose Exposure
Fuels, diesel LC50 Inhalation Dusts and mists Rat 4.1 mg/l 4 hours
LD50 Dermal Rabbit >4300 mg/kg -
LD50 Dermal Rabbit >4300 mg/kg -
LD50 Oral Rat 17900 mg/kg -
LD50 Oral Rat 7600 mg/kg -
Irritation/Corrosion
Product/ingredient name Result Species Score Exposure Observation
Fuels, diesel Skin - Irritation Rabbit - - -
Skin - Irritation Rabbit - - -
Eyes - Non-irritating to the Rabbit - - -
eyes.
Eyes - Non-irritating to the Rabbit - - -
eyes.
Skin Causes skin irritation.
Sensitisation
Product/ingredient name Route of Species Result
exposure
Fuels, diesel skin Guinea pig Not sensitising
skin Guinea pig Not sensitising
Mutagenicity
Product/ingredient name Test Experiment Result
Fuels, diesel OECD 471 Experiment: In vitro Positive
Subject: Non-mammalian species
Equivalent to OECD Experiment: In vitro Negative
476
Subject: Mammalian-Animal
Cell: Germ
not guideline Experiment: In vivo Negative
Subject: Unspecified
Cell: Somatic
Conclusion/Summary Not classified. Based on available data, the classification criteria are not met.
Carcinogenicity
Product/ingredient name Result Species Dose Exposure
Fuels, diesel Positive - Dermal - Mouse - 2 years
Unspecified
Conclusion/Summary Suspected of causing cancer.
Reproductive toxicity
Product/ingredient name Maternal Fertility Developmental Species Dose Exposure
toxicity toxin
Fuels, diesel - - Negative Rat Dermal 20 days
- - Negative Rat Dermal 10 days
- - Negative Rat Dermal 10 days
Conclusion/Summary Development: Not classified. Based on available data, the classification criteria are
not met.
Fertility: Not classified. Based on available data, the classification criteria are not
met.
Effects on or via lactation: Not classified. Based on available data, the classification
criteria are not met.
Specific target organ toxicity (repeated exposure)
Name Category Route of Target organs
exposure
Fuels, diesel Category 2 Not determined bone marrow, liver
and thymus
Aspiration hazard
Name Result
Fuels, diesel ASPIRATION HAZARD - Category 1
Alkanes, C10-20-branched and linear ASPIRATION HAZARD - Category 1
Information on likely routes Routes of entry anticipated: Oral, Dermal, Inhalation.

of exposure
Potential acute health effects
Eye contact No known significant effects or critical hazards.
Inhalation Harmful if inhaled.
Skin contact Causes skin irritation.
Ingestion Irritating to mouth, throat and stomach. Aspiration hazard if swallowed -- harmful or
fatal if liquid is aspirated into lungs.
Symptoms related to the physical, chemical and toxicological characteristics

Eye contact Adverse symptoms may include the following:
pain or irritation
watering
redness
Inhalation Adverse symptoms may include the following:
nausea or vomiting
headache
drowsiness/fatigue
dizziness/vertigo
unconsciousness
Skin contact Adverse symptoms may include the following:
irritation
redness
Ingestion Adverse symptoms may include the following:
nausea or vomiting
Delayed and immediate effects as well as chronic effects from short and long-term exposure
Eye contact Vapour, mist or fume may cause eye irritation. Exposure to vapour, mist or fume
may cause stinging, redness and watering of the eyes.
Inhalation Vapour, mists or fumes may contain polycyclic aromatic hydrocarbons some of
which are known to produce skin cancer. Vapour, mists or fumes may contain
polycyclic aromatic hydrocarbons some of which are known to produce skin cancer.
Vapour, mist or fume may irritate the nose, mouth and respiratory tract.
Skin contact As with all such products containing potentially harmful levels of polycyclic aromatic
hydrocarbons, prolonged or repeated skin contact may eventually result in dermatitis
or more serious irreversible skin disorders including cancer.
Ingestion If swallowed, may irritate the mouth, throat and digestive system. If swallowed, may
cause abdominal pain, stomach cramps, nausea, vomiting, diarrhoea, dizziness and
drowsiness.
General May cause damage to organs through prolonged or repeated exposure. Vapour,
mists or fumes may contain polycyclic aromatic hydrocarbons some of which are
known to produce skin cancer. Vapour, mists or fumes may contain polycyclic
aromatic hydrocarbons some of which are known to produce skin cancer.
Carcinogenicity Suspected of causing cancer. Risk of cancer depends on duration and level of
exposure.
Mutagenicity No known significant effects or critical hazards.
Teratogenicity No known significant effects or critical hazards.
Developmental effects No known significant effects or critical hazards.
Fertility effects No known significant effects or critical hazards.
Numerical measures of toxicity

Acute toxicity estimates
Route ATE value
Inhalation (dusts and mists) 1.895 mg/l
Section 12. Ecological information

Toxicity
Product/ingredient name Result Species Exposure
Fuels, diesel EL50 >1000 mg/l Nominal Fresh water Micro-organism 40 hours
NOELR 3.217 mg/l Nominal Fresh Micro-organism 40 hours
water
Acute EL50 22 mg/l Nominal Fresh Algae 72 hours
water
Acute EL50 210 mg/l Nominal Fresh Daphnia 48 hours
water
Acute EL50 68 mg/l Nominal Fresh Daphnia 48 hours
water
Acute ErL50 78 mg/l Nominal Fresh Algae 72 hours
water
Acute LL50 65 mg/l Nominal Fresh Fish 96 hours
water
Acute LL50 21 mg/l Nominal Fresh Fish 96 hours
water
Acute NOELR 10 mg/l Nominal Fresh Algae 72 hours
water
Acute NOELR 1 mg/l Nominal Fresh Algae 72 hours
water
Acute NOELR 46 mg/l Nominal Fresh Daphnia 48 hours
water
Chronic NOEL 0.083 mg/l Nominal Fish 14 days
Fresh water
Chronic NOELR 0.2 mg/l Nominal Daphnia 21 days
Fresh water
Conclusion/Summary Toxic to aquatic life with long lasting effects.
Persistence and degradability

Partially biodegradable.
Product/ingredient name Test Result Dose Inoculum
Fuels, diesel OECD 301 F 60 % - Readily - 28 days 30 mg/l -
OECD 301 F 57.5 % - Not readily - 28 days 25 mg/l -
Equivalent to 35 % - Not readily - 28 days 5 mg/l -
EPA OTS 796.
3100
Conclusion/Summary Non-persistent per IMO criteria
Section 12. Ecological information
Bioaccumulative potential
This product is not expected to bioaccumulate through food chains in the environment.
Mobility in soil
Soil/water partition Not available.
coefficient (KOC)
Mobility Spillages may penetrate the soil causing ground water contamination. This material
may accumulate in sediments.
Other ecological information Spills may form a film on water surfaces causing physical damage to organisms.
Oxygen transfer could also be impaired.
Section 13. Disposal considerations

Disposal methods The generation of waste should be avoided or minimised wherever possible.
Significant quantities of waste product residues should not be disposed of via the
foul sewer but processed in a suitable effluent treatment plant. Dispose of surplus
and non-recyclable products via a licensed waste disposal contractor. Disposal of
this product, solutions and any by-products should at all times comply with the
requirements of environmental protection and waste disposal legislation and any
regional local authority requirements. Waste packaging should be recycled.
Incineration or landfill should only be considered when recycling is not feasible. This
material and its container must be disposed of in a safe way. Care should be taken
when handling emptied containers that have not been cleaned or rinsed out. Empty
containers or liners may retain some product residues. Vapour from product
residues may create a highly flammable or explosive atmosphere inside the
container. Do not cut, weld or grind used containers unless they have been cleaned
thoroughly internally. Avoid dispersal of spilt material and runoff and contact with
soil, waterways, drains and sewers.
Special Precautions for Empty packages may contain some remaining product. Hazard warning labels are a
Landfill or Incineration guide to the safe handling of empty packaging and should not be removed.
Section 14. Transport information

ADG IMDG IATA
UN number Not regulated. UN3082 UN3082
UN proper - ENVIRONMENTALLY ENVIRONMENTALLY

shipping name HAZARDOUS SUBSTANCE, HAZARDOUS SUBSTANCE,
LIQUID, N.O.S. (Fuels, diesel) LIQUID, N.O.S. (Fuels, diesel)
Transport hazard - 9 9
class(es)
Packing group - III III

Environmental No. Yes. Yes.
hazards
Section 14. Transport information
Additional Remarks This product is not regulated This product is not regulated
information Combustible liquid Class C1 as a dangerous good when as a dangerous good when
(AS 1940). transported in sizes of ≤5 L or transported in sizes of ≤5 L or
≤5 kg, provided the ≤5 kg, provided the
Hazchem code packagings meet the general packagings meet the general
3Z provisions of 4.1.1.1, 4.1.1.2 provisions of 5.0.2.4.1, 5.0.2.6.
and 4.1.1.4 to 4.1.1.8. 1.1 and 5.0.2.8.
Initial emergency response
guide Emergency schedules
47 (EmS)
F-A, S-F
Special precautions for user Not available.
Transport in bulk according Proper shipping name MARPOL Annex 1 rules apply for bulk shipments
to Annex II of Marpol and by sea.
the IBC Code Category: gas oils, including ship's bunkers
Section 15. Regulatory information

Standard Uniform Schedule of Medicine and Poisons
Not scheduled
Consumer products - This product is exempt per Appendix A of the SUSMP.

Industrial Products - Labelling requirements for SUSMP do not apply to a poison that is packed and sold solely for
industrial, laboratory or manufacturing use. However, this product is labelled in accordance with NOSHC National
Code of Practice for labelling of workplace substances.
Model Work Health and Safety Regulations - Scheduled Substances
No listed substance
International lists
National inventory
REACH Status For the REACH status of this product please consult your company contact, as
identified in Section 1.
Australia inventory (AICS) All components are listed or exempted.
Canada inventory All components are listed or exempted.
China inventory (IECSC) Not determined.
Japan inventory (ENCS) Not determined.
Korea inventory (KECI) Not determined.
Philippines inventory Not determined.
(PICCS)
Taiwan Chemical All components are listed or exempted.
Substances Inventory
(TCSI)
United States inventory All components are listed or exempted.
(TSCA 8b)
Section 16. Any other relevant information
History
Date of printing 07/04/2016
Date of issue/Date of 07/04/2016
revision
Date of previous issue 07/04/2016
Version 1
Product Stewardship
Key to abbreviations ADG = Australian Dangerous Goods
ATE = Acute Toxicity Estimate
BCF = Bioconcentration Factor
GHS = Globally Harmonized System of Classification and Labelling of Chemicals
IATA = International Air Transport Association
IBC = Intermediate Bulk Container
IMDG = International Maritime Dangerous Goods
LogPow = logarithm of the octanol/water partition coefficient
MARPOL = International Convention for the Prevention of Pollution From Ships,
1973 as modified by the Protocol of 1978. ("Marpol" = marine pollution)
NOHSC = National Occupational Health and Safety Commission
STEL = Short term exposure limit
SUSMP = Standard Uniform Schedule of Medicine and Poisons
UN = United Nations
TWA = Time weighted average
VOC = Volatile Organic Compound
SADT = Self-Accelerating Decomposition Temperature
Varies = may contain one or more of the following 101316-69-2, 101316-70-5,
101316-71-6, 101316-72-7, 64741-88-4, 64741-89-5, 64741-95-3, 64741-96-4,
64741-97-5, 64742-01-4, 64742-44-5, 64742-45-6, 64742-52-5, 64742-53-6,
64742-54-7, 64742-55-8, 64742-56-9, 64742-57-0, 64742-58-1, 64742-62-7,
64742-63-8, 64742-64-9, 64742-65-0, 64742-70-7, 72623-85-9, 72623-86-0,
72623-87-1, 74869-22-0, 90669-74-2
Procedure used to derive the classification
Classification Justification
Flam. Liq. 4, H227 On basis of test data
Acute Tox. 4, H332 Calculation method
Skin Irrit. 2, H315 Calculation method
Carc. 2, H351 Calculation method
STOT RE 2, H373 (bone marrow, liver and thymus) Calculation method
Asp. Tox. 1, H304 Calculation method
Indicates information that has changed from previously issued version.
Notice to reader
All reasonably practicable steps have been taken to ensure this data sheet and the health, safety and environmental
information contained in it is accurate as of the date specified below. No warranty or representation, express or implied
is made as to the accuracy or completeness of the data and information in this data sheet.
The data and advice given apply when the product is sold for the stated application or applications. You should not use
the product other than for the stated application or applications without seeking advice from BP Group.
It is the user’s obligation to evaluate and use this product safely and to comply with all applicable laws and regulations.
The BP Group shall not be responsible for any damage or injury resulting from use, other than the stated product use
of the material, from any failure to adhere to recommendations, or from any hazards inherent in the nature of the
material. Purchasers of the product for supply to a third party for use at work, have a duty to take all necessary steps to
ensure that any person handling or using the product is provided with the information in this sheet. Employers have a
duty to tell employees and others who may be affected of any hazards described in this sheet and of any precautions
that should be taken. You can contact the BP Group to ensure that this document is the most current available.
Alteration of this document is strictly prohibited.
Appendix B - Pipe Specification
Piping Class C1
SERVICE: Naval Fuel F-76, Diesel Fuel
Design Condition Temperature 500C
Maximum Operating 1500 kPa(g)
Pressure
Hydrotest Pressure 1960 kPa(g)
AS 4041, ANSI B36.10, ASME B16.9, ASME B16.11, ASTM A182, ASTM A234,
Applicables Codes
ASTM A105, ASTM A53
Size Range DN15 - DN450
Flange Rating Class #150
Material Carbon Steel
Corrosion Allowance 1.5 mm
MATERIAL DIMENSION
SIZE DESCRIPTION NOTES
SPECIFICATION SPECIFICATION
PIPE:
ERW OR SEAMLESS, SCH 80, ASTM A53 GR B; API 5L
DN15 - DN40 ASME B36.10
NPT THREADED GR B; ASTM A106-B
ASTM A53 GR B; API 5L
DN50 – DN450 ERW OR SEAMLESS, SCH 40, BW ASME B36.10
GR B; ASTM A106 GR B
FITTINGS:
DN15 - DN40 CLASS 3000#, NPT THREADED ASTM A105 ASME B16.11
DN50 – DN450 SCH 40, BW ASTM A234 GR WPB ASME B16.9 1,2
ELBOW RADII:
SCH 40, BW, Elbow shall be long radius,
unless otherwise specified on project design
DN50 - DN450 ASTM A234 GR WPB ASME B16.9 1,2
drawings or approved by principal.
SCH 80, BW, unless otherwise specified on

project design drawings or approved by
DN15 - DN40 ASTM A234 GR WPB ASME B16.9 2
principal.
UNIONS:
DN15 3000#, FEMALE NPT THREADED ASTM A234 GR B ASME B16.3
‘OLETS:
MSS-SP-97,
DN15 - DN40 CLASS 3000#, NPT THREDOLET ASTM A105 2
ends as per ASME B1.20.1
MSS-SP-97,
DN50 - DN80 WELDOLET, SCH 40 ASTM A105 2
ends as per B16.9 & B16.25
FLANGES:
DN50 - DN450 WELD-NECK, RF, STOCK-FINISH, ASTM A105 ASME B16.5
CLASS 150#, SCH 40
GASKETS:
DN50 - DN450 4.5mm THK, SPIRAL WOUND, STAINLESS STEEL 316 ASME B16.20
GRAPHITE FILLED, OUTER RING GRAPHITE FILLED
STAINLESS STEEL 316L
BOLTING:
BOLTS / STUDS CARBON STEEL ASTM A193 GR B7 ASME B18.2.1
NUTS CARBON STEEL ASTM A194 GR 2H ASME B18.2.2
Valves
Size Valve Specification Valve Type
DN15 - DN40 BA4 Ball Valve, Threaded, Female NPT
DN50 - DN350 BA1, BA2 Ball valve, Flanged
DN50 - DN350 NR1 Non Return Valve, Flanged
DN15 - DN80 PRV1 Pressure Relief Valve
DN15 - DN25 TRV1 Thermal Relief Valve
Notes:
1) Where butt-welding elbows are specified, long radius type shall be used, unless specified by the design engineer.
2) For permitted methods of connecting branches refer to “Branch Connection Chart”
3) Refer to valve specification and valve datasheets for full valve description
4) Flat faced equipment or pipe fitting flanges shall be provided with flat faced flanges.
5) Where pipeline standard detail drawings show Class 300 flanges, these should be to the same specification as that described for
Class 150, with the exception of Class rating. Gaskets to be installed between Class 300 flanges should conform to the same
specification as those described for Class 150, with the exception of flange rating.
6) Where possible, piping shall be arranged in parallel groups to facilitate multiple uses of supports and to minimise the walkway
requirements over the pipes.
Piping schedule requirements may be reviewed at the discretion of the Head Contractor
7) Threads shall be sealed with appropriate PTFE sealing compound (not tape)
8) Non-destructive testing as per works description and AS 4041 (most stringent requirements to take precedence)

01-1022-000-SPC-FU-0007-IFC (02) - Spec Fuel

Caricato da

Informazioni sul documento

Descrizione originale:

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

01-1022-000-SPC-FU-0007-IFC (02) - Spec Fuel

Caricato da

Copyright:

Formati disponibili

Temporary Central Emergency Power

Station (CEPS) Specification

Sydney | Brisbane | Perth | Broome | Central Coast | Newcastle | Western Sydney

Issue Date Purpose Prepared By Approved By

01 05/04/19 Issued for Construction Junelle Llorente Daniel Lay

Lendlease Elie Sakr

ACOR ACOR Consultants

AS/NZS Australian/ New Zealand Standard

GI S2 Garden Island Stage 2

CEPS Central Emergency Power Station

Client Lend Lease

HMI Human Machine Interface

LEL Lower Explosive Limit

PLC Primary Logic Controller

UPP Universal Polyethylene Pipework

VFD Variable Frequency Drive

VST Vertical Storage Tank

1.2 Existing Facility Description

1.3 Hierarchy of documentation

1.4 Proprietary Items

1.5 Deviations and Alternatives to Specification

2.1 Authority Approval

4 Inspection of the Works and Hold Points

5.1 Temporary CEPS

5.3 Excluded Works

5.4 Interface with Other Trades

5.5 Removal of the Temporary CEPS System

7.4.1 Ball Valves

7.4.2 Check Valves

8.2 Materials Use

8.4 Carbon Steel Pipe

8.5 Carbon Steel Pipe Fittings

8.6 Pipe Branch Connection Sizing Table

8.7 Flanges & Flanged Joints

8.8 Flange Guards

8.9 Underground Piping

8.11 Tie In Point

8.13 Pipe Welding Consumables

8.14 Pipe Support System

DN 15 20 25 50 80 100 150 200 250 300

8.15 Quarantine, Storage & Segregation

8.15.1 Quarantine & Segregation

8.15.3 Material Certification & Markings

8.15.4 Quality Assurance

9 Mechanical Installation and Piping Specification

9.1 Operation Procedures

9.2 Piping Systems Performances

Dispensing Diesel fuel Design Pressure – 1000kPa

9.3 Design & Fabrication

9.5 Vents and Drains

9.6.1 Tank Markings

9.6.2 Pipe Labelling and Marking

9.7 Equipment Tagging

9.7.1 Valve Tagging

9.8 Paint scheme

Potential paint systems include:

9.9 Pipe Spacing

9.10 Pipe Cleaning

9.11.2 Qualification of Welders

9.11.3 Radiographic Inspection of Welds

9.11.4 Permanent Records of Pipe Installations

9.11.5 Cleaning Welds