ASSAREL-MEDET JSC Town of PANAGYURISHTE

ASSAREL-MEDET JSC Town of PANAGYURISHTE

Document Index:ATTACHMENTNo. 4

РИ-ИСУ08.02.00.00.00/3-1

ASSAREL-MEDET JSC – town of PANAGYURISHTE

Registration NumberЗ-67/ 19.04.2017

APPROVED BY,

Executive Director:

Date:

TERMS OF REFERENCE

REGARDING: DevelopmentofaworkdesigntobuildawatertreatmentplantforthewatersfromLyulakovitsatailingsdamclosetothecontactwaterpondofatreatmentcapacityof 400 m3/hour.

І. Currentstate:

Assarel-MedetJSCMiningandProcessingComplexislocatedintheSashtinskaSrednaGoramountainat 11 kmnorthwestfromthetownofPanagyurishteand 90 kmtotheeastfromthecapital, Sofia(42.547516 degrees north latitude and 24.136276 degrees east longitude). It covers an area of 20, 000 dka under the conditions of a mountainous cross hilly relief. Theaveragealtitudeisabout 1,000 masthe lowest one is 600 meters and the highest is 1,500 meters. (accordingtotheBalticaltitudesystem).

Amajorunitofthecompany’stechnologicalprocessflowis Lyulyakovitsa tailings dam. The latter is a depot of the final tailing from the Assarel Concentrator Plant. The facility has a main dam wall and a buttressed wall. The tailings dam stability is of a crucial significance.

Underforcemajeurecircumstancessuchastorrentialrainswhichcontinueforalongtime, the capacity of the free waters in the tailings dam pond increases several times and it is necessary that part of the waters be treated and discharged in the river system.

Threetechnologicalconceptualdesignshavebeenprepared – evaporativefacility, aclassicaltechnologyofneutralizationofupto рН10,5 and consequent рН adjustment and a technology which involves oxidation of metal ions and neutralization to рН8. An option has been selected for the respective location.

ІІ. Requirements for the objective, contents and the peculiarities of the service

2.1. Objectiveandtasks

AworkdesignofatreatmentplantforthewastewatersfromLyulyakovitsatailingsdamshallbepreparedwhichensuresthatthewatersarefitfordischarginginto the Lyulykovitsa river with the needed auxiliary processes and facilities.

2.2. Contents and peculiarities of the tasks

The technical solutions need to be flexible and allow operation under various conditions.

Table1.Patameters of the treated water

No. / Index description / Unit / From / To
Treated water flow / m3/hour / 50 / 400
1 / Suspended substances / mg/dm3 / 98 / 24
2 / Dry residue / mg/dm3 / Н.а / 3187
3 / Active рН reaction / pH един. / 4 / >8.8
4 / Sulphates SO42- / mg/dm3 / 3.850 / 1930
5 / Magnesium Mg2+ / mg/dm3 / 35 / 20
6 / Calcium Ca2+ / mg/dm3 / 780 / 820
7 / Sodium Na+ / mg/dm3 / 30 / 65
8 / Potassium K+ / mg/dm3 / Н.а. / 40
9 / Copper Cu++ / mg/dm3 / 45 / 0,006
10 / Manganese Mn++ / mg/dm3 / 23,8 / 0,007
11 / Lead Pb++ / mg/dm3 / <0,01 / <0,01
12 / Aluminum Аl+++ / mg/dm3 / 131 l / 0,18
13 / Iron Fe+++ / mg/dm3 / 98,5 / < 0,03
14 / Zink Zn++ / mg/dm3 / < 0,03 / < 0,05
15 / Silicon Si++++ / mg/dm3 / 1,44 / < 1

Note: ThelimitparametersvalueshavetocorrespondtothewaterpH. .

Table 2.Individual emission limits. Indices of discharged waters

Index / Individual emission limits
рН / 6 – 8.5
Chemically consumed oxygen / 70 mg/dm3
Insoluble substances / 50 mg/dm3
Petroleum products / 0.3 mg/dm3
Cyanides (total) / 0,5 mg/dm3
Cyanides (free) / 0,05 mg/dm3
Arsenic / 0,05 mg/dm3
Cadmium / 0,01 mg/dm3
Copper / 0,1 mg/dm3
Chrome (six valence) / 0,05 mg/dm3
Mercury / 0,001 mg/dm3
Lead / 0,05 mg/dm3
Nickel / 0,2 mg/dm3
Zink / 5,0 mg/dm3
Iron / 1,5 mg/dm3
Uranium / 0,6 mg/dm3
Radium / 150 mBq/ dm3
Manganese / 0.3 mg/dm3

1.The following auxiliary subsites shall be developed:

1.1.Induction pipeline or concrete channel. If the option of a channel is selected, no mixing with surface rain waters shall be allowed.

1.2.Sandlock, ifneeded.

2.ThetreatedwatersshallmeettheindividualemissionlimitsdeterminedinaComplexPermitNo. КР 404-НО/2010 г.

3.AworkdesignshallbepreparedfordischargingthetreatedwaterintotheLyulyakovitsariver.

4.The detailed requirements for the technical equipment shall be specified at working meetings arranged for this purpose.

5.To Part Technology:

-AnoptimaltreatmenttechnologyshallbeselectedwhichistobeofaminimalcostpriceofthetreatedwaterandtocomplywiththerequirementsstipulatedbyBulgarianstandardsandthelatestachievementsofscientificandtechnicalprogressinthisarea.

-Thetechnologicaltreatmentcircuitsshallcomplywiththebestavailabletechnologiesandtoenvisionuniformfacilitiesofthesametechnologicallevelworkinginparallelwhoseoperationcouldbediscontinuedforacertainperiodoftimeandbypassconnectionswhichallowsdiscontinuingtheoperationoftheindividualfacilities, technologicallevelsandtheentiretreatmentplant.

-A possibility shall be envisioned for partial or full discontinuing of the operation of the Waste Water Treatment Plant with a bypass for the purposes of inspections, cleaning, ongoing or overall repairs.

-Method and way of residue and water treatment. Thetechnologicalcircuitstotreattheresiduesshallcomplywiththeselectedtechnologyfortheirremovalfromthetreatmentplantandtheirutilization. Thetreatmentplantresiduesshallbecollected, transported, storedand/ordisposedmeetingtherequirementsoftheapplicablewastemanagementstandards.

-The treatment plant shall be sized for uniform operation for 24 hours per day.

-Apotentialforaperiodicorseasonaloperationshallbeenvisionedastherespectivemeasuresforpreservingtheequipmentoperationcapacityshallbetakenintoconsideration.

-Allunitsshallbeconsideredtohaveasufficientcapacitywhichallowsthatthefulltreatmenteffectbeachievedifanyunitisstopped.

-The used reagents shall be available and delivered by more than one supplier.

-An option for adding a desulfatization module into the system shall be envisioned as the latter shall undergo minimal technical modifications in the circuit.

-The suggested technological solutions shall be reviewed at an intermediary stage by the Client.

6.Thematerialsforthetechnicalfacilitiesofthetreatmentplantshallberesistantagainstcorrosionfor the substances which are contained in waste waters and residues.

7.Facilitiesanddevicestomeasurethewastewaterquantitiesandtherecirculationtechnologicalflowsshallbeenvisionedto be placed in appropriate locations. Facilitiesanddevicestomeasurethemainqualityindicesofthetreatedwatersandresidueflowsshallalsobeenvisionedascomponentsof the operative control and technological process management. Devices to measure the flowing water quantities shall be designed at the input and the output of the treatment plant without fail.

8.Power supply of at least two independent power sources shall be envisioned in the water treatment plant design. The water treatment plant shall be designed in such a way that the normal operational state be able to be readily restored after resolving a power outage. A diesel generator shall be envisioned for backup power supply to the pumps which pump untreated water to the tailings dam and other crucial consumers which have to be operational under emergency situations.

9.Inordertoexerciseoperationalcontrolandprocessmanagementinthewatertreatmentplant, a SCADA automated dispatch system shall be designed based on state-of-the-art simulation models of the technological processes and the respective software applications used in the world practice. The processes shall be managed from the same panel.

10. Theoperationalpremiseshallcontainasparepartwarehouse, repairworkshop, laboratoryand a room for the personnel.

11. The treatment plant shall be designed with a minimal number of operators and it shall be easily managed and operated.

12. Designing a recycling water supply system with technological water.

13. Anoperationallifeofthefacilityofatleast 30 yearsshallbeenvisioned as the technological parameters of the treatment plant shall be warranted and the long durability of the building structures and facilities shall be ensured (including when the adverse impact of waste waters is considered).

14. The design operational life of the mechanical equipment in the water treatment plant shall meet the requirements of its rate as per Bulgarian State Standard EN 12255-1.

15. The mechanical equipment shall be maximally standardized.

16. The waste water treatment plants shall be built on the area stated in Appendix No. 9.

2.3. Task fulfillment deadline – within3(three) months after signing the contract.

III. Scope of the task

In order to achieve the task objective, a WorkdesigntobuildawatertreatmentplantforthewatersfromLyulakovitsatailingsdamclosetothecontactwaterpondofatreatmentcapacityof 400 m3/hour shall be developed meeting the following requirements:

The work design shall involve the development of at least the following design parts:

  • Geodesy - Geodesy and layout plan. A balance of the earth moving works. An explanatory note containing the data of the adopted principles of geodetic works and the vertical planning of the site, data about the designed local geodetic networks: type, description of the solution, point location, tools, measurement, coordinate system: 1950 (local), altitudinal Baltic system, processing, results, accuracy, features of the selected and coordinate points, output points and benchmarks needed for design and construction, etc.
  • Engineering geology and hydrogeology– to a degree of accuracy which is sufficient for the development of the work design for the subsite.
  • Engineering geological and hydrogeological studies in the region of the envisioned for building facilities shall be conducted, involving geological and geological characteristics of the region, data about the specific construction conditions such as measures taken with regards to seismic activity, soil types, failures, requirements for special protection of the geological base and/or underground water, lithological rock types and weathering degree, category of construction soils, physical and mechanical indices of the rock types, conditional estimated loads (bearing capacity of the layers), modulus of deformation, trench for excavation, underground waters and their lever and aggressiveness, recommendations for laying the foundations and necessity for using any special construction materials such as sulphate resistant concrete, etc.
  • Architecture–planning solution, building indices, distribution, plan of the roof lines, façade images, insulations, floor structures and flooring, cross and longitudinal vertical sections, architectural details which clarify the performance of the individual building and installation works. Specification of the materials which are planned to be used (materials, products, sets and systems) for the architectural part with the technical requirements to them in compliance with the applicable norms and standards; the way in which they are processed, laid and/or installed; color image of the site, etc. The water-proofing on the roofs which is to be used in the work design shall be Sarnafil TS 77-20 for the horizontal surfaces and TG 66-20 for the vertical surface sides, vents, stacks, etc. with a mechanical attachment to the roof structure. Drawings, bill of quantities, quantity surveys and an explanatory note shall be attached.
  • Building and construction – designing the reconstruction of existing facilities and building new ones. Shuttering and reinforcement plans. Foundations of machines and devices. Construction and installation details. Specific details of the building structure components. Anti-corrosion protection of concrete and metal surfaces, anti-abrasion protection. Statistical calculations with detailed drawings and data, manufacturing drawings of metal structures, specifications of devices, materials, permissible deviations, control and takeover of the construction components and explanatory note, ongoing supervision of the construction supervision, including the preparation of a Construction Opinion. Drawings, bill of quantities, quantity surveys and an explanatory note shall be attached.
  • Technology – water treatment technology with technological and hydraulic calculations. Technological flow of the water and residue route. Sizing the technological facilities and connections. Detailed technological drawings. Description of the technology and operation mode under all possible operation mode options. Description of the technology considering its technical and economic indices (capacity, specific electric power consumption, degree of mechanization, reagent consumption, etc.). Supplying water, electric power, air and others to the facility. Technological circuits, sections and axonometric schemes, technological calculations, specification of the operational equipment, the mechanization degree of the technological processes, needed manpower, raw material and fuel supply for the operations, etc. Characteristics of raw material and auxiliary material consumption, electric power, technological fuels, reagents, air, water consumption, waste water generation, heat balance of the operations, load circulation and other indices which are typical for the technological solutions, achieved occupational health and safety conditions, sanitary services and fie precaution. Arrangement of mechanical repairs, warehouses and laboratory control;drawings in an appropriate scale (plans, profiles, sections, installation plans, details, detailed data). Drawings, bills of quantities, quantity surveys and an explanatory note shall be attached.
  • Hydrotechnical facilities –situational and alignment location of the envisioned facilities and pipelines corresponding to the current terrain. Hydraulic sizing of the system, initiatives to ensure protection against hydraulic shock, etc. Drawings, bills of quantities, quantity surveys and an explanatory note shall be attached.
  • Equipment–mechanical and technological equipment, reinforcing steel along the pipeline route, material, technical requirements for the manufacturing of the respective equipment, protection of the metal parts against corrosion. Drawings, bills of quantities, quantity surveys and an explanatory note shall be attached.
  • Water Supply and Sewrage System – A domestic module with a restroom and a washing sink shall be envisioned to the treatment plant. Water supply and general piping schemes in the water treatment plant, external networks and internal facilities, longitudinal and cross sections, axonometric details, installation plans, technical parameters of the facilities, details, hydraulic calculations, specification of the materials. Drawings, bills of quantities, quantity surveys and an explanatory note shall be attached.
  • Electrical part, including Electric Power Supply, Electric Equipment “Electric Engineering Facilities and Lightening Protection, grounding device, local lighting. Electric Power Supply to the Water Treatment Plant – backup and alternative, lighting facility, electrical equipment, lightening protection, bill of quantities and cable carnet. The needed power supply lines and devices, complex switchgears, circuit breakers and secondary commutation of the Indoor Switchgear at the Recycled Water Substation (the Recycled Water Substation is provided in AttachmentNo. 7). The lightening protection facility shall be designed with a lightening receiver of overtaking action with overtaking time of up to 27µs.Drawings, bills of quantities, quantity surveys and an explanatory note shall be attached.
  • Evacuation plan in compliance with the effective norms and standards, including needed emergency, evacuation tables, schemes and lighting bodies.
  • Energy efficiency in scope and contents in compliance with Regulation No. 7 from 2004 for the energy efficiency, heat preservation and energy saving in the buildings (State Gazette, issue 5 from 2005).
  • HVAC - Drawings, bills of quantities, quantity surveys and an explanatory note shall be attached.
  • Instrumentation and Automation – The technical requirements stated in the AttachmentNo.5, Automation Technical Requirements shall be observed for the design of this part.Drawings, bills of quantities, quantity surveys and an explanatory note shall be attached.
  • Information and Communication Systems, including fire alarm system as per the requirements in AttachmentNo.6, Technical Requirements for Information and Communication Systems. An automated fire extinguishing facility shall be designed in the switchgear at the substation. Drawings, bills of quantities, quantity surveys and an explanatory note shall be attached.
  • Vertical planning, connection to existing servicing roads, grassing–approaches to build the facilities, area dewatering, cultivation of the ambient space, area fence. Longitudinal and cross profiles, drawings, bills of quantities, quantity surveys and an explanatory note shall be attached.
  • Roads– designing of building and servicing roads. Drawings, bills of quantities, quantity surveys and an explanatory note shall be attached.
  • Fire precaution. The development shall comply with the effective normative acts.
  • Occupational Safety and Health Planin compliance withRegulationNo.2 from 2004, which is to include a part for Manufacturing and Installation of Guiding Tags and Tables and a way for development that eliminates all risks of potential contamination in compliance with the effective normative acts. It shall also take into consideration the site conditions.

- Arrangement plan

-Construction situation plan

-Complex plan schedule for the sequence of the building and construction works

-Measures and requirements to ensure occupational safety and health during the building and installation work performance, including the specific hazard area.

-A scheme of temporary arrangement of the traffic and its safety along haulage and evacuation roads and pedestrian walkways on the construction site and the approaches to it.

-A scheme of the places on the construction site where the presence of two or more workers is envisioned.

-A scheme of the places on the construction site where there are specific hazards

-A scheme of the places where to install lifting devices and scaffoldings.

-A scheme of the places to store construction products and equipment, temporary workshops and waste containers.

-A scheme of the location of sanitary and domestic premises.

-A scheme for power supply, water supply, heating sewerage, etc.

-A scheme and type of the alarms in case of calamities, incident, fire or accident with a determined spot where first aid shall be rendered.

  • Manuals for operation, maintenance, repairs and preventive maintenance activities with compulsory included optimal input, technological and output parameters as well as technological equipment monitoring, including:

- Instruction for stopping and starting the water treatment facilities.

- Measurestoavoidmassivecontaminations

- Instructionsforextraordinarymodeofoperation – discrepanciesandcorrectiveactions.

ThestatedinstructionsshallcomplywiththeWorkInstructionsfromtheIntegratedManagementSystemforQuality, Environment, OccupationalSafetyandHealthforminingwatertreatment РИ-ИСУ 06.07.24.00.00.05-2011 and РИ-ИСУ 06.07.27.00.00.03-2011 of Assarel-Medet JSC. The requirements under the stated instructions shall be given to the contractor.

  • Constructionarrangementandperformanceproject,includingasequenceoftheactivities, buildingandinstallationtechnology, equipmentselection, etc. A linear and network complex plan and a plan-schedule for the construction sequence.
  • Generalarrangementplan–location, boundariesanddimensionsoftheconstructionareaenvisionedfordesignedbuildings, facilitiesandnetworks, arealandgeologicalconditions, landscapeconditionsandlimits, overallsituational, functionalandspecialsolutionanditsconnectionwiththeadjacentterritories; transportationconnectionsandtheapprovedindiesfortheroadandothercommunicationareas; thesolutionsfortheconnectionstothesurfaceandundergroundnetworksofthetechnicalinfrastructure.
  • Environmentandenvironmentalregulation– initiativesforenvironmentalandwaterprotection, restorationandrehabilitationofdamagedareasandinfrastructuralelements. The work design shall comply with all resolutions and permits regarding the normative environmental regulations issued so far.
  • Prevention plan for production accidents (Emergency plan);
  • Instructions for conducting water tests. Technologicalcircuitandtechnicalsolutionsforswitchingtoanoperationalmodeandaprogramforcarryingoutsingletestsand 72-hourtestsunderoperationalconditions inordertoprovethesystemparametersandissuingacertificateasper RegulationNo.3 for these activities;a bill of quantities for the needed tools and consumables.
  • Detailed quantityregistersandspecificationsoftheusedmaterialsandbillsofquantitiesfortheindividualpartsaswellasasummarizedbillofquantity(the building and installation works and equipment delivery are split in the bills of quantities. The needed tools and equipment which ensure the water tests and single tests shall be envisioned in the bills of quantities.
  • Explanatorynotes for the individual design parts with the needed calculations, drawings and details.
  • Preparationoftermsofreferencesforthedeliveryofspecificmaterials, devicesandtechnologicalstandardandnon-standardequipment. The detailed requirements about the technical equipment shall be specified at arranged for the purpose meeting between the client and the contractor.
  • Miscellaneous (ifany) depending on the technical solution and on discretion of the quoting companies, included in the price of the work design.
  • Reproductionoftheworkdesign – Itshallbeprovidedin7(seven) paperoriginalsinBulgarian andon 1 (one) CD (thegraphicalparts – in AutoCAD 2004 – dwg-format, the text parts – in Word and the detailed quantity registers and bills of quantities – in Excel).
  • Author’ssupervisiononthesite inordertocomplywiththedesignduringthebuildingandinstallationphaseandtoensurethattheoccupationalsafetyandhealthandenvironmentalprotectionrulesaremet in compliance with the legislation of Republic of Bulgaria. The design company shall prepare a Program (presented for each part of the design) in order to exercise author’s supervision in man hours needing for the project implementation considering the specifics and complexity of the respective task, travel times, tests and the final commissioning of the site in order to justify the needed time frame during which author’s supervision shall be exercised by the design company. Theclientrequiresthatthedesigncompanyshallbeavailableonceperweekinordertoexerciseauthor’ssupervision, takeoverofthecompletedconstructionandbillsofquantitiestotheconstructioncertificates. The number of man hours needed for author’s supervision until the full construction completion is based on this requirement and the construction timeframe determined by an expert. Thewayforexercisingauthor’scontrolisstipulatedinAuthor’sSupervisionMethodologywhichisan- Attachmentto the draft contract.
  • Preparationofas-builtdocumentationin 3(three) paperoriginalsand 1 (one) CD (the graphical parts shall be in AutoCAD 2004 – dwg-format, and the text parts - in Word)

Theindividualpartsofthedesignshallbedevelopedinawayensuringthecloseinterconnectionbetweenthem, withadetailedexplanatorynoteandcalculationswhichsubstantiatethesuggesteddesignsolutionsandtheircompliancewiththerequirementsof169 of the Territorial Planning Act for safe, secure, healthy and widely accessible environment.

IV. Other designing initiatives. Specific requirements:

  1. Theconceptuallayoutsolutionsshallbecoordinatedwiththeclientbeforeproceededtodetaileddesigndevelopment.
  2. Thecontractorshallpreparetheworkdesignincompliancewiththecriteriaandtherequirementsof RegulationNo.4 from May 21, 2001 for the scope and contents of investment projects. AlltechnicalsolutionsshallcomplywithEurocode, theeffectivestandards, rulesandinstructionsforoccupationalsafetyandenvironmentandwaterprotection.
  3. Thecontractorshallidentifyandapplyallnormativedocuments, requirementsandguidelinesapplicabletotheproject. In the project implementation process, the Contractor shall follow the modifications in the applicable norms which affect the project results.
  4. Occupational safety shall be ensured in the future site and all preventive measures shall be undertaken in order to avoid any potential accidents.
  5. Whilepreparingtheworkdesign, thedesigncompanyshalltakeintoconsiderationthepossibilitiestoimplementtoprojectontheparticularlocationbyusingtheexistinginfrastructuretoamaximalextent, includingapproaches, powersupply, etc. The technical solution shall be highly reliable, energy efficient and the facilities shall be fit for maintenance, servicing and repair activities.
  6. Thecalculationswhichsubstantiatethedesignsolutionsshallbeattachedtoallpartsof the work design in order to guarantee a high extent of security while they are being built and in their future operation.
  7. The needed tools and equipment which ensure the water tests and single tests shall be included in the bills of quantities. В
  8. Terms of Reference for the delivery of specific materials, devices, technological standard and non-standard equipment shall be prepared. The design company shall coordinate and give their opinion about the Terms of Reference and the quotation proposals for the delivery of specific materials, devices, technological standard and non-standard equipment, including the opinions of manufacturers of such equipment.
  9. Detailswhichrequiredeliveryofspecificequipmentshallbemarkedwith “ON HOLD” and shall be further developed in the working phase after the particular equipment selection and they shall be planned for implementation in the bill of quantities and the quantity survey.
  10. Theworkdesignshallrequireminimalinvestmentand a minimal period for construction works.
  11. Allthe parts of the work design shall be coordinated by all designers who have worked on it.
  12. Ifinstallationfacilitiesand /or highriskfacilitiesaretobeinstalled, thedesigncompanyshallprepareworkdesignsfortheirregistrationand regularization in a scope and volume in compliance with the enforced normative base for this activity.

V. General requirements to the quoting organizations

Top View