Part 3: Scope of Work: Employer

TRANSNET PORT TERMINALS
CONTRACT NUMBER: iCLM HQ 150/TPT

UPGRADE OF ELECTRICAL, MECHANICAL, INSTRUMENTATION, CONTROLS & STRUCTURAL REFURBISHMENT
OF CAILLARD 7 & 8 SHIP UNLOADERS AT THE DRY BULK TERMINAL, PORT OF RICHARDS BAY FOR TRANSNET
SOC LTD (REG. NO. 1990/000900/30) OPERATING AS TRANSNET PORT TERMINALS, (HEREINAFTER REFERRED
TO AS “TPT”), AS A ONCE OFF SUPPLY.
PART 3: SCOPE OF WORK
Document reference Title No of

pages
This cover page 1
C3.1 Employer’s Works Information 32
Total number of pages 33
Contract 0 C3
Part C3: Scope of Work Rev 2 Cover page
Table of Contents
Part 3: Scope of Work ................................................................................................................................... 1
1.1 Background ........................................................................................................................................ 5
1.2 Project timelines ................................................................................................................................. 5
1.3 Interpretation and terminology .......................................................................................................... 6
1.3.1 Abbreviations ................................................................................................................................ 6
2.1 General Description of the Works ...................................................................................................... 7
2.1.1 Upgrade of electronic systems: .................................................................................................... 7
2.1.2 Electrical systems: ........................................................................................................................ 7
2.1.3 Mechanical systems: .................................................................................................................... 7
2.1.4 Structural: .................................................................................................................................... 7
2.2 Upgrade of electronic systems ........................................................................................................... 7
2.2.2 Variable speed drive (VSD’s) ........................................................................................................ 8
2.2.2.6 Upgrade Wind speed meter as per OEM specification ................................................................. 8
2.2.2.7 Hopper and Grab .......................................................................................................................... 8
2.2.2.8 Replace compact vsd x3 ............................................................................................................... 8
2.2.2.9 Camera System ............................................................................................................................ 8
2.2.2.10 Aircraft Warning Light Control ...................................................................................................... 8
2.3 Electrical systems ............................................................................................................................... 9
2.3.1 High Voltage ................................................................................................................................. 9
2.4 Mechanical systems.......................................................................................................................... 10
2.4.1 Ground section ........................................................................................................................... 10
2.4.1.5 Shuttle belt ................................................................................................................................. 12
2.4.1.6 Shaker bed ................................................................................................................................. 12
2.4.1.7 Hopper ........................................................................................................................................ 12
2.4.2 THIRD FLOOR .................................................................................................................................. 13
2.4.2.1 Spill plate .................................................................................................................................... 13
2.4.2.2 Grab Hopper ............................................................................................................................... 13
2.4.2.3 Traversing and Grab Trolley Travel Rail ..................................................................................... 13
2.4.2.4 Traversing Trolley....................................................................................................................... 13
2.4.2.5 Grab Trolley and Sheaves .......................................................................................................... 14
2.4.2.6 Closing Winch ............................................................................................................................. 14
2.4.2.7 Folding Boom Stays (Front Ties) ................................................................................................ 14
2.4.2.8 Boom Latches ............................................................................................................................. 14
Contract PAGE 1 C3.1

Part C3: Scope of Work Rev 2 Employer’s Works Information
2.4.2.9 Passenger Lift ............................................................................................................................. 14

2.4.2.10 Electrical House .......................................................................................................................... 14
2.4.2.11 Operators Cabin ......................................................................................................................... 15
2.5 Structures ......................................................................................................................................... 15
2.5.1 Platforms, Walkways, Handrails and Cat-ladders ....................................................................... 15
2.5.2 Main Structural Repairs .............................................................................................................. 15
3 Management and start up ................................................................................................................. 16
3.1 Management meetings ..................................................................................................................... 16
3.2 Documentation control ..................................................................................................................... 16
3.3 Safety risk management .................................................................................................................. 16
3.4 Environmental constraints and management .................................................................................. 17
3.5 Quality assurance requirements ....................................................................................................... 17
3.6 Programming constraints ................................................................................................................. 17
3.6.1 General ....................................................................................................................................... 17
3.6.2 Programme submission .............................................................................................................. 17
3.6.3 Contract programme (baseline) ................................................................................................. 18
3.6.4 Revisions to contract schedule ................................................................................................... 18
3.6.5 Supplementary programmes ...................................................................................................... 18
3.6.6 Cash flow .................................................................................................................................... 18
3.6.7 Progress reporting ...................................................................................................................... 18
3.6.8 Progress monitoring and review ................................................................................................. 18
3.6.9 Weekly status report .................................................................................................................. 19
3.6.10 Monthly expediting report .......................................................................................................... 19
3.7 Contractor’s management, supervision and key people .................................................................. 19
3.8 Training workshops and technology transfer ................................................................................... 20
4 Engineering and the Contractor’s design ....................................................................................... 20
4.1 Employer’s design requirements ...................................................................................................... 20
4.1.1 PLC Upgrade parameters ........................................................................................................... 20
4.1.2 Basic performance requirements ................................................................................................ 21
4.1.3 Basis of Upgrade and Replacement ........................................................................................... 21
4.1.3.1 Provide a safe working environment for people and equipment. .............................................. 21
4.1.3.2 Minimise the environmental impact ........................................................................................... 21
4.1.3.3 Have low levels of maintenance and operating costs (low total cost of ownership) ................. 21
4.1.3.4 Be cost-effective, with the low life cycle costs ........................................................................... 21
4.1.3.5 Provide a reliable electrical installation based on sound engineering utilising as far as practicable
concepts which have been tested and proven in the existing operations ................................................ 21
4.1.3.6 Integrate with the existing installations ..................................................................................... 21

4.1.3.7 Incorporate advanced technology practices where this is advantageous to operational reliability,
efficiency or process control and management. ....................................................................................... 21
4.2 Instrumentation ............................................................................................................................... 21
4.2.1 General ....................................................................................................................................... 22
4.2.2 Environmental conditions ........................................................................................................... 22
4.2.3 Functional requirements ............................................................................................................. 22
4.2.4 Maintenance Requirements ........................................................................................................ 22
4.3 Parts of the works which the Contractor is to design ...................................................................... 22
4.4 Procedure for submission and acceptance of Contractor’s design ................................................... 22
4.5 Use of Contractor’s design ............................................................................................................... 23
4.6 As-built drawings, operating and maintenance manuals ................................................................. 23
5 Procurement ......................................................................................................................................... 24
5.1 Subcontracting ................................................................................................................................. 24
5.1.1 Subcontract documentation, and assessment of subcontract tenders....................................... 24
5.1.2 Attendance on subcontractors.................................................................................................... 24
5.2 Plant and Materials ........................................................................................................................... 24
5.2.1 Quality ........................................................................................................................................ 24
5.2.2 Contractor’s procurement of Plant and Materials ....................................................................... 24
5.2.3 Spares and consumables ............................................................................................................ 24
5.3 Tests and inspections before delivery .............................................................................................. 25
6 Site work and completion of the works .......................................................................................... 25
6.1 Working Areas, Site services & construction constraints ................................................................. 25
6.1.1 Working Areas ............................................................................................................................ 25
6.1.2 Housing ...................................................................................................................................... 26
6.1.3 Clearing of site ........................................................................................................................... 26
6.1.4 Site books ................................................................................................................................... 26
6.1.5 Co-operation with Others ........................................................................................................... 26
6.1.6 Customs and port regulations .................................................................................................... 26
6.1.7 Health and safety facilities on Site ............................................................................................. 26
6.1.8 Site services and facilities........................................................................................................... 27
6.2 Completion, testing, commissioning and correction of Defects ....................................................... 27
6.2.1 Work to be done by the Completion Date .................................................................................. 27
6.2.2 Testing and commissioning ........................................................................................................ 27
6.2.2.2.1 Tests required for the commissioning of protection systems are specified in enough detail, ... 28
6.2.2.2.2 Resources are allocated to perform the tests, ........................................................................... 28
6.2.2.2.3 Accountability for performance of the tests rests with the resource allocated, ......................... 28
6.2.2.2.4 Documentation is available which indicates: .............................................................................. 28

6.2.3 Taking Over the Works for Hot Commissioning ......................................................................... 28

6.2.4 Start-up procedures required to put the works into operation .................................................. 29
6.2.5 Take over procedures ................................................................................................................. 29
6.2.6 Correction of Defects .................................................................................................................. 29
6.2.7 Access given by the Employer for correction of Defects ............................................................ 30
6.2.8 Performance tests after Completion ........................................................................................... 30
6.2.9 Operational maintenance after Completion ................................................................................ 30
6.2.10 Technical support after Completion ........................................................................................... 30
7 Plant and Materials standards and workmanship ........................................................................ 30
7.1 Referenced standard specifications .................................................................................................. 30
7.2 General ............................................................................................................................................. 30
7.3 Annexures ........................................................................................................................................ 32
7.3.1 Transnet Port Terminals standards specifications, annexure 01 ..................................................... 32
7.3.2 All drawings for the Caillard ship unloaders, annexure 02 .............................................................. 32
7.3.3 Health and Safety requirement OHS Act No 85 of 1993. Annexure 03 ........................................... 32
7.3.4 Drawing list Annexure 04 ................................................................................................................. 32

1. DESCRIPTION OF THE WORKS

1.1 Background
At the Richards Bay Terminal, the demand for continual operation of equipment forms the back-bone
of an efficient operation.
Material handling at the import section is done via a network of conveyors and associated equipment.
In order for these machines to function efficiently, deliver continuous availability and remain
compliant it is necessary to periodically repair and/or refurbish the aging unloaders.
The Caillard 7&8 Ship-unloaders play a major role in the off-loading of vessels quickly, adequately
and efficiently. It is Transnet Port Terminals main priority to ensure the reliability, performance and
safety is acceptable when the machine is in operation. The Caillard No 7&8 Ship-unloaders were
commissioned 18 years ago. These unloaders are positioned on the quayside and as such have been
subjected to a highly corrosive environment.
In order to achieve safety compliance with relevant standards a safety compliance assessment was
undertaken and work has already been carried out to address the critical elements identified.
However further items were identified that need to be implemented. The works that the Contractor
is to perform involve implementation of these changes which include:
1.1.1 Upgrade of electronic systems: The current status of Caillard unloaders control and
instrumentation control system is challenged regarding availability of spares which are now
absolete.
1.1.2 Electrical systems: Replacement of electrical motors, electrical cables burnt due to fire
incident and general lighting on the unloaders.
1.1.3 Mechanical systems: Corrosion protection on structural joint pins that results in limiting
mechanism.
1.1.4 Structural: Structures has deteriorated as a result of corrosion and has reduced the life span
of these unloaders.
1.2 Project timelines
The tenderers are encouraged to propose reasonable time lines to complete the scope of work.
These are operational ship unloaders and operations will be impacted due to this project. One ship
unloader at a time will be taken out of operation during the upgrade and refurbishments.

1.3 Interpretation and terminology

1.3.1 Abbreviations
The following abbreviations are used in this Works Information:
Abbreviation Meaning given to the abbreviation
VSD Variable Speed Drives
LED Light Emitting Diode
OHS Health and Safety requirement
EEAM Equipment Engineering and Asset Management
PLC Programmable Logic Controller
VLF Very Low Frequency
TPT Transnet Port Terminals
IP Ingress Protection
ISPS International Ship and Port Security
NEC New Engineering Contract
PDF Portable Document File
BS British Standards Institute Specifications
SANS South African National Standards
NDT non-destructive testing
MPI Magnetic particle Inspection

2. SCOPE OF WORKS
2.1 General Description of the Works
2.1.1 Upgrade of electronic systems:
The current status of Caillard unloaders control and instrumentation control system is challenged
regarding availability of spares which are now absolete.
2.1.2 Electrical systems:
Replacement of electrical motors, electrical cables burnt due to fire incident and general lighting on
the unloaders
2.1.3 Mechanical systems:
Corrosion protection on structural joint pins that results in limiting mechanism
2.1.4 Structural:
Structures has deteriorated as a result of corrosion and has reduced the life span of these unloaders.
2.2 Upgrade of electronic systems

2.2.1 Upgrade and Function
The contractor is to upgrade and refurb the below components:
2.2.1.1 Asi-modules
2.2.1.1.1 Upgrade DP/AS-I link 20E address 4
2.2.1.2 Grab and Hopper

2.2.1.2.1 Refurb hopper load cells
2.2.1.2.2 Refurb grab scale
2.2.1.3 Profibus network DP/AS-I link 20E to profinet

2.2.1.3.1 Upgrade profibus network address 4


2.2.1.4 Operators (OP) screen upgrade X3

2.2.1.4.1 Operator cabin screen
2.2.1.4.2 Electrical house screen
2.2.1.4.3 B1 panel 9 (new installation, should be the same as the other 2 screens)
2.2.2 Variable speed drive (VSD’s)

2.2.2.3 Variable speed drive cards (x12 Invertors)
2.2.2.3.1 Firing card
2.2.2.3.2 Power supply
2.2.2.3.3 Snubber
2.2.2.3.4 IVR card
2.2.2.3.5 IGBT’s
2.2.2.3.6 Encoder
2.2.2.3.7 Taco meter
2.2.2.4 Variable speed drive cards (x3 Rectifier)

2.2.2.4.1 CUR
2.2.2.4.2 Power supply
2.2.2.4.3 Thyristor
2.2.2.5 Upgrade the cabin travel Variable speed drive

2.2.2.6 Upgrade Wind speed meter as per OEM specification
2.2.2.7 Hopper and Grab
2.2.2.7.1 Reinstate 4 Hopper scale
2.2.2.7.2 Reinstate 4 grab scale
2.2.2.8 Replace compact vsd x3

2.2.2.9 Camera System
2.2.2.9.1 1 Camera with zoom functionality for holding function
2.2.2.9.2 1 Camera for latching,
2.2.2.9.3 2 Cameras for long travel
2.2.2.9.4 2 Cameras in the machine house
2.2.2.9.5 1 Camera on the conveyor
2.2.2.9.6 All wire identification numbers are to be reinstated as per the OEM design.
2.2.2.10 Aircraft Warning Light Control

2.2.2.2.10.1 main lights
2.2.2.2.10.2 emergency lights
2.2.2.2.10.3 illuminated push button on main control desk
Replace all aircraft warning lights and push button with new components as per the OEM and

TPT specification.
All wiring is to be tidied and brought to the OEM and TPT standard.
All the appropriate labelling (tag and equipment numbers) is to be fitted to the equipment.
All wire identification numbers are to be reinstated as per the OEM design.
2.3 Electrical systems

The Contractor is to clean, inspect and test the functionality of all electrical cubicles including protection
equipment as per the original OEM design and TPT specification. All relay and overload protection settings
are to be verified.
All components are to be inspected for damage and reported to the Project Manager in writing. The
Project Manager must approve the replacement of damaged components.
Cubicle locking mechanisms and seals must be repaired or replaced to reinstate protection to the IP65
requirement.
All bridged and/or bypassed circuits are to be investigated, bridges removed and the equipment and circuits
are to be repaired back to their original specification and condition.
The Contractor is to clean, inspect, repair and service all control panels, junction boxes, marshalling cubicles,
termination boxes and associated equipment according to the OEM specification and SANS Standards.
The outer surfaces must be polished or painted (mild steel) to the TPT standards for electrical panels.
All damaged or missing panel components i.e. selector switches, push buttons, pilot lights, e-stops, heaters
and fans must be replaced.
All trunking and other covers are to be reinstated.

Where applicable, new cubicle fans are to be supplied and installed.
All the appropriate labelling (tag and equipment numbers) is to be fitted to the panels.
All wire identification numbers are to be reinstated as per the OEM design
All wires that are redundant on the unloader are to be removed
General lighting across the machine to be replaced with new lighting technology (LED). (Drawing 11 20 006)
2.3.1 High Voltage

2.3.1.1 Slip-Ring Box
2.3.1.1.1 Upgrade the slip-ring box condition
2.3.1.1.2 install the heaters
2.3.1.1.3 Quote the copper rings to become more resistive to moisture
2.3.1.2 Transformer Room

2.3.1.2.1 Properly seal the transformer room to eliminate leaks when it rains
2.3.1.2.1 Supply and install three light fittings with an illuminance suitable for the transformer
housing
2.3.1.2.2 Ensure the transformer room gate can be readily opened from the inside with an outward
opening
2.3.1.2.3 Supply and prominently display a live Voltage warning sign at the gate

2.3.1.2.4 Supply and prominently display a prohibition of entry for un-authorised persons in the
transformer room, and this shall include prohibition to touching and interfering with the
electrical live parts
2.3.1.2.5 Supply and prominently display a notice prohibiting persons from opening the transformer
room gates without ensuring in writing that the transformer is dead
2.3.1.3 11kV SWITCHGEAR

2.3.1.3.1 Remove the existing 11kV switchgear and replace with an SBV4 vcb, preferably a
matching unit to the plant switchgear
2.3.1.3.2 the new breaker shall be in a 11kV panel and have a spare circuit breaker, and each shall
have a protection circuit wired
2.3.1.3.3 for the protection circuit the preferred relay will be a micom p122
2.3.1.3.4 the protection circuit shall protect the transformer against over current and earth faults,
and it shall have the 100/5A CT’s for both metering and protection
2.3.1.3.5 Configure the relay and obtain the upstream settings from the HT Technician
2.3.1.3.6 Each of the two new circuit breakers shall have an option for local and remote switching
2.3.1.3.7 Each breaker shall have the locking device and be lockable in the open position, the 11KV
shutters must also be lockable
2.3.1.3.8 Each breaker shall have an earthing equipment, to ensure it is dead when isolated
2.3.1.3.9 Each breaker shall be interlocked such that it can only be operated to close once it is fully
racked in
2.3.1.3.10 Each breaker shall have a tapping point for all safety interlocks and breaker statuses to be
wired on to scada
2.3.1.4 E-HOUSE
2.3.1.4.1 Each entrance to the E-House shall have a prohibition sign specified under EMR 5(a)(b)(c)
and (d)
2.3.1.4.2 Supply and install emergency doors for both entrances to be treated as emergency doors
2.3.1.4.3 Install emergency lighting for the E-House, transformer room and the machine house
2.3.1.5 Earthing and Bonding

2.3.1.5.1 All electrical equipment and structures is to be suitably earthed in accordance with SANS
10142 regulations.
2.3.1.5.2 All bolted sections must be bonded with 70mm2 insulated copper cable.
2.3.1.5.3 The rail earthing mechanism is to be totally refurbished and tested to ensure a solid earth
bond.
2.3.1.5.4 All lightning protection equipment is to be inspected and/or renewed as required. In
particular, a stainless steel earth strap 40mm x 6mm is to be installed from the top
structure to the rail earth.
2.4 Mechanical systems

The condition of some components cannot be accurately determined without first dismantling the component.
In such circumstances, the Contractor is required to dismantle the component, inspect it and then submit a
report to the Project Manager on the component’s condition.
2.4.1 Ground section

2.4.1.1 Sea Side
2.4.1.1.1 Replace all sea side bogies x12 (drawing No 01 010)

2.4.1.1.2 Replace all sea side bogies pivot pins x12 (drawing No 11 01 10)
2.4.1.1.3 Replace all sea side bogies sliding plate x12 (drawing No 11 01 10)
2.4.1.1.4 Corrosion protection on all sea side connecting beams x4
2.4.1.1.5 Replace all sea side connecting beams pivot pins x4 (drawing No 11 01 10)
2.4.1.1.6 Corrosion protection on all sea side bottom equalizing beams x4
2.4.1.1.7 Replace all sea side bottom equalizing beams pivot pins x4
2.4.1.1.8 Corrosion protection on all sea side top equalizing beams x2
2.4.1.1.9 Replace all sea side top equalizing beams pivot pins x2
2.4.1.1.10 Replace buffer badly corroded and rubber boot perished x2
2.4.1.1.11 Refurbishment of all travel motors x12
2.4.1.1.12 Refurbishment of all travel motor gear box x12
2.4.1.1.13 Replace all wheel bearings x24
2.4.1.1.14 Replace earth shoe with new x2
2.4.1.1.15 Refurb storm brake mechanism x1
2.4.1.1.16 Refurb storm brake hydraulic power pack x1
2.4.1.1.17 Replace anti-collision probes x2
2.4.1.1.18 Corrosion protection on all ground floor machine structures
2.4.1.1.19 Repair welds on all ground floor machine structures
2.4.1.2 Landside
2.4.1.2.1 Corrosion protection on all land side bogies x8
2.4.1.2.2 Replace all land side bogies pivot pins x8
2.4.1.2.3 Replace all land side bogies sliding plate x8
2.4.1.2.4 Corrosion protection on all land side connecting beams x4
2.4.1.2.5 Replace all land side connecting beams pivot pins x4
2.4.1.2.6 Corrosion protection on all land side bottom equalizing beams x4
2.4.1.2.7 Replace all land side bottom equalizing beams pivot pins x4
2.4.1.2.8 Corrosion protection on all land side top equalizing beams x2
2.4.1.2.9 Replace all land side top equalizing beams pivot pins x2
2.4.1.2.10 Replace buffer badly corroded and rubber boot perished x2
2.4.1.2.11 Refurbishment of all travel motors x8
2.4.1.2.12 Refurbishment of all travel motor gear box x8
2.4.1.2.13 Replace all wheel bearings x16
2.4.1.2.14 Replace earth shoe with new x2
2.4.1.2.15 Refurb storm brake mechanism x1
2.4.1.2.16 Refurb storm brake hydraulic power pack x1
2.4.1.2.17 Replace anti-collision probes x2
2.4.1.2.18 Corrosion protection on all ground floor machine structures
2.4.1.2.19 Repair welds on all ground floor machine structures
2.4.1.3 SECOND FLOOR

2.4.1.3.1 Corrosion protection on cable reel drum;
2.4.1.3.2 Refurb winding drum gear box
2.4.1.3.3 Refurb cable reel gear box and slip ring
2.4.1.3.4 Replace cable reel clutch
2.4.1.3.5 Refurbish cable reel
2.4.1.3.6 Replace drive pulley with new pulley x1
2.4.1.3.7 Replace tail pulley with new pulley x1

2.4.1.3.8 New pulley bearings x4

2.4.1.3.9 New Plummer block x4
2.4.1.3.10 New adapter sleeve x4
2.4.1.3.11 Replace conveyor belt class 800x…
2.4.1.3.12 Refurbish shuttle belt gear box x1
2.4.1.3.13 Replace Troughing brackets x29
2.4.1.3.14 Replace Troughing idlers x(29x3)
2.4.1.3.15 Replace return brackets x15
2.4.1.3.16 Replace all return idlers x15
2.4.1.3.17 Replace primary scrapper x1
2.4.1.3.18 Replace secondary scrapper x1
2.4.1.3.19 Replace V-scrapper x1
2.4.1.3.20 Replace shaker bed mounting rods x24
2.4.1.3.21 Replace buffers (rubber) x48
2.4.1.3.22 Refurbish hydraulic system
2.4.1.3.23 Replace cylinders with new x4
2.4.1.3.24 Replace cylinder pins, bushes and clevis for each cylinder
2.4.1.3.25 Replace hydraulic hoses
2.4.1.3.26 Replace gate control unit
2.4.1.3.27 Replace pump couplings
2.4.1.3.28 Replace crunking skirting rubbers
2.4.1.3.29 Replace deflector x4
2.4.1.3.30 Replace spindles x4
2.4.1.4 Electrical
2.4.1.4.1 Refurb cable reel motor x1
2.4.1.4.2 Service main incomer panel
2.4.1.4.3 Service shuttle belt panel
2.4.1.4.4 Service terminal panel
2.4.1.4.5 Replace shaker motors x4
2.4.1.4.6 Replace vibrator motor x8
2.4.1.4.7 Replace belt alignment switches x2
2.4.1.4.8 Refurbish cross conveyor drive motor x1
2.4.1.4.9 Replace pull cords x4
2.4.1.4.10 Replace remote controller panel x1
2.4.1.4.11 Refurbish power pack electric motor
2.4.1.5 Shuttle belt

2.4.1.5.1 Strip all idler frames, conveyor belt, discharge chute, pulleys, trunking ;
2.4.1.5.2 Refurb shuttle belt structure and reassemble all components
2.4.1.5.3 Refurb shuttle belt supporting stringers
2.4.1.5.4 Refurb shuttle belt discharge chute
2.4.1.6 Shaker bed

2.4.1.6.1 Refurbish shaker bed
2.4.1.6.2 Install liners inside shaker with fire resistance liners (exclude the top section of the shaker
bed)
2.4.1.7 Hopper

2.4.1.7.1 Refurbish the hopper panel

2.4.1.7.2 Replace center support beams inside the hopper
2.4.1.7.3 Replace all bolts and for main supporting frames to be HT 10.9 and stainless on flow
passages
2.4.1.7.4 Install new hopper liners that are fire resistance
2.4.1.7.5 Secure liners with counter sunk stainless bolts
2.4.1.7.6 Replace walkways and hand railing around the hopper
2.4.1.7.7 Refurbish hopper support members
2.4.1.7.8 Replace trunking together with supporting legs
2.4.2 THIRD FLOOR

2.4.2.1 Spill plate
2.4.2.1.1 Corrosion protection of spill plate
2.4.2.1.2 Install new green UV resistant UWHMPE liners.
2.4.2.1.3 Supply and fit handrails along full length of east and west side of spill plate. Ensure
handrails clear structure when spill plate is in raised position.
2.4.2.1.4 Repair structure at spill plate area.
2.4.2.1.5 Supply and fit new hinge bearings and pins
2.4.2.1.6 Remove, clean and inspect sheaves on spill plate (total 4 sheaves, each Ø 355 mm).
2.4.2.1.7 Check for cracks using dye penetrant method. Check rope groove profile on sheaves.
Report on condition.
2.4.2.1.8 Carry out ultrasonic non-destructive testing (NDT) on hinge plates and sheave mounting
points. Supply test certificate.
2.4.2.1.9 Carry out ultrasonic non-destructive testing (NDT) on 2 sheave carriers. Supply test
certificates. Replace sheave pins and carrier swivel pins.
2.4.2.1.10 Supply and fit new bearings and seals for sheaves.
2.4.2.1.11 Install sheaves in sheave carriers.
2.4.2.2 Grab Hopper

2.4.2.2.1 Replace land side hopper beam, plating and stiffeners
2.4.2.2.2 Repair/replace other damaged or corroded steelwork on hopper.
2.4.2.2.3 Replace hopper mounting pins.
2.4.2.2.4 Service hopper load cell.
2.4.2.2.5 Repair hopper access man doors and keeps.
2.4.2.2.6 Remove and replace cladding and damaged support steel.
2.4.2.2.7 Replace hopper liners with material of equal specification.
2.4.2.3 Traversing and Grab Trolley Travel Rail

2.4.2.3.1 Remove rail on both side and replace with new rail
2.4.2.3.2 Perform corrosion protection on the beam where the rail is mounted
2.4.2.3.3 Replace hold down bolts with new
2.4.2.3.4 Replace the rail back with new rail clips
2.4.2.4 Traversing Trolley

2.4.2.4.1 Refurbish complete traversing trolley assembly and replace liners
2.4.2.4.2 Refurbish existing trolley. Trolley refurbishment includes, but is not limited to:

2.4.2.4.3 Remove travel wheels, clean and inspect. Build up flanges and treads and machine to
original profile.
2.4.2.4.4 Check condition of trolley structure. Repair where necessary
2.4.2.4.5 Carry out non-destructive testing (NDT) on sheave pin mountings and travel wheel
mountings. Supply test certificate.
2.4.2.4.6 Install travel wheels with new bearings and seals.
2.4.2.5 Grab Trolley and Sheaves

2.4.2.5.1 Refurbish complete grab trolley assembly, including sheaves
2.4.2.5.2 Refurbish existing trolley. Trolley refurbishment includes, but is not limited to:
2.4.2.5.3 Remove travel wheels, clean and inspect. Build up flanges and treads and machine to
original profile.
2.4.2.5.4 Check condition of trolley structure. Repair where necessary
2.4.2.5.5 Carry out non-destructive testing (NDT) on sheave pin mountings and travel wheel
mountings. Supply test certificate.
2.4.2.5.6 Install travel wheels with new bearings and seals.
2.4.2.5.7 Replace grab rope sheaves, together with bearings, seals, pins, spacers and fasteners.
2.4.2.6 Closing Winch

2.4.2.6.1 Replace one complete planetary assembly with all new components.
2.4.2.6.2 Supply and fit silica gel-type breather.
2.4.2.7 Folding Boom Stays (Front Ties)

2.4.2.7.1 Carry out non-destructive testing (NDT) on each hinge point. Supply test certificate.
2.4.2.7.2 Check condition of pins and bushes. Check effectiveness of lubrication. Report on
condition.
2.4.2.7.3 Supply and install grease nipples, pipes and hoses to facilitate greasing of intermediate
bearings from main boom level
2.4.2.8 Boom Latches

2.4.2.8.1 Remove both latch arms. Abrasive blast clean latch arms to bright bare metal. Examine
arms for cracking, particularly in the area of the hook and the bearing housing. Submit
condition report to Project Manager.
2.4.2.8.2 Remove motors and test.
2.4.2.8.3 Remove return spring cylinder and strip components.
2.4.2.8.4 Replace existing steel bushes with brass equivalents.
2.4.2.8.5 Drill grease ways in all pivots where grease is not present and install self-lubricators.
2.4.2.8.6 Assemble complete and test.
2.4.2.9 Passenger Lift

2.4.2.9.1 Carry out inspection and test of Alimak rack and pinion passenger lift, in accordance with
the requirements of the Lift, Escalator and Passenger Conveyor Regulations 1994, as
amended, of the Occupational Health and Safety Act No 85 of 1993. A comprehensive
report, as contemplated in the regulations, is to be provided on completion.
2.4.2.9.2 The contractor is to price for refurb of the passenger lift to its original equipment
manufacturer condition.
2.4.2.9.3 The contractor is also allowed to give quotation on an alternative passenger lift type that
will be compactable with the ship unloader.
2.4.2.10 Electrical House

2.4.2.10.1 Replace E-house roof with new stainless steel roof sheeting
2.4.2.10.1 Replace all access doors with new
2.4.2.10.2 Clean floor and paint with new non slip paint
2.4.2.10.3 Replace service opening with new closure
2.4.2.10.4 Service existing aircons and install drip trays
2.4.2.10.5 Service all brakes SIM1ST and Emergency ( refurb hydra spring, replace HYD pump
piston, replace circuit board, replace scoop switch, replace electro valve, replace brake
pad set, replace HYD hose, replace holder pin set, replace link arm pin set, replace link
arm set, replace bush set, refurb motor and clean and test)
2.4.2.10.6 Service all gearboxes (change oil, clean magnet, change bearings, change seals, change
thrust washer, check gear back lash, inspect gear condition, inspect cluster gear shaft
and take old oil sample give results to the site supervisor)
2.4.2.10.7 Service crawl beam and issue load test certificate
2.4.2.10.8 Service crane and issue load test certificate
2.4.2.11 Operators Cabin

2.4.2.11.1 Corrosion protection of the entire cabin
2.4.2.11.2 Replace both control joysticks.
2.4.2.11.3 Install trafolite engraved labels for pushbuttons on control consoles.
2.4.2.11.4 Close openings in control console.
2.4.2.11.5 Remove all existing overhead operator alarm and mimic displays.
2.5 Structures
2.5.1 Platforms, Walkways, Handrails and Cat-ladders
2.5.1.1 All handrails and stanchions on the ship un-loader that are in good condition are to be
retained.
2.5.1.2 Replace corroded, damaged or missing hand rails and stanchions, as instructed by the
Supervisor, using material to the same specification, section and dimensions as the original.
2.5.1.3 Replace all corroded and damaged stairway and walkway sections with new galvanized stair
treads and grating panels. All floor grating is to have kick plates welded in place to extend
150 mm above the bottom of the grating. Each grating panel is to be secured with at least
four suitable saddle clamps with lock nuts
2.5.1.4 Repair or replace corroded grating support steelwork as instructed by the Supervisor.
2.5.1.5 Replace sections of cat-ladders that are severely corroded. All welds are to be inspected, with
25% subject to non-destructive testing (NDT). Carry out Magnetic particle Inspection non-
destructive testing (NDT) inspection of every weld fixing a cat ladder to the structure of the
ship un-loader. Repair defective welds.
2.5.1.6 Replace all bolts securing handrails, stanchions, and stairway and walkway sections to the
machine with galvanised bolts, diameter and length.
2.5.2 Main Structural Repairs
2.5.2.1 During the time that the ship un-loader is out of operation, complete corrosion repair and
protection works is to be carried out.
2.5.2.2 This will include all super structures, cross structures, longitudinal structures and bracing
associated with the entire crane at all levels including the complete boom structure.
2.5.2.3 Replace badly corroded bracing at sea side Hopper level.

2.5.2.4 Remove all covers associated with the structures and inspect internal surfaces. Report on
condition.
2.5.2.5 Carry out necessary corrosion repairs and protection painting in accordance with the TPT
specification.
2.5.2.6 All covers are to be refitted, suitably sealed, and new fasteners fitted, in accordance to the
OEM specifications.
2.5.2.7 Where corrosion damage may affect structural integrity, non-destructive testing (NDT) will be
required to determine extent of damage. Magnetic particle Inspection (MPI) process should
be utilised.
2.5.2.8 A corrective action plan, approved by a Registered Structural Engineer, will be provided by
Transnet port Terminals for each separate case.
3 Management and start up
3.1 Management meetings

The Project Manager shall arrange for a PLC upgrade review and refurbishment method statement
to be performed. For the remainder of the contract, the Contractor shall attend all management
meetings as called by the Project Manager. It is envisaged that at least monthly contract
management meetings, plus weekly site meetings during the site erection phase and daily meetings
during the commissioning phase, will be held. The Contractor must present all relevant information
including quality plans, schedules, (including progress) subcontractor management, and health,
environmental and safety issues at such meetings.
The Project Manager shall arrange for regular inspections during the manufacturing phase in
accordance with agreed hold and witness points and shall also be used as a manufacturing progress
report evaluation.
The Contractor shall attend risk reduction meetings as and when called by the Project Manager.
Other meetings of a specialist nature may be convened as specified elsewhere in this Works
Information or if not so specified by persons and at times and locations to suit the Parties, the nature
and the progress of the works. Records of these meetings shall be submitted to the Project Manager
by the person convening the meeting within five days of the meeting.
All meetings shall be recorded using minutes or a register prepared and circulated by the person
who convened the meeting. Such minutes or register shall not be used for the purpose of confirming
actions or instructions under the contract as these shall be done separately by the person identified
in the conditions of contract to carry out such actions or instructions.
3.2 Documentation control

The Contractor shall submit all documentation (including correspondence and drawings) to Transnet
(Employer) standards and to the Project Manager’s requirements in accordance with the Project
Manager’s document control procedure. The Contractor shall use his own suitable document control
system for the control, maintenance and handling of all relevant documentation and drawings issued
to him.
3.3 Safety risk management

All aspects of the works must comply with the Health and Safety requirement OHS Act No 85 of
1993. Refer to Annexure 3.
The Contractor must submit a project specific safety plan that takes into consideration the operation,
the site environment and associated risks with the Works.
3.4 Environmental constraints and management
All aspects of the works must comply with the Employer’s environmental management plan, statutory
requirements and regulations made by relevant authorities and the Contractor must ensure
compliance of Site activities
3.5 Quality assurance requirements

Refer to EEAM-Q-009 for the Employer’s Quality Management
Special attention must be paid to the following:
3.5.1 Quality management objectives.
3.5.2 Design control system with emphasis on design review procedures and Employer
requirements evaluation.
3.5.3 Documentation and change control procedures.
3.5.4 Quality control procedures that will apply to purchased materials.
3.5.5 Quality control plan for all components manufactured or supplied to ensure conformance.
3.5.6 The identification of suitable hold points to ensure proper quality assurance throughout
manufacturing.
3.5.7 Quality control of all welding and corrosion protection activities.
3.5.8 The quality control procedure that will apply to erection and painting on site.
3.5.9 Hold point on manufacture until design review approved.
The Contractor shall ensure that the quality assurance requirements placed on him under this
Contract are transferred into any subcontracts.
Quality system requirements shall be applied on all subcontracts to the point where the acceptability
of supplies can be demonstrated solely by the conduct of inspection and/or examination of goods
upon receipt at the designated point of delivery.
The Contractor’s quality plan shall include or reference the quality plans of subcontractors.
3.6 Programming constraints

3.6.1 General
The Contract programme, progress reports, subsequent updates, revisions and supplementary
programmes as detailed in this section are an essential part of the project control system used by
the Employer for managing the works and in monitoring the progress of the work under the Contract.
The information and data provided by the Contractor pursuant to this procedure must therefore be
reliable, accurate and timely in presentation.
3.6.2 Programme submission
A copy of the Contractor’s First Programme shall be submitted with the Tender Document returnable
that shall comply with the requirements as indicated in the Works Information. The Contractor’s
Detailed Programme shall be submitted in both hard and soft copy forms within two weeks of award
using a computer software package approved by the Project Manager.

The preferred software package is Microsoft Projects or similar approved.

3.6.3 Contract programme (baseline)
The Contractor’s First Programme, agreeing with the tender submission, shall become the “Contract
Programme” or “baseline” against which actual time performance will be compared. Once the
baseline has been established, all subsequent programmes will have baseline (target) bars shown
against each activity.
This programme will be used as the basis on which all variations, extensions of time and changes to
methods of delivery shall be assessed.
Identified deviations from the baseline shall be addressed by the Contractor by either demonstrating
that the deviation does not constitute a problem to the overall Contractor’s Programme or providing
a course of action to remedy the deviation.
3.6.4 Revisions to contract schedule
The Project Manager’s written approval of any revised contract programme shall be given prior to
the revised contract programme becoming the new contract programme.
Additional detail may be inserted into the Contract Programme at the request of either the Contractor
or the Project Manager. In such cases, the overall start and finish dates of the detail activities shall
not vary from the original summary activity(s) that were replaced.
All revisions to the contract programme shall be prepared by, and at the cost of the Contractor.
3.6.5 Supplementary programmes

The Project Manager may at any time, and at the cost and expense of the Contractor, direct the
Contractor to produce supplementary programmes to highlight a particular aspect of the work under
the Contract. The Project Manager shall not unreasonably request supplementary programmes.
3.6.6 Cash flow
The Contractor shall submit to the Project Manager a detailed cash flow chart based on the contract
programme showing the anticipated cash flow as represented by expected payment claim
submissions, not only payments received.
3.6.7 Progress reporting

To demonstrate the actual progress of the work under the Contract the Contractor shall, on a monthly
basis, update and submit the contract programme and the progress to the Project Manager.
The contract programme shall be in the form of a three week look ahead schedule, and shall show
the following two separate bars for each activity so as to enable comparison of the actual progress
to the contract programme:
2.6.7.1. The contract programme “baseline” activity bar
2.6.7.2. The current schedule activity bar identifying the currently forecast start and finish
dates of the activity, and the status (% completion of each activity).
3.6.8 Progress monitoring and review

Monitoring and review of the progress of work under the Contract shall consist of an assessment of
all activities currently in progress. The following shall be determined:
3.6.8.1. Percentage complete;
3.6.8.2. Forecast completion date
3.6.8.3. Deviations from the baseline programme; and
3.6.8.4. Actions required to remedy any deviations.
3.6.9 Weekly status report

The Contractor shall provide a written status report by the 15th of each month or such other reporting
period as may be required by the Project Manager from time-to-time. The report shall summarise
progress and problems encountered during that month in respect of all parts of the work under the
Contract.
As a minimum the report shall include:
3.6.9.1. Progress against the current approved contract programme;
3.6.9.2. Summary of progress achieved during the period;
3.6.9.3. List of milestones achieved during the period;
3.6.9.4. Status of design, procurement, and off-site works;
3.6.9.5. Status of on-site works;
3.6.9.6. Deviations from the contract programme “baseline”, and in particular, the
forecast completion dates of activities which have or should have commenced;
3.6.9.7. Status of approvals;
3.6.9.8. Actual or anticipated problems with corresponding action plans to minimise the
impact;
3.6.9.9. Summary of works planned for the following period, and
3.6.9.10. Cash flow status versus the original forecast.
The progress report shall form the basis of a monthly progress meeting between the Project Manager
and the Contractor.
3.6.10 Monthly expediting report
The Contractor shall submit to the Project Manager by email within four (4) days after month end a
report on progress of any off-site manufacturing activities of the Contractor during the previous
month.
The report shall state the current percentage progress of each major piece of equipment as applies
at that date.
Each report shall state the actual completion date for those manufacturing activities completed in
the last reported period shall advise the anticipated completion date for each major piece of
equipment and shall comment on any delay or variance with respect to scheduled progress.
The Contractor shall also report his calculated overall completion percentage for each Subcontract
at each report date.
3.7 Contractor’s management, supervision and key people

The Contractor shall make an adequate, experienced and stable project team available for the
duration of the contract. Every effort must be exercised by the Contractor to minimise replacement
of individual project team members in order to ensure optimum contract management continuity.
It is a requirement of this contract that the Contractor employs a full time, fully qualified and
experienced site manager who has been delegated sufficient authority to manage the contract
efficiently on Site during erection and commissioning.
The site manager is required to be fluent in English, both in writing and orally.

An organogram of all the Contractor‘s people who will be directly involved with the management and
execution of this contract down to supervisory level, showing each key person named to do the job
as stated in the Contract Data, shall be submitted with the Tender Document Returnable.
3.8 Training workshops and technology transfer

The upgrade of the control system of the Caillard unloaders will make a significant change in the
operation and maintenance requirement for the Employer. Both Operations and Maintenance
personnel will be exposed to new technology.
It is therefore essential that the Contractor provides comprehensive training (both theoretical and
practical) to the Employer’s staff members in the operation and maintenance of the works. On
completion of the training, it is expected that the Employer’s personnel will be able to deal
competently with any out-of-course situation that may arise during daily operation of the plant.
The Contractor compiles a Training Manual containing easy-to-understand notes on all the subject
matter covered in the training courses. Separate manuals shall be prepared for Operations training
and Maintenance training. Each Learner must receive a copy of the Training Manual for the course
that he/she has attended. In addition, three copies of each Training Manual must be provided for
the Project Manager to deliver to the Employer for reference purposes.
All training must be completed before the commencement of hot commissioning. The Employer will
not accept responsibility for the Operation and Maintenance of any of the works in use until the
training has been satisfactorily completed.
The Contractor submits a Training Programme to the Project Manager for review no later than four
weeks before the commencement of the cold commissioning. Because the Employer’s personnel are
engaged on shift work, it may be necessary to schedule a number of training courses at different
times in the day.
The Contractor maintains an accurate record of the training given and is to submit a report on
completion of the training. The report will include, but not be limited to, details of the Trainer, the
scope of the training, the duration of training on each topic and the Employer’s personnel who
received training.
4 Engineering and the Contractor’s design
4.1 Employer’s design requirements

The objective is to upgrade the electrical instrumentation and control components to the latest
available technology. This entails the migration of Actuator Sensor Interface (ASI) to S7 ET200
modules and the Control Unit (CU2) second version cards to CUVC cards. The PLC upgrade and
refurbishment strategic objective is to improve operating efficiencies. This will be achieved by
increasing the reliability of two (2) grab unloaders at berth 702.
4.1.1 PLC Upgrade parameters

The contractor is required to submit for acceptance the operating philosophy, control equipment and
displays prior to any associated manufacture/procurement.

The Contractor must ensure that the PLC upgrade meets all performance and operational
requirements and must clearly indicate where the upgrade parameters values will differ to the
existing values.
4.1.2 Basic performance requirements
General requirements:
The equipment as made and supplied shall be complete in every respect, of modern upgrade using
most advanced technology extensively supported by reputable local companies, and be upgraded
and built to applicable recognised standards and good engineering practices.
All electrical and mechanical plant to be fitted shall have been type tested for reliability and extended
lifetime in the conditions to be expected.
The PLC shall be upgraded and constructed such that as many common components as possible are
used on the equipment to enable the minimization of spares types and numbers.
This must also be applied to drives, brakes, ropes, sheaves, electrical Plant and components,
bearings and wheels if any of these components are replaced.
All drives must be such that the same drive can be used in both left hand and right hand applications.
All refurbishment should be completed according to OEM recommendations.
All services to equipment should be completed according to the OEM recommendations
4.1.3 Basis of Upgrade and Replacement

This PLC upgrade and replacement basis in this section provides the electrical engineering basis,
upgrade philosophy and concepts that will be used in the development, selection and upgrade of the
electronic systems associated with the current ship unloader design.
The electronic equipment must be upgraded, engineered and/or selected in accordance with the
following:
4.1.3.1 Provide a safe working environment for people and equipment.
4.1.3.2 Minimise the environmental impact
4.1.3.3 Have low levels of maintenance and operating costs (low total cost of ownership)
4.1.3.4 Be cost-effective, with the low life cycle costs
4.1.3.5 Provide a reliable electrical installation based on sound engineering utilising as far as
practicable concepts which have been tested and proven in the existing operations
4.1.3.6 Integrate with the existing installations
4.1.3.7 Incorporate advanced technology practices where this is advantageous to operational
reliability, efficiency or process control and management.
4.2 Instrumentation
The upgrade of the control system must be an extension of the existing plant control system and is
an automated control system that supports the plant operation under normal operating conditions
and under maintenance conditions within predefined operational limits. It comprises of existing
centralised components (PLCs, servers and client stations) and decentralised components (field
instrumentation / sensors and final control elements / actuators).
A detailed control philosophy is to be developed, functional control requirements, functional design
to be addressed in a detail functional specification.

4.2.1 General
The Contractor shall allow for the numbering and labelling of cables as per Transnet (TPT)
requirements. The Contractor shall produce a cable-pulling schedule, which must be approved by
the Project Manager prior to the installation of any cables.
The entire cable installation must meet with the Employer’s requirements and standards. Should
any cable be installed and not meet with these requirements it will be re-laid at the Contractor’s own
cost. All cables are to be meggered or VLF tested prior to final connections after termination.
4.2.2 Environmental conditions
The equipment offered must be able to operate in a marine environment subject to the following
conditions:
 Altitude Sea Level
 Ambient temperature 5 – 45°C
 Relative humidity Frequently 100%
 Air Pollution Heavily saline, dust laden and industrial fumes
 Wind speed range 0 – 100 km/hr
All electrical, hydraulic and pneumatic components shall be suitable and treated for use in tropical
climate where rapid changes in weather conditions produce severe moisture condensation problems.
The equipment shall be capable of withstanding the highly corrosive effects of the moist, saline
atmosphere. All electrical components not installed in controlled environments must have a minimum
enclosure protection of IP65, unless otherwise specified in the Technical Specification.
4.2.3 Functional requirements

The Caillard Ship-unloader plays a major role in the off-loading of vessels quickly, adequately and
efficiently at Berth 702. It is TPT main priority to ensure the reliability, performance and safety is
satisfactory when the machines are in operation.
4.2.4 Maintenance Requirements
The Contractor shall identify all maintenance activities with restricted access and cover the method
statements for such activities in the maintenance manuals.
Two sets of any special tools required shall be provided.
4.3 Parts of the works which the Contractor is to design

The Contractor shall do all the designs for the works to comply with the Employer’s design
requirements.
4.4 Procedure for submission and acceptance of Contractor’s design

Immediately after the starting date, the Contractor shall start with the design of the equipment.
During this design phase of the contract the Contractor is required to hold regular design review
meetings to confirm all Employer requirements and to obtain the Project Manager’s acceptance for
all design concepts, design interfaces and specifications to ensure that quality is designed into the
final material.

Structural and component design shall be verified by the Contractor by using finite element analysis
models and tested material properties.
The Contractor must give the necessary co-operation and supply all the necessary design data as
required.
The Contractor must prepare and submit by the dates as indicated on the Accepted Programme two
copies of black line paper prints of the general arrangements, working drawings and schematics for
acceptance by the Project Manager. These drawings and schematics are to be submitted in a
systematic manner, accompanied by an index sheet of all the completed and planned drawings and
schematics.
Drawings which are submitted for the acceptance of the Project Manager must bear the signature
and designation of the Contractor’s responsible professional Engineer.
General arrangement drawings must show the complete component layout arrangements.
Notwithstanding any formal acceptance of drawings and schematics submitted by the Contractor,
the sole responsibility for the adequacy of the design remains entirely with the Contractor.
Time required for all the activities associated with the design of the equipment must be allowed for
and indicated by the Contractor in his programme.
4.5 Use of Contractor’s design

The Contractor will grant to the Employer a non-exclusive licence, in accordance with the provisions
of section 22 of the Copyright Act 1978 (Act 98 of 1978), (a) to copy any plan, diagram, drawing,
specification, bill of quantities, design calculation or other similar document made other than under
the direction or control of the Employer, by the Contractor in connection with the installation, (b) to
make free and unrestricted use thereof for its own purposes, (c) to provide copies thereof to
consultants to be used by them for the purpose of the consultancy and (d) to provide other parties
with copies for tenders invited by it. The Contractor, furthermore, if any plan, diagram, drawing,
specification, bill of quantities, design calculations or other similar document made, other than under
the direction or control of the Employer, by any principal or sub-contractor of the Contractor, is used
in connection with the installation, shall cause such principal or sub-contractor to grant to the
Employer a similar non-exclusive licence in respect of such plan, diagram, drawing, specification, bill
of quantities, design calculation or other similar document. The provisions of this clause shall not
apply to documents made, in the case of equipment to be supplied in connection with the
manufacturing process of the equipment supplied but only to the equipment supplied itself. No
separate or extra payment shall be due by the Employer in respect of any non-exclusive licence
granted in terms of this clause.
4.6 As-built drawings, operating and maintenance manuals

The Manuals and Data Packs shall each be supplied by the Contractor as manuals in a loose-leaf A4
hard covered, red, grease- and water-proof 4D-ring binder. The Data Pack and Operation and
Maintenance Manuals shall be supplied as separate documents, each bearing a unique document
reference number provided by the Employer.
Drawings and charts larger that A4 and those greater than A3 shall be included in an A3 hard
covered, red, grease- and water-proof 4D-ring binder.
Manuals and Data Packs shall be well indexed and user friendly. Manuals and Data Packs shall include
a summarised Table of Contents and in manuals comprising a number of files/volumes there should
be one summarised Table of Contents in each of the files/volumes. The draft Table of Contents shall
be submitted for review to the Project Manager prior to the compilation and official submittal of the
Manuals and Data Packs. The technical content of manuals shall be specified by the Project Manager.
The originals of all brochures shall be issued to the Project Manager. When a general brochure is
applicable to a range of equipment, then a specific item, catalogue number or model number shall
be stated, which is best achieved by introducing a separate index page, which cross-references the
specific item to a tag number.

The address, phone numbers, fax numbers and reference numbers of all Sub-Contractors and Service
providers shall be provided.
Where manuals contain drawings that still need to be revised to “As-Built” status, and such manuals
are required prior to “As-Built” status, the manual will not be considered to be in its final form until
the “As-Built” version of each drawing has been incorporated.
A typical example of what the binder/file(s) shall be marked with on the spine and the front cover is
as follows:-
 Project Name
 Manual Title, e.g. Installation, Maintenance and Operating Manual
 FBS No. and Title
 Manual Numbering (e.g. Volume 1 of 2, etc.)
 Contract Number
 Contractor Name
Four hard copies of each Manual and Data Pack are to be supplied. One copy of each of the
Maintenance and Operation Manuals are to have each page laminated in clear plastic. In addition to
the hard copies, the Contractor provides two electronic copies of each manual in PDF format. Each
copy of each manual is to be provided on a separate, clearly marked CD-ROM. The naming of the
electronic files on the CD-ROM shall correspond exactly to the corresponding files in the printed copy.
5 Procurement
5.1 Subcontracting
5.1.1 Subcontract documentation, and assessment of subcontract tenders
The Contractor is required to appoint his sub-contractors under the NEC3 Engineering Contract Sub
Contract unless accepted otherwise by the Project Manager.
5.1.2 Attendance on subcontractors

The Contractor must notify the Project Manager of all inspections at his Subcontractors at least 3
working days in advance of such inspections. The Contractor must ensure that his Subcontractor
has the relevant quality management plans available at such inspections. The Supervisor will give
the Contractor 24 hour notice in writing of his intention to be present at the inspections.
5.2 Plant and Materials

5.2.1 Quality
If requested by the Supervisor, the Contractor must produce evidence to show that both his welding
procedures and welders have passed all the relevant requirements and tests in terms of BS 5135
and SANS 10044 Parts III and IV.
5.2.2 Contractor’s procurement of Plant and Materials

The Contractor must take all necessary steps to ensure that all Plants and Materials are adequately
protected against damage during shipping, transport and storage.
5.2.3 Spares and consumables

The Contractor shall supply to site all the spares and consumables as identified by the Project
Manager from the Contractor’s recommended spares list. Packaging of the spares and consumables
shall be suitable to protect its contents from environmental damage when stored in warehouses in
close proximity to the coast.
Packaging of sensitive spares and consumables shall be suitable to protect its contents from
mechanical damage due to handling. All remaining spares after project completion should be handed
over to Transnet.
The contractor shall try by all means to utilise components of the Caillard 7&8 PLC upgrade that are
available on the local markets. This will assist Transnet after the project completion to source the
spares locally and break down time will be kept to the minimum.
5.3 Tests and inspections before delivery

Where the Works Information requires inspections or tests to be performed, the Contractor shall
provide such assistance, labour, materials, electricity, fuel, stores, apparatus and instruments as may
be a requisite and as may be reasonable demanded to carry out such tests efficiently.
The Contractor shall ensure that all gauges, templates, tools and other equipment required to check
the accuracy of the work are calibrated at regular intervals by a laboratory approved by the National
Calibration Services of the Council for Scientific and Industrial Research of South Africa, or by the
respective authority in the country of origin of the equipment.
Unless the Project Manager otherwise accepts, no Plant or Materials shall be delivered to the working
areas until the Supervisor issues an inspection certificate in respect of such Plant or Materials. The
Contractor is responsible for taking delivery of all Plant and Materials delivered to the working areas.
The associated test and inspection protocol submitted by the Contractor must show the estimated
duration for each item on the protocol.
6 Site work and completion of the works
6.1 Working Areas, Site services & construction constraints

6.1.1 Working Areas
When required in terms of the delivery methodology, the Contractor will indicate his requirements
for site erection on a suitable drawing submitted with the tender.
At least some of the Site work will take place while the adjacent port terminal areas will be in
operation. The Contractor shall take all necessary steps for his works not to interfere with port
operations and to ensure that normal traffic flow of the operational terminal is not obstructed.
Establishment, fencing and other work required to make the working area fit for use is entirely the
Contractor’s responsibility.
The Contractor is responsible for the security of the works until completion and hand-over, and must
make his own arrangements for security and the safekeeping of his property. The Contractor's
watchmen are allowed on Site for this purpose.

The Contractor must ensure that the working area is well lit at night and that all the fences, obstacles
and hazards are marked.
The Contractor must maintain the working area in a neat and tidy condition to the satisfaction of the
Project Manager.
6.1.2 Housing
Housing of the Contractor's people on site is not permitted.
6.1.3 Clearing of site
The Contractor, within fourteen days after completion, must completely remove from site all his
plant, materials, Equipment, stores and temporary accommodation or any other asset belonging to
him and leaves the site in a tidy condition to the satisfaction of the Project Manager.
6.1.4 Site books
The Contractor must supply and have available at the site office at all times, the following site books
which remains the property of the Employer:
6.1.4.1. Risk register book:
This is a suitable carbon copy book, size A4, with two detachable sheets for registering risks and
early warnings in triplicate as identified by the Project Manager, Supervisor or Contractor.
6.1.4.2. Site diary book:
This is a suitable carbon copy book, size A4, with two detachable sheets for a page to a day where
all events affecting execution of the works, such as arrivals of plans, breakdown of Equipment,
weather conditions etc., are entered. Equipment, labour, Plant and Materials on site are recorded as
well as work performed. Entries are made by the Contractor (or his appointed agent) and signed
daily by both the Contractor and the Supervisor. The site diary may be used to establish the validity
of claims for Compensation Events.
6.1.5 Co-operation with Others
During the course of the contract, departments of Transnet and other contractors may be working
in the general area surrounding the working area. The Contractor must make allowance for the
necessity to interface with the activities of others, and to allow for safe access and working
conditions.
The success of the project depends on the effective co-operation of all contractors on site, and the
Contractor, if necessary, must discuss his programme on a day to day basis with the Project Manager
to ensure effective co-ordination.
6.1.6 Customs and port regulations

The working area is situated within a Customs controlled area and the Contractor and his people
shall observe all Customs regulations within the port area.
The working area is also within a promulgated port area and the Contractor and his people shall
observe all ISPS and Port Regulations within the port area. Copies of the Harbour Regulations are
obtainable from the Port admin offices.
The fullest collaboration between the Contractor, the Port and the Project Manager is essential in
regard to the working of the port.
6.1.7 Health and safety facilities on Site

At all times during the fabrication, erection and testing of the equipment the Contractor is responsible
for the safety of all persons on the Site and on the equipment and shall have the necessary systems
and procedures in place to effectively manage this.
6.1.8 Site services and facilities
The contractor shall indicate what services and facilities are required if any. The Contractor is
responsible for connecting up and for electrical cabling in the working area together with any
associated costs.
A water supply point is available to the Contractor if required in the working area.
The Contractor must make his own arrangements for the disposal of sewerage and wastewater.
Sewerage may not be wasted on site. Transnet facilities may not be used.
The Contractor must make his own arrangements for telecommunication facilities, if required, for his
use during the execution of the works.
The Contractor shall provide everything else necessary for providing the Works.
6.2 Completion, testing, commissioning and correction of Defects

6.2.1 Work to be done by the Completion Date
On or before the Completion Date the Contractor shall have done everything required to provide the
Works. The Project Manager cannot certify Completion until all the work is done and is also free of
Defects which would have, in his opinion, prevented the Employer from using the works and others
from doing their work.
6.2.2 Testing and commissioning

6.2.2.1 Commissioning
Commissioning will be performed prior to completion.
The Contractor submits the commissioning protocol to the Project Manager for acceptance not less
than 14 days before commissioning starts. This commissioning protocol includes all tests and
inspections deemed necessary by the Contractor and Supervisor to prove to the Project Manager’s
satisfaction that all equipment has been delivered according to this specification and must include
inter alia operational tests under simulated conditions, functional tests, tests to prove the integrity
of the safety and limit systems and inspections for final quality, including paint and corrosion
protection quality.
6.2.2.2 Pre-commissioning
Pre-Commissioning is to be carried out on all components and equipment supplied and/or installed
by the Contractor on this Contract. These tests include appropriate inspections and functional tests
to demonstrate that all items of equipment can be operated safely and at their design performance
specification during the commissioning test. In particular this includes proofing of all protection and
safety devices, direction tests, loop checks, alignment checks, interlocks checks and safety limit
checks.
The Contractor performs electrical testing as part of pre-commissioning. The Contractor is establishes
a QA system for the testing and commissioning of the MV and LV Systems Documentation is to be
provided with sufficient detail to enable the complete commissioning of the electrical equipment and
protection systems. The purpose of this documentation is to ensure that commissioning electrical

plant and protection systems is performed according to acceptable historic standards. The objective
is that:
6.2.2.2.1 Tests required for the commissioning of protection systems are specified in enough
detail,
6.2.2.2.2 Resources are allocated to perform the tests,
6.2.2.2.3 Accountability for performance of the tests rests with the resource allocated,
6.2.2.2.4 Documentation is available which indicates:
 Test results
 Equipment tested
 Person who performed the test
 The date on which the tests were performed.
These Pre-Commissioning Tests are carried out after the Contractor’s own proving of the equipment
and are conducted in the presence of the Supervisor. The required tests on all items of equipment
will be agreed between the Supervisor and the Contractor. The Contractor provides the
commissioning team with the necessary test equipment, and ensures that the test equipment used
has a valid calibration certificate.
Initial Defects listing will be done at this time.
The Contractor gives the Supervisor a minimum of 48 hours’ notice of his readiness to carry out the
Pre Commissioning Activities.
After successful completion of the Contractor’s pre-commissioning tests, a Mechanical Completion
Certificate will be issued by the Supervisor.
6.2.2.3 Cold Commissioning
Cold Commissioning will not be permitted to start unless the mechanical Completion Certificate has
been issued following successful completion of Pre-Commissioning tests and inspections. All
Category A and B items on the Defect List (also known as the Punch List) must be rectified before
Cold Commissioning can start.
After acceptance of the pre-commissioning tests and inspection by the Supervisor, the Contractor
will fully test the equipment supplied and/or installed by him in the presence of the Project Manager
and the Employer’s representatives and according to the accepted protocol.
6.2.3 Taking Over the Works for Hot Commissioning
After successful cold commissioning the unloader will be taken over by the Employer for the purposes
of hot commissioning and then becomes the Employer’s responsibility in terms of any Health and
Safety regulations pertaining. The Contractor is required to remain in attendance.
6.2.3.1 Hot Commissioning
After successful completion of cold commissioning, the unloader will be hot commissioned i.e. with
material.
The Employer will endeavour to make material available for hot commissioning as soon as possible
after the Plant has been made available for hot commissioning by the Contractor.
The Employer gives the Contractor a minimum of 48 hours’ notice of the date and time that hot
commissioning can take place. The Contractor must, however, make provision for a maximum delay
of 3 days to accommodate ship or rail transport schedules. Any standing time delays exceeding
three days will be paid for by the Employer at scheduled rates in accordance with the conditions of
contract. The Contractor makes provision for hot commissioning to start at any hour of the day or
night.

Hot commissioning involves 100 hours of trouble free operation of each Caillard unloader. This fully
operational test will be undertaken by the Employer with the Contractor in attendance. This test, to
prove the operational capacity of the each Caillard unloader to the satisfaction of the Project Manager
and the Employer, must be with manning levels as agreed beforehand and be based on that which
is considered sufficient to rectify any likely faults that may occur, to ensure the minimum of
disruption to the Employer’s operations.
Any adjustment, repair, etc. necessary to achieve the required capacity and specified condition of
the installation is to be done at the expense of the Contractor.
If any part of the system fails to meet its designed performance criteria, or breaks down during the
hot commissioning period, it is to be repaired or replaced and, at the discretion of the Project
Manager, a further similar performance test will be carried out. Stoppages of less than 30 minutes
during the first twenty hours of operation are acceptable to facilitate minor adjustments and repairs.
Any other breakdown during the performance test will result in the test being abandoned. After the
necessary repairs or modifications have been carried out, the performance test will be repeated in
its entirety. Hot commissioning will not be considered complete until the system has operated for
100 continuous hours’ trouble-free (interruptions for operational reasons excepted).
The plant is to be capable of sustaining the designed capacity on a continuous basis under normal
operating conditions relating to this type of plant in the bulk materials handling industry. The decision
as to the plant’s ability to maintain such operating conditions will remain entirely with the Project
Manager. Plant which meets the design capacity under conditions of obvious stress or overload will
not be accepted by the Project Manager.
The costs of any abortive tests are for the Contractor’s account. The Contractor is also responsible
for costs incurred by the Project Manager and the Employer resulting from these abortive tests.
6.2.4 Start-up procedures required to put the works into operation
The Contractor submits a detailed start up protocol as part of the commissioning protocol, two weeks
prior to commissioning.
6.2.5 Take over procedures

Take-over is after successful commissioning and correction of defects.
The Contractor ensures that the Project Manager has a full and accurate dossier of As-built
documents that represent the Mechanical, Electrical, Control and Instrumentation status of the
completed works (to include Plant within the works) to present to the Employer.
The Contractor ensures that the Project Manager has a full and accurate dossier of Maintenance and
Operating Manuals at the earlier of take-over or Completion.
Where the Contractor has presented Maintenance and Operating Manuals to the Project Manager at
take-over, the Contractor modifies and updates As-built documents as necessary prior to Completion.
6.2.6 Correction of Defects
The Contractor guarantees the entire Works to be free from all latent defects and
warrants that the Caillard unloaders will operate at the proven capacity for the period
stated in the Contract Data. The Contractor guarantees the modifications made to the
PLC and SCADA software to be free of all latent defects and warrants that the changes
made to the software will not adversely affect the operation of the existing
infrastructure.
A defect is any occurrence which prevents any part of the works from functioning or performing at
its proven capacity.

The Defects Period commences from the date of hand-over of the completed works. The Contractor
remains in attendance, or is available on site within two hours of the notification of the defect (or
with reasonable notice by agreement of the Project Manager), to attend to any defects in the works
that become manifest during this period. The Contractor is liable for the observance and performance
of his Sub-Contractors and Service providers in respect of any guarantees given by them with any
item of plant or equipment supplied to the Contractor.
All costs of remedial works, including materials, services and labour, are for the
Contractor’s account.
6.2.7 Access given by the Employer for correction of Defects
The Employer will arrange access dates to rectify defects.
The Contractor complies with the constraints and procedures of the Employer as described in section
3.1 above where the Project Manager arranges access for the Contractor after Completion. The
Contractor complies with the requirements of the Employer’s Health and Safety Standard.
6.2.8 Performance tests after Completion
The 100 hour performance test will be conducted as part of the hot commissioning
6.2.9 Operational maintenance after Completion
Operational maintenance of the Caillard unloader after completion of the Performance Test remains
the responsibility of the Contractor until the Data Packs, Training Manuals and Maintenance and
Operation Manuals have been delivered and accepted. No additional payment will be made for any
maintenance which may become necessary during this period.
6.2.10 Technical support after Completion

The Contractor shall undertake that spares for all mechanical and electrical components of the
Caillard unloader shall be readily available for at least 7 years from date of Completion. Should spares
be required during this period but not be readily available, the Contractor shall make modifications
to the Caillard unloader to use readily available spares at that time, and at no cost to the Employer
Should the equipment become substantially inoperable, inefficient or unsafe during the period
between take over and the defects date due to defects, the defects date will be extended by the
same amount of time that it takes to return the equipment to satisfactory operating state.
7 Plant and Materials standards and workmanship
7.1 Referenced standard specifications

The tests prescribed in the relevant standard specifications shall be carried out at the manufacturer’s
works before delivery of the Plant and Materials ordered by the Contractor. The test results shall be
submitted to the Project Manager.
Plant and Materials made and tested to alternative standard specifications will be considered at the
discretion of the Project Manager, provided that such specifications are not less stringent than those
laid down.
7.2 General
All Plant and Materials shall be new.
All Plant shall be installed according to the manufacturer’s recommendations.
All Plant must be securely mounted on the Caillard unloader such that vibration and movement will
not dislodge any components.

All rotating components shall be statically balanced before fitting. High speed rotating components
shall also be dynamically balanced.
All fatigue sensitive welds on manufactured components shall be post weld treated by local burr
grinding and shot preening afterwards.
All drawing will be provided to the bidders in a compactable disc (CD). This is due to the big size of
these drawings

7.3 Annexures
7.3.1 Transnet Port Terminals standards specifications, annexure 01
7.3.2 All drawings for the Caillard ship unloaders, annexure 02

7.3.3 Health and Safety requirement OHS Act No 85 of 1993. Annexure 03
7.3.4 Drawing list Annexure 04


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TRANSNET PORT TERMINALS

CONTRACT NUMBER: iCLM HQ 150/TPT

PART 3: SCOPE OF WORK

Document reference Title No of

This cover page 1

C3.1 Employer’s Works Information 32

Total number of pages 33

Contract PAGE 1 C3.1

2.4.2.9 Passenger Lift ............................................................................................................................. 14

Contract PAGE 2 C3.1

Contract PAGE 3 C3.1

6.2.3 Taking Over the Works for Hot Commissioning ......................................................................... 28

Contract PAGE 4 C3.1

1. DESCRIPTION OF THE WORKS

Contract PAGE 5 C3.1

1.3 Interpretation and terminology

Abbreviation Meaning given to the abbreviation

VSD Variable Speed Drives

LED Light Emitting Diode

OHS Health and Safety requirement

EEAM Equipment Engineering and Asset Management

PLC Programmable Logic Controller

VLF Very Low Frequency

TPT Transnet Port Terminals

ISPS International Ship and Port Security

NEC New Engineering Contract

PDF Portable Document File

BS British Standards Institute Specifications

SANS South African National Standards

NDT non-destructive testing

MPI Magnetic particle Inspection

Contract PAGE 6 C3.1

2.2 Upgrade of electronic systems

2.2.1.2 Grab and Hopper

2.2.1.3 Profibus network DP/AS-I link 20E to profinet

Contract PAGE 7 C3.1

2.2.1.3.17 Upgrade profibus network address 52

2.2.1.4 Operators (OP) screen upgrade X3

2.2.2 Variable speed drive (VSD’s)

2.2.2.4 Variable speed drive cards (x3 Rectifier)

2.2.2.5 Upgrade the cabin travel Variable speed drive

2.2.2.8 Replace compact vsd x3

2.2.2.10 Aircraft Warning Light Control

Contract PAGE 8 C3.1

2.3 Electrical systems

All trunking and other covers are to be reinstated.

2.3.1 High Voltage

2.3.1.2 Transformer Room

Contract PAGE 9 C3.1

2.3.1.3 11kV SWITCHGEAR

2.3.1.5 Earthing and Bonding

2.4 Mechanical systems

2.4.1 Ground section

Contract PAGE 10 C3.1

2.4.1.3 SECOND FLOOR

Contract PAGE 11 C3.1

2.4.1.3.8 New pulley bearings x4

2.4.1.5 Shuttle belt

2.4.1.6 Shaker bed

Contract PAGE 12 C3.1

2.4.1.7.1 Refurbish the hopper panel

2.4.2 THIRD FLOOR

2.4.2.2 Grab Hopper