Commissioning Procedure Goedehoop

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Page of Enprotec Commissioning Procedure

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Objectives ................................ ................................ ................................ ................................ .. 4

2.

Scope ................................ ................................ ................................ ................................ ......... 4

3.

Definitions ................................ ................................ ................................ ................................ . 4

4.

Signature responsibilities per commissioning phase................................ ................................ ... 5

5.

Punch list Description................................ ................................ ................................ ................. 6

6.

THE COMMISSIONING STUCTURE AND RESPONSIBILITIES ................................ .......................... 7 6.1.

Commissioning Manager ................................ ................................ ................................ .... 7

6.2.

General ................................ ................................ ................................ .............................. 8

7.

Logistic Support ................................ ................................ ................................ ......................... 8

8.

Commissioning Control ................................ ................................ ................................ .............. 8 8.1. C1 level ʹ Commissioning ͞Punch Listing͟ ʹ Contractor and/or Suppliers & Construction Team. Pre Commissioning Checks ʹ Power Off ................................ ................................ ............... 9 8.2. C2 level ʹ Commissioning ͞Dry͟- Construction Team, Contractors and/or Supplier and Plant. Pre Commissioning Checks ʹ Power On ................................ ................................ .............. 10 8.3.

C3 level ʹ Commissioning ͞Material͟ ʹ Commissioning Team and Plant Cold Commissioning 11

8.4. C4 level ʹ Commissioning ʹ Commissioning Team and Production Process Engineer. (Hot Commissioning) ................................ ................................ ................................ ........................... 12 8.5. C5 level ʹ Commissioning ͞Production Build-up and Optimisation͟- Production Process Engineer and Plant Operating Personnel (performance Test) ................................ ....................... 12 8.6. 9.

General ................................ ................................ ................................ ............................ 13

Request for Site Modifications ʹ Construction Team ................................ ................................ 13

10.

Final Handover ................................ ................................ ................................ ..................... 13

11.

Commissioning team Identification and Induction................................ ................................ 13

12.

Attachments Commissioning Acceptance Certificates................................ ........................... 14

C1 LEVEL ʹ COMMISSIONING ACCEPTANCE CERTIFICATE ................................ ................................ . 15 DETAILS OF WORK BEING HANDED OVER ................................ ................................ ..................... 15 RESPONSIBLE PERSON................................ ................................ ................................ .............. 15 C2 LEVEL ʹ COMMISSIONING ACCEPTANCE CERTIFICATE ................................ ................................ . 16 DETAILS OF WORK BEING HANDED OVER ................................ ................................ ..................... 16 RESPONSIBLE PERSON................................ ................................ ................................ .............. 16 Page of Enprotec Commissioning Procedure

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C3 LEVEL ʹ COMMISSIONING ACCEPTANCE CERTIFICATE ................................ ................................ . 17 DETAILS OF WORK BEING HANDED OVER ................................ ................................ ..................... 17 RESPONSIBLE PERSON................................ ................................ ................................ .............. 17 C4 LEVEL ʹ COMMISSIONING ACCEPTANCE CERTIFICATE ................................ ................................ . 18 DETAILS OF WORK BEING HANDED OVER ................................ ................................ ..................... 18 RESPONSIBLE PERSON................................ ................................ ................................ .............. 18 C5 LEVEL ʹ COMMISSIONING ACCEPTANCE CERTIFICATE ................................ ................................ . 19 DETAILS OF WORK BEING HANDED OVER ................................ ................................ ..................... 19 RESPONSIBLE PERSON................................ ................................ ................................ .............. 19 Final Handover Certificate ................................ ................................ ................................ ............... 20 List of Exceptions ................................ ................................ ................................ ......................... 20 RESPONSIBLE PERSON................................ ................................ ................................ .............. 20 Project Handover to Owner Certificate ................................ ................................ ............................ 21 List of Exceptions ................................ ................................ ................................ ......................... 21 RESPONSIBLE PERSON................................ ................................ ................................ .............. 21 Request for site Modifications ................................ ................................ ................................ ......... 23 Full Description of Modification Requested ................................ ................................ .............. 23 Reasons and Justification for Modification ................................ ................................ ................... 23


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@ p 1.1.p To define the commissioning strategy and control procedures required to allow for a smooth transition from completion of construction by the Contractor ʹ C1 to formal hand over and acceptance of equipment and systems by the Project Commissioning Team ʹ C3 and to final hand over to the Plant after C5 commissioning. 1.2.p To clarify and define the different phases of hand over, the different parties involved, their responsibilities and obligations at each stage

R p This procedure will cover the commissioning strategy that will be adopted for the commissioning of the Flotation B-Bank i.e. Multi Cell upgrades to Enprotec Dual Cell Technology. (Complete with it material handling sections)

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The Plant refers to Plant Management who is represented by the Construction Manager, Metallurgical Manager and the Engineering Manager The OMR refers to the Plant appointed operation team who will act on behalf of the plant from commissioning stages C3 through to C5 and ongoing plant operation These certificate are signed by the Contractor and his Sub-contractor at stages C1 & C2 of the commissioning process signifying acceptance that the equipment is ready for C3 commissioning

These certificates are signed by the Contractor and the OMR at stage C3 once the construction completion certificate/s is signed off. This means the plant is ready for operation by the Operations Team & Beneficial use is Identified. At this point there is a shift in Safety Responsibility as well as plant Operation and Maintenance from contractor to client GHC team. The contractor is still available for support and commissioning modification identified in the first 24 hrs of operation This certificate is signed off by the OMR and the Contractor


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At stage C4 of the commissioning process signifying acceptance of plant operations

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This certificate is signed by the OMR and the Contractor and the Client Projects Manager at stage C5 of the commissioning process signifying acceptance of the plant performance as per design requirements

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This takes place once all the plant equipment has met the expected ''Performance Specifications" to the satisfaction of the Plant. Exceptions will be noted on the Final Acceptance Certificate

½ p Contractor, Vendor or supplier and Sub- Contractor c

Enprotec Construction Manager ( Main Area Contractor) Client Area Construction Manager Contractor, Vendor or supplier and Sub- Contractor

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Enprotec Construction Manager ( Main Area Contractor) Client Area Construction Manager C & I Vendor assistance during this phase

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Enprotec Commissioning Manager ( Main Area Contractor) Goedehoop Colliery Commissioning Manager Enprotec Commissioning Manager ( Main Area Contractor)

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Goedehoop Colliery Commissioning Manager Enprotec Commissioning Manager ( Main Area Contractor) c'

Enprotec Projects Manager ( Main Area Contractor) Anlgo Senior Project Manager Enprotec Commissioning Manager ( Main Area Contractor)

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Enprotec Projects Manager ( Main Area Contractor) Anlgo Senior Project Manager

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Anlgo Senior Project Manager Anlgo General Manager Anglo Board Representative

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ë p r * 1 Sequence for punching list sign off͛s Õp Õp Õp Õp Õp

Sub-Contractor punch list to be completed, then A request from the Enprotec Construction Manager/Supervisor to generate their punch list, Enprotec punch list to be generated and the punch list items to be worked off, A request for the client͛s representative to generate their punch list, The client͛s representative to generate punch items, which in turn the items are to be worked off.

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At each stage of the commissioning phase a detailed and thorough inspection is performed by the relevant parties. This is aimed at identifying any deviations from design or short comings in the construction or performance of the plant or equipment prior to signing of the Final Acceptance Certificate

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This refers to the degree of seriousness of the said deviation or punch list items ,the definition of such is noted below:

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This deviation may affect health and/or safety of the plant personnel. The deviation must therefore be rectified before signing of the Acceptance Certificate and proceeding to the next commissioning phase

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Deviations can be rectified during the next stage of commissioning. However, an interim authorization may be given by the Responsible Engineer to allow the next stage of commissioning to proceed.

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These are deviations that can be rectified while the plant is running, but must be rectified before the Final Handover Acceptance Certificate sign off

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Commonly revered to as "Wish list items", which fall outside the Contractual Scope Of Work. These are detailed on a separate form Referred to as a Request for Site Modification. These forms are generated by the plant but are subject to approval and authorization by the Construction Manager & Engineering Manager.

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p c c r The Commissioning structure consists of the following key personnel:

@ pc The commissioning Manager of each area Underground/Surface is responsible for managing both the dry and the ore commissioning of plant. His responsibilities shall include the following activities: Õp Commissioning strategy. Õp Commissioning procedure. Õp Initiation of audits and monitoring activities to ensure compliance to the commissioning procedures and safety standards. Õp Commissioning structure and functions. Õp Identification and appointment of personnel on the commissioning structure. Õp Identification of infrastructure requirements and ensuring availability ahead of commissioning. Õp Development of the commissioning program and monitoring of progress with the assistance of the Project Planning Co-ordinator. Õp Ensuring that the required operational parameters are identified and met before the plant is handed over to the Plant. Õp Manage and control the commissioning and hand over to the Plant. Õp Ensure compliance with laid down procedures. Õp Ensuring all documents, drawings and ͞as-build͟ drawings are available for Final Handover to the Plant at the C5 Commissioning stage.

The commissioning package for each Commissioning Manager will typically contain the following: Õp P & ID highlighted to show equipment forming the particular module or piece of equipment to be commissioned. Õp An equipment summary extracted from the P & ID indicating all equipment by discipline. Õp Commissioning Hand over certificates C1 to C5. Õp Commissioning schedule and plan for the respective area. Õp Applicable check lists from the contractor submitted for approval. Õp Equipment data sheets. Õp Applicable commissioning, operating and maintenance procedures and manuals. Page 3 of Revision Enprotec 01 Approved By: Date: Commissioning 10/01/2011 Procedure

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Õp Lubrication schedules and any vendor instructions. Õp Operational parameters and system data for process equipment.

R p Õp Other key members of the Commissioning Team shall be selected from mining personnel or representatives as required. Õp The relevant Discipline Engineers shall assist the Commissioning Managers in compiling procedures and check lists. These will be handed over to the Documentation controller for filling and issuing as required. Õp All Commissioning planning will be co-ordinated by the project planning coordinator.

£ p The project has included where necessary, maintenance and training requirements in the relevant contract document. These requirements have been identified in conjunction with Goedehoop and the Contractor/Supplier. In the event of additional commissioning requirements this shall be arranged directly by the Commissioning Manager in conjunction with the Contractor/Supplier taking cognizance of the time and cost involved for the supplier to present themselves on site. The logistic support work typically involves liaising with Contractors to identify specifics such as; the maintenance frequency for specific equipment, recommended and strategic spares requirements, tools, personnel training, potential maintenance contracts and al related documentation. On completion of commissioning a Flotation technician from Enprotec will be on site for six months thereafter. This will ensure adequate training to the relevant plant operators.

º p c c The responsibilities for the various stages of commissioning and handover shall be as follows: c From the Contractor and/or supplier to the construction Engineer, technical punch list completed5 c c #6 7 c From the Contractor and/or supplier to the Construction Engineer, no Process involvement, technical punch list completed and Contractor and/or Supplier5 c c #6 7 Page 4 of Enprotec Commissioning Procedure

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c From the construction Engineer and Plant Engineering staff to Process Operational staff and process punch list completed. * c c %& 6$& 7 $!$ 7 c Operational staff introducing limited process material and checking process functionality and safety5( c c' Operational staff introducing plant/equipment functionality for throughput, volumes and flow rates as specified in compliance with the test on completion contractually. The Construction Electrical, Mechanical and C & I Engineers shall be responsible for their specific discipline throughout all the various stages of commissioning in conjunction with the Plant Process and Engineering staff on a modular basis.

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This means Punch Listings of discrete parts of equipment of systems By Contractors and/or suppliers before handing over to the Plant/Process Engineers. The Commissioning manager will sign off this stage of commissioning when following have been achieved: Punch Listings by Contractor and Project Construction Team. Rectification of punch list by Contractor. Cleaning of the area intended for handover. Completion of test sheet as for Megger, alignment and pressure test.(Power off) The equipment shall have all hardwired interlocks and protective systems checked and tested by the Contractor or Supplier. Õp Loss control and applicable security checks completed. Õp The Contractor and/or Supplier shall complete the C1 Acceptance Form provided by the Construction Engineer (copies also in contract document). This form shall be the Acceptance Certificate and shall reflect outstanding punch list items. Õp The Construction Engineer shall accept and sign off the certificate once he has satisfied himself that all the items on the punch list can be carried forward to run

Õp Õp Õp Õp Õp


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testing without endangering life of the safety of the works. He shall clear any uncertainties with the Construction Manager if in doubt. Õp C1 ʹ Commissioning shall be considered complete when all the above including the entire Category A punch list items have been addressed and all the documentation has been handed over to the Documentation Controller. Õp C1 Document Package consists of; op Acceptance Certificate. op Contractors punch list. op Construction Team punch list. op Note pertaining to acceptable punch list items that may be carried to the next stage of commissioning. op After all safety checks have been completed. op All certifications must be identified by Commissioning Manager. The C1 Commissioning Acceptance Certificate must be signed of before proceeding to the next stage of commissioning.

º R pcRc rc c c c Individual system/s check (interlocks) to take place. This involves running the equipment or module dry to test or perform relevant checks on the equipment or system, all equipment such as motor etc. are run for short periods under the supervision of the Commissioning Manager, Contractor and/or Supplier in accordance with the running test and procedures provided by the Commissioning Manager, Contractor and/or Supplier. All witnessing certificates such as Megger test, loop checks, pressure test, rotational speed test etc. The following shall be done during these tests: Õp The equipment or module PLC sequence interlocks shall be checked. Õp The checking, calibration and rectification of all instrumentation such as level, flow, pressure, density, and power meter shall be done. Õp The leaks, splashing and any other adverse operating features shall be eliminated. Õp Unacceptable structural vibrations shall be identified and eliminated. Õp Warranty repairs shall be identified and the installation Contractor and/or Supplier will provide a programme for rectification.


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The Plant/Process Engineer shall be present during these test to familiarise himself with equipment. C2 Commissioning Acceptance certificate must be signed of before proceeding to the next stage of commissioning.

º i pci c c c c All individual interlocks are completed and the control room to then take ownership of the completed interlocks system for sequential testing. It is essential that all the construction activities, in the applicable area, are complete at this stage. All equipment that forms a module or stream shall be run together to allow balancing and to check all the interlocks and process control. Material shall only commence once a discreet piece of equipment or system is ready to run sequentially. The purpose of wet commissioning is limited running of discreet piece of equipment or system with water to essentially check pump ,pipes, shuts, cells, pumps, etc, confirm instrument calibrations and confirm sequences and interlocks. The Commissioning Manager must ensure that all outstanding C1 and C2 punch list items are complete or progressing as planned before handing over. At this stage, no ͞modification requests͟ shall be accepted until proven during the next phase of commissioning i.e. if a pump does not perform as expected during this phase, for example, it is essential to establish that the pump will not behave entirely differently under normal operating conditions. It is essential that the Plant/Process Engineer and plant Operation Team be involved at this stage of commissioning in order to facilitate a seamless progression to the next stage of commissioning. The C3 Commissioning Acceptance Certificate must be signed of before proceeding to the next stage of commissioning. At this stage prior to the start of C4 commissioning; the plant or sections of the works must be handed over and accepted by the Plant Operations team from the commissioning team. All Page of Enprotec Commissioning Procedure

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safety, plant operations and maintenance of the works is the responsibility of the plant operations.

º ½ pc½c c c The Production Process Engineer shall take over full operational, safety and maintenance responsibility for the water/ore commissioning on the discreet piece of equipment or system. The purpose of this stage of commissioning is to introduce material to the equipment or system, starting at low rates and building up progressively until rated capacities are achieved. The Commissioning Ma anger and his team will be available to assist the Production Process Engineer during this phase. The two Managers, Engineers and their respective teams will work together until the discreet piece of equipment or system is running with material at the rated capacity. Once the equipment or system is fully commissioned with material, the Senior Process Metallurgist/Plant Process Engineers shall commence with the optimisation of each relevant piece of equipment. The equipment and/or system shall be manned and run for at least eight hours during the optimisation process. This optimisation process is to optimise the process in line with the plant design parameters only. The C4 Commissioning Acceptance Certificate must be signed off before proceeding to the next and final stage of the commissioning stage.

º ë pcëc Production build-up and optimisation follows material commissioning. A comprehensive list of all process equipment requiring optimisation shall be made available together with the expected performance criteria. The Contractors and/or Suppliers where deemed necessary may be asked to be available during optimisation of their equipment to assist the team and ensure that process/performance guarantees are met. This would also provide an opportunity to reinforce training of operators and artisans. Once the process/performance guarantees and the operational efficiencies are met by a specific piece of equipment, a C5 Commissioning Acceptance Certificate will be filled in and signed by the Construction Engineer who shall then arrange for the Plant representative to observe the process and accept on behalf of the plant Page of Revision Enprotec 01 Approved By: Date: Commissioning 10/01/2011 Procedure

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Once all the C5 Certificates have been signed off, the equipment or system shall be run at full production as per the requirements of test on completion before official hand over to the Plant. The Construction Manager shall submit the Final Hand over Certificate to the relevant Plant representative.

º p + c $& such as fire detection/prevention, fire hydrants, portable fire extinguishers, fire escape routes and general loss control shall be commissioned by a nominated Loss Control representative and audited by the Plant Loss Control Manager. The relevant Construction Engineer shall provide all the required certification and back-up documentation. The Electrical Engineer shall commission the 7 $& before acceptance. The commissioning engineers shall accept the system.

[ p c The Request for Site Modifications, Procedure PPP-RSM shall apply to all modifications. These are generated by the Construction Team and/or Plant personnel and reviewed and approved/rejected by the Construction Manager. The cost implication for such a modification determined prior to completing such a request.

@ p Ô After the final handover to the Plant, the following activities may remain to be completed and are the responsibility of the Project and Construction Engineers. Õp Updating of operating manuals, flow sheets and P & Ids to reflect any modifications, which have been made during commissioning. Õp The completion and forwarding to production of as-build drawings resulting from modifications during commissioning. Õp Compilation of a post completion audit and report.

@@ p c All personnel to undergo commissioning induction understand the lockout procedure and adhere to the lockout procedure Stickers on hard hats and different ID cards are to be utilized to identify the commissioning team. Page of Enprotec Commissioning Procedure

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@R p c c C1 Level ʹ Commissioning Acceptance Certificate............................................................ENP -C1 C2 Level ʹ Commissioning Acceptance Certificate............................................................ENP -C2 C3 Level ʹ Commissioning Acceptance Certificate............................................................ENP -C3 C4 Level ʹ Commissioning Acceptance Certificate............................................................ENP -C4 C5 Level ʹ Commissioning Acceptance Certificate............................................................ENP -C5 Final Hand-Over Certificate..................................... ....................................................... ...ENP-FHC Project Hand-Over to Owner Certificate...........................................................................ENP -POC Commissioning Punch List............................................. ....................................................ENP -PL Request for Site Modifications..........................................................................................ENP -RSM

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c@c cccc Ô c Form No. ENP C1

REF DATE: 13/01/2011

REV. NO.:00

CONTRACTOR/SUPPLIER CONTRACT NUMBER DESCRIPTION OF EQUIPMENT PUNCH LIST NUMBER

This is to certify that the Equipment/System as described below has been tested and punch list to the satisfaction of the Construction Engineer. Upon signing this certificate the Construction Engineer undertakes to carry out the next stage of the commissioning process namely C2 level ͞Dry͟ Commissioning. It is the responsibility of the Contractor/Supplier to address the attached Punch List as per the programme agreed with The Construction Manager.

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SUB- CONTRACTOR/SUPPLIER ENPROTEC CONSTRUCTION MNGR CLIENT AREA MANAGER

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cRc cccc Ô c Form No. ENP C2

REF DATE: 13/01/2011

REV. NO.:00


This is to certify that the Equipment/System as describe below has been ͞Dry͟ Commissioned to the satisfaction of the Construction Engineer. Upon signing this Certificate the Commissioning Engineer undertakes to carry out the next stage of the commissioning process, namely C3 level ͞Wet͟ Commissioning. It is the responsibility of the Contractor/Supplier to address the attached Punch List as per the programme agreed with the Construction Manager

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SUB- CONTRACTOR/SUPPLIER ENPROTEC CONSTRUCTION MNGR CLIENT AREA MANAGER


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cic cccc Ô c Form No. ENP C3

REF DATE: 13/01/2011

REV. NO.:00


This is to certify that the Equipment/System as described below has been successfully ͞Wet͟ Commissioned tested and that all outstanding C1 and C2 Punch List items are completed or progressing as planned. Upon signing this certificate the Commissioning Process Engineer undertakes to carry out the next stage of the commissioning process, namely C4 level ͞Material͟ Commissioning.

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Enprotec Commissioning Mgr Client Commissioning Mgr


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c½c cccc Ô c Form No. ENP C4

REF DATE: 13/01/2011

REV. NO.:00


This is to certify that the Equipment/System as described below has been successfully commissioned with MATERIAL and the rated capacities of the Equipment/System were achieved. Upon signing this certificate the Maintenance and Commissioning Process Engineers undertake the responsibility to out the next stage of the commissioning process, namely C5 level, Production Buildup, Maintenance, Operation and Optimisation. It is the responsibility of the Contractor/Supplier to address the attached Punch List items as per the programme agreed with the Commissioning Process Engineer & Construction Manager.

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cëc cccc Ô c Form No. ENP C5

REF DATE: 13/01/2011

REV. NO.:00


This is to certify that the Equipment/System as described below has been successfully commissioned with Material at the rated production capacities of the said Equipment/System. It is the responsibility of the Commissioning Process Engineer/Construction Manager to address the outstanding Punch List items as per attached programme prior to handover. Upon signing this certificate the Maintenance and Commission Process Engineers undertakes the responsibility to carry out the next stage of the commissioning process, namely FINAL HANDOVER TO THE PLANT.

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Enprotec Commissioning Mgr Enprotec Project Mgr Client Senior Project Mgr


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Ô c Form No. ENP- FHC

REF DATE: 13/01/2011

REV. NO.:00


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c Form No. ENP-POC

REF DATE: 13/01/2011

REV. NO.:00


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Anglo Snr Project Mgr Anglo General Mgr Anglo Board Representative


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Commissioning Punch List Form No. ENP-PL

REV Date: 13/01/2010

Punch List No:

REV No.:00

Date:

Sheet__________of__________

Location/Plant:

Contract Number:

Equipment Number:

Contractor/Supplier:

Description of Equipment: Drawing Number:

Item No.

Commissioning Level: (C1 to C5)

Description of Defect

Defect

Type

Due Date

Actual Date

Responsibility

Legend DEFECT: TYPE:

Discipline

D= Design S = Safety Required Required A = Equipment/System is not handed over or approved for "Dry" commissioning C = Equipment/System is handed over subject to the attached punch list programme Name

Signature

Date

Discipline

Originator

Originator

Clerk of Works

Clerk of Works

Enprotec Commissioning Mgr

Enprotec Commissioning Mgr

M = Modification O =Outstanding Required Item B = "Dry" commissioning is authorized

Name

Signature

Date


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Form No. ENP-RSM

REV Date: 13/01/2011

Modification No: Location/Plant: Plant or Plant Section: Orginator:

REV NO:00 Date:

Signature:

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Decision and Actions Taken __________________________________________________________________________________ __________________________________________________________________________________ Page of Enprotec Commissioning Procedure

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Commissioning Procedure Goedehoop

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