Waste Water Disposal Project
Student Name: Paul Seiler
Student ID: 030411347
ChallengerTAFE
Waste Water Disposal Plant Project
TABLE OF CONTENTS
1
Executive Summary............................................................................................ 1
2
Project Execution Plan ....................................................................................... 2
3
Scope ................................................................................................................. 4
3.1
Design Capacity ...................................................................................... 4
3.2
Mechanical .............................................................................................. 4
3.3
Electrical ................................................................................................. 4
3.4
Scada Control ......................................................................................... 4
3.5
What is not in scope ................................................................................ 4
4
Project Organisation ........................................................................................... 5
5
Engineering and Safety Codes/Standards .......................................................... 6
6
ISO 9002 Quality Systems Design and Design Safety ........................................ 7
7
Estimate ............................................................................................................. 9
8
Specifications and Procurement ....................................................................... 10
9
Fabrication, Manufacture Installation, Construction .......................................... 11
10
11
9.1
Fabrication Program.............................................................................. 11
9.2
Bolted Connections ............................................................................... 11
9.3
Tolerances and Workshop Assembly .................................................... 11
Testing and Commissioning .......................................................................... 13
10.1
Test Results .......................................................................................... 14
10.2
Fabrication Program.............................................................................. 14
Project Safety ............................................................................................... 15
Appendices ............................................................................................................. 16
© Challenger Institute of Technology
Rev 1 – Submitted June 2015
ChallengerTAFE
Waste Water Disposal Plant Project
1
Executive Summary
The aim of the Waste Water Disposal Plant project are four-fold.
1. Establish and follow a competency development plan in an electro technology
engineering discipline.
This includes developing requirements to be incorporated into the writing of
specifications for electrical engineering projects. It encompasses determining
the safety requirements to be met, establishing client expectations, ensuring
cost effective solutions are pursued and documenting design and technical
requirements.
2. Estimate electrotechnology projects.
This covers estimate material and labour costs for competitive
quotation/tenders for work exceeding $20k. It encompasses reading and
understanding job specifications, material take-offs, determining labour and
site requirements, costing and documenting
3. Implement and monitor energy sector OHS policies and procedures.
The mandatory requirements of a person in supervisory roles are to
implement and monitor an organisation’s occupational health and safety
policies, procedures and programs. It encompasses understanding an
organisation’s OHS obligations, providing safety information to staff,
implementing and monitoring participative arrangements, safety procedures
and training and maintaining safety records.
4. Facilitate continuous improvement.
The performance outcomes, skills and knowledge required to lead and
manage continuous improvement systems and processes are detailed.
Particular emphasis is on the development of systems and the analysis of
information to monitor and adjust performance strategies, and to manage
opportunities for further improvements.
The project outcomes included successful implementation of tasks by all members
which resulted in overall deadline accomplishments. Also, the variation of task
integration between team member was deemed satisfactory by the project leaders
and faculty staff.
Key learnings by the author of this document, who was positioned initially within the
engineering section of the group are detailed. He was chosen as one of two team
leaders for the engineering section with deliverables that included maintaining a
drawing register and fielding member queries.
© Challenger Institute of Technology
Rev 0 – Issued February 2015
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Waste Water Disposal Plant Project
2
Project Execution Plan
Each section needs to be summarized
Project Brief
'Wastewater' flows in to the primary inflow distribution tank (First tank)
At any given time one of the 2 primary treatment tanks is filling and the other is
emptying.
From the primary treatment tanks the water will flow into one of the batch reactor
tanks, these tanks have 4 possible states and will proceed through them in
sequence.
Filling
The tank is being filled from one of the primary treatment tanks
Aerating
The tank is being aerated by process air through the aeration system on the bottom
of the tank
Settling
The tank is left alone and any particulates are allowed to settle out
Emptying
The tank is discharging into the outflow
As there are 4 tanks at any given time 1 will be in each of the 4 states allowing for
continuous operation of the plant. Inflow will be from an external reservoir (one of the
existing fluids lab tanks has been reserved) and outflow will be into the same tank.
© Challenger Institute of Technology
Rev 0 – Issued February 2015
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Waste Water Disposal Plant Project
•
Project Timeline
•
Project Budget
$20,000
•
Project Organisation
PM
Eng/Design
Co-ordinator
Estimation
Scheduling
Doc Control
Procurement
Construction
Commissioning
TM 1
TM3
TM1
TM3
TM1
TM3
TM1
TM3
TM2
TM4
TM2
TM4
TM2
TM4
TM2
TM4
TM5
TM6
TM5
TM6
TM5
TM6
TM5
TM6
•
Project Safety
© Challenger Institute of Technology
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Waste Water Disposal Plant Project
3
Scope
3.1
Design Capacity
3.2
–
–
–
–
–
–
–
–
–
–
Key Documents
Project Document
Progress Status Update - Communications
Project Schedule
Estimate Spreadsheet
Activity Hours Spreadsheet
Deliverable List Status
Lessons Learnt Spreadsheet
Document Control Setup and management
Document Standards and Revision Status
–
Quality
Mechanical
–
–
–
–
3.3
Electrical
–
–
–
–
–
3.4
Power Load
Power Consumption
Instrument Settings
VSD/DOL Settings
Design Safety
Scada Control
–
3.5
Flow, Pressure and Volume
Pump Size
Piping Size
Design Safety
Design Safety
What is not in scope
Warranty
© Challenger Institute of Technology
Rev 0 – Issued February 2015
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Waste Water Disposal Plant Project
4
Project Organisation
•
•
Student is to develop a project org chart explaining all the functions of
project management, engineering, procurement, estimating and
construction.
The student need to highlight which roles they were involved with and
what was the major activity they did in each role.
© Challenger Institute of Technology
Rev 0 – Issued February 2015
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Waste Water Disposal Plant Project
5
Engineering and Safety Codes/Standards
Codes and Standards referred to in this guideline are as follows:
Australian Standards = AS
Australian Standard of Structural AS/NZS 5131.
AS 1163 Structural Steel Hollow Sections
AS 1171 Methods for Magnetic Particle Testing of FerroMagnetic Products and Components
AS 1250 Use of Steel in Structures
AS 1252 High Strength Steel Bolts with Associated Nuts
and Washers for Structural Engineering
AS 1397 Steel Sheet and Strip - Hot Dipped Zinc Coated or
Aluminium/Zinc-Coated
AS 1538 Cold-Formed Steel Structures Code
AS 1553 Covered Electrodes for Welding
AS 3678 Structural Steel - Hot rolled plates, Floorplates and
Slabs
AS 3679 Structural Steel (Hot rolled bars and sections and
welded sections)
AS 3990 Mechanical Equipment - Steelwork
AS 4100 Steel Structures
© Challenger Institute of Technology
Rev 0 – Issued February 2015
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Waste Water Disposal Plant Project
6
ISO 9002 Quality Systems Design and Design Safety
Design
The student was technical lead in the coordination and implementation of the
design drawing registry for this project in the Engineering stream. It consisted of a
hard copy library of all drawings for reference by the team as well as electronic lists
of all team member producing drawings. Please refer to the Appendix for the final
table of drawings. This also encompassed behaviour management of stakeholders
as it was crucial to keep documents up to date and readily accessible under tight
deadlines taking into account the loss of five classes due to various holidays.
The key learning outcomes from the design registry maintenance included
constraints from multiple tasks that stakeholders were responsible for and assisting
them with their own time management. In the project we determined areas where
some stakeholders would be better used elsewhere in the project and tasks were
juggled according to timeline. This offered a substantial insight into project
management and how efficiency and alternative pathways are essential to meeting
goals.
The student also took on the role for completing four designs to keep the target
deadlines viable. This gave members the ability to put out fires in other areas of the
project as they arose and kept the progress flow in a forward direction.
•
•
•
•
PL-WTP-001 Plant Layout
S-WTP-002 Process Layout
E-WTP-004 SB PANEL - DB-001 Internal
SC-WTP-001 Electrical Network Map
.
© Challenger Institute of Technology
Rev 0 – Issued February 2015
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Waste Water Disposal Plant Project
.
© Challenger Institute of Technology
Rev 0 – Issued February 2015
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Waste Water Disposal Plant Project
7
No
Estimate
WBS Level
WBS Level 0
Directs
1 Structural
2 Mechanical
3 Electrical
Indirects
4 Overheads (7%)
5 Contingency (10%)
Total
$
Materials
Subtotals
$
$
$
Labour
Subtotals
4,358.80 $
5,970.42 $
4,619.00 $
Plant
Subtotals
500.00 $
800.00 $
1,000.00 $
Subtotals
Subtotals
$
$
200.00 $
4,858.80
6,770.42
5,819.00
$
$
4,073.30
407.33
Subtotals
Subtotals
Subtotals
Total
21,928.85 $
14,948.22 $
2,300.00 $
200.00 $
© Challenger Institute of Technology
Rev 0 – Issued February 2015
21,928.85 .
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Waste Water Disposal Plant Project
8
Specifications and Procurement
•
The author was tasked with providing management of the design drawing
register for this project.
•
Key learning was the lesson of organisation of a well-planned process is
vital for outcomes to be assessed.
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Waste Water Disposal Plant Project
9
Fabrication, Manufacture Installation, Construction
9.1
Fabrication Program
A detailed fabrication program shall be submitted to the
Owner's Representative before fabrication commences.
This program shall be upgraded during fabrication and shall
be made available to the Owner's Representative upon
request.
9.2
Bolted Connections
9.2.1 Bolts
Bolts for connections shall be grade 8.8 (high strength) or 4.6
(commercial grade).
Torqued bearing type bolted joints complying with AS 4100
and denoted as 8.8/TB shall be used for all connections,
unless noted otherwise on the drawings.
Torqued friction joints complying with AS 4100 and denoted
as 8.8/TF shall be used in joints as specified on the drawings
where bolt slip is to be avoided.
If the bolt size is not shown on the drawings, it shall be taken
to be M20. Each bolted connection shall contain at least two
bolts, unless shown otherwise on the drawings.
Bolt holes shall be 2 mm larger in diameter than the nominal
bolt diameter unless noted otherwise on the drawings. Holes
for bolts shall be drilled or punched (for plates less than
10 mm thick). These holes shall not be flame cut.
9.3
Tolerances and Workshop Assembly
9.3.1 Tolerances
The Contractor shall provide all necessary personnel,
equipment and instruments necessary to fabricate the
steelwork to the design dimensions and tolerances. All
instruments used shall have the current valid calibration
certificates. The tolerance limits for fabrication shall be those
specified by AS 4100.
© Challenger Institute of Technology
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Waste Water Disposal Plant Project
Monitoring of dimensions shall be carried out during
fabrication of individual members, and before fit up of
sections and sub-assemblies for conformance with the
dimensions and tolerances.
Out of tolerance fabricated steel items shall be rectified at
the Contractor's cost.
Where conflict between the drawings and the specifications
occur, the most stringent requirements shall apply and the
Contractor shall notify the Owner's Representative of the
conflict.
Where no appropriate tolerance is stated, then these
tolerances shall be obtained from the Owner's
Representative prior to fabrication continuing.
9.3.2 Workshop Assembly
Fabrication shall be carried out on a flat and level surface.
During workshop assembly the drifting of misaligned bolt
holes shall not be permitted.
Critical field splices and joints shall be mated in the shop on
completion of fabrication to ensure satisfactory fit when
installed.
9.3.3 Surface Treatment and Paint Finish
•
All structural steelwork shall be surface treated and painted in accordance
with SE11 and the type of surface protection shall comply with as shown
on the design drawings..
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Waste Water Disposal Plant Project
10
Testing and Commissioning
All inspection and testing required by this specification and
the relevant Australian Standards shall be performed.
An Inspection and Test Plan (ITP) shall be submitted for
approval at least two weeks before the start of fabrication.
The ITP shall describe the inspections, tests and verifications
for the works required, identify the mandatory hold and
witness points and describe the sequence of work activities.
Inspection and testing shall comply with ISO 9002.
The minimum acceptance requirements in the ITP shall be:
•
100% visual check on materials and copies of certificates
(if applicable).
•
100% check on dimensions.
•
100% visual check on all welds.
•
100% visual check on surface treatment.
•
Signed off inspection check for each item by Contractor's
inspector. (This shall be made available to the Owner's
Representative).
•
NDT as required by this specification.
•
Completion report within two weeks of completion of
work.
Any subsequent amendments to the ITP shall be submitted
for review and approval prior to being implemented. The ITP
shall include all of the non-destructive weld testing required,
as shown on the drawings or in the detailed specification.
The ITP shall be adhered to. All ITP inspection activities
shall be performed by appropriately qualified personnel
acceptable to the Owner's Representative. The name of the
person who has the responsibility of upholding the ITP shall
be submitted to the Owner's Representative.
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Waste Water Disposal Plant Project
10.1
Test Results
A copy of the test results shall be provided to the Owner's
Representative as specified in Section 17, . Copies of these
test results, plus any relevant documentation shall be
retained by the Contractor until the defects liability period has
expired. The Contractor shall permit examination of such
results by the Owner's Representative.
10.2
Fabrication Program
The fabrication program shall include allowance for
inspection and testing, including that by the Owner's
Representative.
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Waste Water Disposal Plant Project
11
Project Safety
•
Safety was documented through a JSA (Job Safety Audit) procedure.
A register was kept on file..
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Waste Water Disposal Plant Project
Appendices
Drawing Register
Process Engineering
Drawing Number:
Drawing Title:
Drawn By:
Revision
EL-WTP-001
PFD-WTP-001
PL-WTP-001
PID-WTP-001
PID-WTP-002
Symbol List
Process Flow Diagram
Plant Layout
P&ID
P&ID
E.WATSON
David
Paul
Milan
Milan
A
A
A
S-WTP-001
S-WTP-002
Structural Layout
Process Layout
Jason Webb
Paul S
A
A
Piping Iso - SHT 1
Piping Iso - SHT 2
AIR SUPPLY DRAWING
Instrument Air
E.WATSON
E.WATSON
FRED
David
A
A
A
A
Electrical Layout
SLD
SB PANEL - DB-001 External
SB PANEL - DB-001 Internal
SB PANEL - DB-002 External
SB PANEL - DB-001 Internal
JB-001 (Typical)
Electrical Network Map
JB1 Schematic
JB2 Schematic
JB3 Schematic
DB-001 Schematic SHT1
DB-002 Schematic SHT1
DB-002 Schematic SHT2
CONTROL CIRCUIT
Paul
Ellise
Jack
Paul
A
A
A
A
A
A
A
A
A
A
A
Structural Engineering
Mechanical Engineering
PI-WTP-001
PI-WTP-002
PI-WTP-003
PI-WTP-004
Electrical Engineering
E-WTP-001
E-WTP-002
E-WTP-003
E-WTP-004
E-WTP-005
E-WTP-006
E-WTP-007
SC-WTP-001
SC-WTP-002
SC-WTP-003
SC-WTP-004
SC-WTP-005
SC-WTP-006
SC-WTP-007
CC-WTP-001
© Challenger Institute of Technology
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Quon Tan
Paul
Fabiana
Fabiana
Fabiana
Fabiana
Jack
A
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