KMK Consulting Engineers Ltd

Filton, Bristol, UK

Enquiry document

For

RAILCAR UNLOADER PLATFORM CRANE

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KMK Consulting Engineers Ltd

Filton, Bristol, UK

Table of Contents
1. GENERAL ......................................................................................................................................................... 5
1.1. PURPOSE ................................................................................................................................................. 5
1.2. EQUIPMENT ............................................................................................................................................ 5
1.2.1. Railcar Unloader Platform Crane .................................................................................................... 5
1.2.2. Electrical System ............................................................................................................................. 5
1.2.3. Warranty ......................................................................................................................................... 6
1.2.4. Manuals .......................................................................................................................................... 6
1.2.5. Options ........................................................................................................................................... 6
1.3. REFERENCES............................................................................................................................................ 6
1.3.1. Codes, Directives, Laws, Norms, Regulations and Standards ......................................................... 7
1.4. UNITS & LANGUAGE ............................................................................................................................... 9
1.4.1. Units .................................................................................................................................................. 9
1.4.2. Language ........................................................................................................................................... 9
1.5. DELIVERABLES ...................................................................................................................................... 10
1.5.1. Bid Proposal Deliverables................................................................................................................ 10
1.5.2. Project Schedule ........................................................................................................................... 10
1.5.3. Drawings ....................................................................................................................................... 10
1.5.4. Materials Documentation............................................................................................................. 11
1.5.5. Work Instruction ........................................................................................................................... 12
1.5.6. Inspection & Test Plan (ITP) .......................................................................................................... 12
1.6. DOCUMENT CONTROL .......................................................................................................................... 13
1.7. CERTIFICATIONS, PERMITS AND TESTS ................................................................................................. 13
2. PRODUCT ...................................................................................................................................................... 14
2.1. DESIGN CRITERIA .................................................................................................................................. 14
2.1.1. Environmental Conditions ............................................................................................................ 14
2.1.2. Operations Requirements ............................................................................................................ 15
2.1.3. Dimensions ................................................................................................................................... 15
2.1.4. Noise Requirements ....................................................................................................................... 18
2.2. INTERFACES .......................................................................................................................................... 18
2.2.1. Electrical Interface ......................................................................................................................... 18
2.2.2. Structure Interface .......................................................................................................................... 19
2.2.3. Railway Interface............................................................................................................................ 19
2.3. M AJOR COMPO N ENTS ....................................................................................................................... 20

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2.3.1. Structure ....................................................................................................................................... 20

2.3.2. Crane............................................................................................................................................. 20
2.3.3. Engine System............................................................................................................................... 20
2.3.4. Swing Mechanism ......................................................................................................................... 20
2.3.5. Boom............................................................................................................................................. 21
2.3.6. Bucket ........................................................................................................................................... 21
2.3.7. Operator Cabin................................................................................................................................ 21
2.3.8. Hydraulic System ............................................................................................................................ 22
2.3.9. Electrical System ............................................................................................................................. 22
2.4. CONTROL SYSTEM................................................................................................................................. 23
2.4.1. General ......................................................................................................................................... 23
2.4.2. Operator Controls ......................................................................................................................... 23
2.4.3. Engine, Controls, Instrumentation and Monitoring System......................................................... 24
2.4.4. Hydraulic System Monitoring System........................................................................................... 24
2.4.5. Safety Devices ............................................................................................................................... 24
2.5. SOFTWARE ............................................................................................................................................ 25
2.6. ACCESSORIES ........................................................................................................................................ 25
2.6.1. Special Tools for the Equipment ................................................................................................... 25
2.6.2. Worker Protection ....................................................................................................................... 25
2.6.3. Safety Identifications ................................................................................................................... 26
2.6.4. Identification Plates ..................................................................................................................... 26
2.7. MATERIALS ........................................................................................................................................... 26
2.7.1. Fasteners ...................................................................................................................................... 27
2.7.2. Flexible Hoses ............................................................................................................................... 27
2.8. PAINT, DECALS AND FINISHES.............................................................................................................. 27
3. EXECUTION ................................................................................................................................................... 28
3.1. PROJECT MANAGEMENT ....................................................................................................................... 28
3.2. DESIGN .................................................................................................................................................. 28
3.3. PURCHASING ........................................................................................................................................ 28
3.4. MANUFACTURING ................................................................................................................................ 28
3.4.1. Inspection ..................................................................................................................................... 29
3.4.2. Factory Acceptance Test (FAT) ...................................................................................................... 29
3.5. SHIPPING, HANDLING AND STORAGE ................................................................................................... 30
3.6. INSTALLATION....................................................................................................................................... 30

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4. OPERATIONS AND MAINTENANCE ............................................................................................................... 30

4.1. MANUALS ............................................................................................................................................. 30
4.2. RECOMMENDED SPARE PARTS ............................................................................................................. 31
5. WARRANTY AND AFTER WARRANTY SERVICES .......................................................................................... 32
5.1. WARRANTY ........................................................................................................................................... 32
5.2. EXTENDED WARRANTY.......................................................................................................................... 32

Table 1: Codes, Directives, Laws, Norms, Regulations and Standards List .................................................. 8
Table 2: Equipment Dimensions Requirements ............................................................................................. 15
Table 3: Rolling Stock List & Dimensions ..................................................................................................... 16

Figure 1: Site Track Layout.................................................................................................................................... 17

Appendix : KM600011_A_WAGON EXCAVATOR LAYOUT

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KMK Consulting Engineers Ltd

Filton, Bristol, UK

1. GENERAL

1.1. PURPOSE

This Technical Specification covers the requirements for the design and the supply of a RAILCAR
UNLOADER PLATFORM CRANE.

1.2. EQUIPMENT
The Supplier shall supply the equipment and all components listed below.

1.2.1. Railcar Unloader Platform Crane

Including:
a) Structure

b) Platform
c) Stairs I Ladders
d) Crane

e) Swing Mechanism

f) Boom
g) Bucket
h) Operator Cabin with air conditioning with 360-degree view
i) Drive and hydraulic systems
j) Special tools as required
k) Touch-up paint
I) Vandalism protection kit

1.2.2. Electrical System

Including:
a) Electrical drive system
b) Lighting system
c) Control System
d) Operator Controls
e) Engine, Controls, Instrumentation and Monitoring System

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f) Hydraulic System Monitoring System

g) Safety Devices
h) Software

1.2.3. Warranty
12-month warranty after receipt of equipment on site.

1.2.4. Manuals

a) Installation, operation, maintenance, start-up and spare parts manuals

b) Service and Training Manual

1.2.5. Options

Supplier shall separately propose in his bid the cost for each of
the following options:

a) Supplier's Several Types of Bucket Attachments available

b) Assistance during site installation

c) A follow up inspection visit 6 months after final acceptance on site
d) 24 months (2 years) Extended Warranty
e) On-Call Service

1.3. REFERENCES

The equipment, its components and materials, the design, the manufacturing and the
commissioning shall comply with all applicable codes, directives, laws, norms, regulations and
standards. Work shall:
• Be in conformance to codes, regulations and standards
• Pass all required inspections carried out by competent authorities
The Supplier shall be responsible for the design of the equipment and the application of the
required codes, directives, laws, norms, regulations and standards.

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Filton, Bristol, UK

1.3.1. Codes, Directives, Laws, Norms, Regulations and Standards

The Supplier shall refer to the following codes, directives, laws, norms, regulations and standards
referred to in this Technical Data Sheet (in alphabetical order), without limiting to.

Entity Description

Association of American Railroads

AAR Website:http://www.aar.org/
American National Standards Institute
ANSI Website: http://www.ansi.org/
• ANSI/NEMA Z535.4 Product Safety Signs and Labels
.
ANSI BllMStandard
Canadian machineAssociation
Tools Safety Package

CSA
CWB Canadian Welding Bureau (Website:
(AWS) http://eng.cwbgroup.org/Pages/default.aspx ) (American
Welding Society (Website: http://www.aws.org/w/a/ )
International Electrotechnical Commission
Safety of Machinery- Electrical Equipment of Machines

IEC • IEC 60529 Degrees of Protection Provided by Enclosures (IP Code) IEC 61508 Functional Safety of
.
Electrical I Electronic I Programmable Electronic Safety-Related Systems

IEEE Institute of Electrical and Electronics Engineers

https://www.ieee.org/ IEEE-SA National Electrical Safety Code (NESC)
International Organization for Standardization
Website: http://www.iso.org/iso/home.html
• EN1991-1-4 Eurocode 1: Actions on Structures - General Actions - P art 1-4: Wind Actions
ISO • EN1998-1Eurocode 8: Design of Structures for Earthquake Resistance- General Rule, Seismic Actions
(EN) and Rules for Buildings
• ISO 12100 Safety of Machinery- General Principles for Design- Risk Assessment and Risk Reduction

• ISO 13849 Safety of Machinery- Safety Related Parts of Control Systems

.
ISO 13850 Safety of Machinery- Emergency Stop Function- Principles for Design
National Electrical Manufacturers Association
NEMA Website:http://www.nema.org/Pages/default.aspx

National Fire Protection Agency

NFPA Website: http://www.nfpa.org/
• NFPA 70 National Electric Code (NEC)

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Occupational Safety et Health Administration

OSHA https://www.osha.gov/
OSHA 1910.212 General Requirements for all Machines

Underwriters Laboratories
UL Website: http://ul.com/

Table 1: Codes, Directives, Laws, Norms, Regulations and Standards List

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1.4. UNITS & LANGUAGE

1.4.1. Units

All units shall be all in the same measuring unit system including drawings, scales and measurements.
The Client's preferred

Units System is as follows (in order of preference):

• Metric System (with Imperial System in reference)

• Imperial System (with Metric System in reference)

Wherever literature contain measurements in the Imperial System or Metric System, this shall be
made clear by the Supplier.

1.4.2. Language

All equipment identification shall be in French. This includes,

without being limited to:

• Nameplates
• Material Safety Data Sheets (MSDS)
• Button identifications
• Indicator lamp identifications
• Outlet identifications

If required, the Supplier shall perform all necessary language translations to the French
language for each deliverable.

• Operation Manual
• Maintenance Manual
• Training Manual
• Spare Parts, Special Tools and Lubrification Oils List

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1.5. DELIVERABLES

1.5.1. Bid Proposal Deliverables

The Supplier shall provide the following information in his proposal.

1.5.1.1. Experience

Demonstrate experience of at least five (5) years in the supply, manufacturing and support of
similar equipment projects.

Provide a list of at least two (2) work experiences of the same type of work (e.g. project sheet,
installation drawing, equipment drawing, etc.) for review by client or designated delegate

1.5.1.2. Quality Assurance Program

Provide an electronic copy of his Quality Assurance Program for review and approval by client or
designated delegate. The Representative foresees to approve the Supplier's Quality Assurance
Program at the latest at the Receipt of Order.

The Supplier shall perform the required work and provide all materials, components and services in
accordance with a Quality Assurance Program (e.g. FTA-IT-90-5001-02.1 Quality Assurance and
Quality Control Guidelines, 150-9001 Quality Management System, etc.) as well as other applicable
codes, standards and guidelines.

1.5.2. Project Schedule

The Supplier shall provide a detailed project schedule from conception to delivery.

1.5.3. Drawings

The Supplier is responsible of providing all the necessary engineering drawings (in 2D/3D native CAD

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files, and in PDF format) of his equipment.

At a minimum, the Supplier shall provide the following drawings with the necessary dimension
tolerances for his components:

• General Arrangement (G.A.) Drawings

• Structural Drawings
• Assembly Drawings
• Detail Drawings
• Electrical Schematic Drawings
• Control System and Control Panels Drawings
• Installation Drawings
• Logic Control Diagram
• Interface Drawings
• Pit Concrete Foundation
• Mechanical Interfaces (e.g. recommended conduits, outlet locations, pneumatic air system,
ventilation, etc.)
• Electrical Power Supply (e.g. electrical cabinet, recommended conduits, outlet locations,
etc.)
• Health & Safety Components (e.g. staircases, ladders, access panels, etc.)
• Telecommunication Interfaces (e.g. telephone line, internet line, etc.)

1.5.4. Materials Documentation

Whenever a commercial material is not covered by this Technical Specification, the Supplier shall
submit the material description sheet through the Change Process for review and approval by client
or designated delegate. The Supplier shall:

• Provide the Bill of Material (BOM) of the components installed on his equipment with
the following minimum
material information (i.e. cut sheet, mill reports, etc.), without being limited to:

• Component's Manufacturer
• Component's Part Number
• Component's Description

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• Provide all fluids (e.g. grease, oils, hydraulic fluids, etc.) used by his equipment with its
related Material Specification

Data Sheet (MSDS)

• Keep on file the Material Safety Data Sheet (MSDS) for all chemical materials (e.g. paints,
solvents, adhesives, etc.)
used for his equipment

• Maintain records that trace all materials used by his Sub-Suppliers.

1.5.5. Work Instruction

For the distinct phases of the project, the Supplier shall provide his work instructions (e.g.
procedures) to perform the following work:
• Incoming Material Inspection Procedures
• Quality Inspection Procedures
• Electrical Wiring and Electrical Cables Installation Procedures
• Welding Procedures
• Painting Work Procedures
• Testing Procedures

1.5.6. Inspection & Test Plan (ITP)

As recommended by the supplier, the ITP shall include all Inspection & Testing activities for the
equipment, without being limited to:

• Supplier Quality Control Program

• Project Schedule
• Incoming Materials Inspections:
 Forms
 Results (i.e. with approved and signed results on Supplier's forms)
• Quality Control Inspections:
 Forms

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 Results (i.e. with approved signed results on Supplier's forms)

• Performance Testing and Acceptance Procedures
• Manufacturing Stop Points (i.e. Inspection Points, Quality Control Points, Testing Points,
etc.)
• Factory Acceptance Test (FAT):
 Test Plan
 Test Results Report

1.6. DOCUMENT CONTROL

After Receipt of Order (ARO), the Supplier shall:

• Provide all necessary engineering documentation through a formal process

• Use a standard format for the transmittals
• Use official transmittal numbering for each electronic correspondence (e.g. emails,
weblinks, etc.) describing:
 The purpose of the transmittal
 The engineering documents: Document revision
 Document number
 Document title
 Document status

1.7. CERTIFICATIONS, PERMITS AND TESTS

Before the equipment is shipped from the Supplier's shop, and as applicable, the Supplier shall
pay all fees and costs that his equipment needs to conform to (e.g. codes, directives, laws, norms,
regulations and standards).

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2. PRODUCT

Please see the attached drawing ‘KM600011_A_WAGON EXCAVATOR LAYOUT’.

The equipment shall:

• Be a construction-class stationary excavator

• Be used "Over Track"
• Perform the following activities:
 Empty gondola railcars on the equipment track
 Load gondola railcars on the equipment side track
• Include all required major components, electrical system, control system and accessories
as shown on the attached drawing.

2.1. DESIGN CRITERIA

The equipment shall comply to the following design criteria.

2.1.1. Environmental Conditions

Unless specifically stated otherwise, the environmental conditions for the design of the
equipment are:

• The local seasons are:

 Dry Season: 6 months per year, from November to April
 Wet Season: 6 months per year, from May to October
• The outside temperature varies as follows:
 Minimum: 10 Deg C (50F)
 Maximum: 35 Deg C (95F)
 The relative humidity is below< 75%
• The wind loads to be used are:
 As per EN1991-1-4 norm
 Wind Speed= 25.0 m/s (90.0 km/h) (82.0 ft/s (56 mph))
• The seismic loads to be used are:
 As per EN1998-1 norm

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 Horizontal Acceleration= 0.05 m/s2 (0.16 ft/s2)

 Vertical Acceleration = 0.025 m/s 2 (0.082 ft/s2)

• The estimated monthly average rain fall is as follows:
 Dry Season: 50 mm/month (1.97 in/month)
 Humid Season: 800 mm/month (31.50 in/month)

2.1.2. Operations Requirements

The equipment shall be electric designed to operate 365 days a year, 7 days a week and 24 hours a
day.

2.1.3. Dimensions

The equipment shall have the following dimensions.

Metric System Imperial System

Description (mm) (in)

Length (Nominal) 10 000 394

Width
• Internal (MIN) 4470 176
• Leg (MAX) 838 33
6147 242
• External (MAX)

Height
• Internal (MIN) 5 563 219
• External (MAX) As Required As Required

Table 2: Equipment Dimensions Requirements

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KMK Consulting Engineers Ltd

Filton, Bristol, UK

Refer to the following table for the rolling stock list & dimensions.

Gross
Rail length
Tare Wheel
Load (Over Couplers pulling
Weight Diameters
(GRL) Face)

# Description Metric Imperial Metric Imperial Metric Imperial Metric Imperial

System System System System · System System System System
(kg) (Ib) (kg) (mm) (in) (mm) (in)
(Ib)

1
1.1 Locomotive - - 166 922 368 000 20 015,0 788,0 1016,0 40,0
1.2 Switcher - - 112 491 248000 13 600,0 535,4 1016,0 40,0
OPTION Locomotive - - 166 922 368 000 21838,0 859,8 1066,8 42,0
OPTION Locomotive - - 195 952 432 000 22 301,2 878,0 1066,8 42,0
2
2.1 Gondola Car 22000 48 500 119 295 263 000 9 500,0 374,0 914,4 36,0
2.2 Flat Car 31661 69 800 99 790 220 000 28 600,4 1126,0 838,2 33,0
2.3 Ballast Hopper Car 24040 53 000 119 295 263 000 12 763,5 502,5 914,4 36,0
2.4 Box Car 28 758 63 400 119 295 263 000 16 240,0 639,4 914,4 36,0
2.5 Side Dump Car 36 968 81500 119 295 263 000 13 300,0 523,6 914,4 36,0
2.6 Tank Car 29 937 66 000 119 295 263 000 18 098,0 712,5 914,4 36,0

Table 3: Rolling Stock List & Dimensions

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The track spacing is the minimal distance between both centerlines of the equipment track and the
secondary track, refer to following illustration.

Figure 1: Site Track Layout

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Filton, Bristol, UK

2.1.4. Noise Requirements

Each equipment maximum noise level shall be as follows.

Description Value

Operator Noise Level 8S dB(A) at the ear of the

Owner's operator

(i.e. actual measurement at the equipment operator control panel)

Bystander Noise Level 80 dB(A) at 4.6 m (1S ft) from the centerline
of the rolling stock

The Supplier shall measure the noise level of each

equipment to validate that:

• All components have been properly installed

• No loose components are present
• If protective hearing devices are needed at specific locations around the equipment

2.2. INTERFACES

The equipment shall be made with the following interfaces.

2.2.1. Electrical Interface

All electrical components and systems must be certified to CSA, UL and/or CE standards. If a
component is not certified or labeled by a certification organization, the Supplier must ensure
that this component is approved by a certification organization. The equipment including its
electrical installation must be approved and labeled CE.

The equipment shall operate entirely with the

building electrical supply:

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High Voltage (for electrical loads> 0.37 kW (0.50 HP))

• Nominal voltage: 400 VAC, 3 PH, SO Hz;

• No load voltage: 420 VAC, 3 PH, SO Hz;
• Impedance System Grounded;
• The electrical sockets shall be /EC 60309, interlocked, 3P+E, 400 VAC, 3 PH, SO Hz with
standard ratings of 16 A, 32 A, 63 A and 125 A
• Residual current devices (RCD) with 30 mA trip setting shall be supplied with electrical
sockets rated 16 A, 32 A and 63 A.

Low Voltage (for electrical loads< 0.37 kW (0.50 HP))

• Nominal voltage: 230 VAC, 1PH, 50 Hz;

• The electrical sockets shall be IEC 60309, 2P+E, 230 VAC, 3 PH, SO Hz (i.e. standard German
Schuko plug).

Control Voltage (for motor starters. disconnect switch and voltage transformers)

• Nominal voltage: 115 VAC, 1PH, 50 Hz.

The following electrical components shall be

designed as follows:

• All electrical panel enclosures shall be IP56 (NEMA 4X)

• The servomotors protection shall be IP56 (NEMA 4X)
• All motors shall be of the totally enclosed fan cooled (TEFC) type

2.2.2. Structure Interface

The equipment shall be anchored to the ground to remain stable in operation of the
equipment.

2.2.3. Railway Interface

The equipment shall be designed for a standard track gauge of 1435 mm (56.5 in).

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2.3. M AJOR COMPO N ENTS

The equipment shall be supplied with the following major components.

2.3.1. Structure

The equipment structure shall be composed of the following minimum features:

• A heavy-duty steel frames

• A protected guarded roof
• A counterweight/anchoring to prevent the equipment from overturning under the
weight of the load
• Stairs I Ladders to access the operator cabin with railings
• Stairs I Ladders lockable gate
• Crane platform, with access

2.3.2. Crane

The equipment crane shall be composed of the following minimum features, without limiting
to:

2.3.3. Engine System

The equipment shall be electric designed with a net rating power of minimum 140 kW (188 HP)
that will power the equipment and all its components.

2.3.4. Swing Mechanism

The equipment swing mechanism shall be designed, without limiting to:

• With a swing mechanism to allow 360° minimum rotations

• To operate at a minimum of 13.5 rpm
• With a minimum torque of 77 500 Nm (57 150 lb.-ft.)
• With a mechanism that clears the crane structure
• With a platform for maintenance and accessibility

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2.3.5. Boom

The equipment boom shall be designed with a, without limiting to:

• Swivel mechanism to allow goo tilt attachment and goo bucket rotation
• Telescopic mechanism
• Load-sensing axial piston pump
• Minimum capacity: reach a height of 33185 mm {125.40 in) from top of rail
• Maximum capacity:
 reach the ground all around the equipment
 reach the bottom of gondola railcars located on tracks on both sides of the
equipment:
• 1073 mm (42 in) from top of rail
• 4700 mm (185 in) from centerline of equipment track to centerline of side
track.

2.3.6. Bucket

The equipment bucket shall be designed with, without limiting to:

• A minimal volume capacity of 1m3 (1.4 yd3)

• A minimal loading capacity of 2 000 kg (4 400 lbf)
• Capacity to load/unload gondola railcar of 84 500 kg (186 000 lbs) of the following
dimensions:

 Payload volume (approximately): 55 m3 (72 yd3)

 Internal width: 2 961mm (117
in)
 Internal length: 9 640 mm (380 in)
 Internal depth: 2 112 mm (84 in)

2.3.7. Operator Cabin

The equipment all-weather operator cabin shall be equipped at minimum with, without
limiting to:

a) 360° cab view with safety glass windows

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b) Adjustable operator's seat with seat belt

c) Skylight
d) Acoustical lining

e) AM/FM radio

f) Filtered fresh air heater, window defroster and air conditioning system

g) Air horn controls

2.3.8. Hydraulic System

The equipment hydraulic system shall be, without limiting to:

• Designed for multiple functions at the same time (e.g. crane rotation, boom
operation, bucket rotation)
• Be supplied with a hydraulic oil tank of 240.00 L (63.00 US gallons) minimum volume
with associated controls

2.3.9. Electrical System

All major components of the equipment shall be interconnected to an integrated control panel
that is supplied with the equipment. Panel shall be fed by the mine electrical system.

2.3.10. Electrical Cables

The Supplier shall:

• Supply all necessary electrical cables starting from the main control panel to all
required
 equipment's electrical components
• Design the electrical system with the necessary junction boxes at strategic locations
to:
 Ensure easy maintenance of the electrical cables
 Prevent interference with other components

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2.3.11. Lighting System

The equipment shall have the following minimum lighting system to work during the
night, without limiting to:

• A roof mounted amber strobe light

• Work lights
• Swing lights

2.4. CONTROL SYSTEM

2.4.1. General

The power and control components shall be identified:

• Using permanent tags (not decals) attached to the surface with screws or rivets (not
adhesive)
• With permanent lettering, resistant to rubbing, chemicals, oil and grease

Stop buttons and emergency stop buttons shall be distinguished as follows:

• Stop buttons shall be red

• Emergency stop buttons shall be red and mushroom-shaped

All panel and remote-control pushbuttons shall be:

• Sized with big buttons type

• Made of durable plastic
• Resistant to chemicals, oil and grease
• Operable by an employee wearing work gloves

2.4.2. Operator Controls

The equipment shall have the following minimum operator controls and control panel:

• A minimum of two (2) electronic multi-button joysticks for the hoist, bucket, boom, and
swing controls

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• A tilting/telescoping steering column for driving functions

• Hydraulic foot pedal for braking functions
• Travel speed regulated with electronic foot pedal control
• Forward/reverse selector
• And if necessary, a switch for gears selection

2.4.3. Engine, Controls, Instrumentation and Monitoring System

The equipment shall have the following minimum engine, controls, instrumentation and
monitoring system without limiting

to:

• Main Battery Disconnect Switch

• Air Cleaner Condition Indicator
• Electronic Monitor Indicates
• Low Battery Charge
• Lube Oil Pressure
• High Coolant Temperature
• Engine RPM
• Engine Hours

2.4.4. Hydraulic System Monitoring System

The equipment shall have the following minimum hydraulic system monitoring system, without
limiting to:

• Electronic monitor in cabin indicates low hydraulic fluid level

• High hydraulic fluid temperature
• System working pressure
• System pilot pressure

2.4.5. Safety Devices

The equipment shall be equipped with:

• An electronic back-up sound alarm

• A horn

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Filton, Bristol, UK

2.5. SOFTWARE

The equipment shall be supplied with a copy of the required software for its operation.

2.6. ACCESSORIES

The Supplier shall supply all following accessories with the equipment.

2.6.1. Special Tools for the Equipment

The equipment shall be supplied with a set of operating keys and spanners to allow the operator
to:

• Perform all necessary settings for a proper use of the equipment

• Install and uninstall all required tools and holders to do any machining operations
• Ensure all current maintenance activities

The Supplier shall provide for maintenance, inspection and troubleshooting:

• All test gauges
• All adjustment templates

2.6.2. Worker Protection

To eliminate risks at the source, all equipment's components presenting a hazard for the
operator, other employees or bystanders shall be protected as per the applicable OSHA safety
standards.

A safety device (e.g. lockout) shall be installed to prevent unintentional starting of the equipment
when the Client's operator is in the working area.

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Filton, Bristol, UK

2.6.3. Safety Identifications

All operating, manipulation, and potential equipment hazards shall be clearly identified by some
form of safety identification
(i.e., signs, labels, inscriptions) attached to or near the equipment as per ANSI/NEMA Z535.4.

The equipment rated load capacity markings shall be legible from the ground level and shall be
marked on a minimum of one
(1) side of the equipment.

All safety identifications shall be clearly visible to workers and nearby personnel.

2.6.4. Identification Plates

All Identification plates shall:

• Be attached in a location in plain sight on each major component.

• Be clearly marked, stamped, and corrosion-resistant.
• Include the following information as a minimum:
 Supplier's name
 Supplier's address
 Model and serial numbers
 Date of manufacture
 Load capacity
 Weight
 All data relevant to equipment operation and use

2.7. MATERIALS

The materials and components entering in the construction of the equipment shall be new,
unused and without defects. Special precautions shall be taken in assemblies with dissimilar
materials in contact to prevent galvanic corrosion.

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Filton, Bristol, UK

2.7.1. Fasteners

The fasteners shall be standards industrial grade components. Appropriate holes for rivets, bolts
and pins shall comply with Supplier's standards.

2.7.2. Flexible Hoses

All flexible hoses shall not be:

• Flexed to less than their rated minimum bending radius

• Installed or routed to expose them to temperatures above or below their rated
operating temperature ranges
• Subjected to any twisting, pulling, kinking, crushing or to abrasion

2.8. PAINT, DECALS AND FINISHES

Prior to painting, all rust, scale and grease shall be removed.

The paint types acceptable for the equipment are:

• Alkyd base
• Epoxy
• Enamel
• Polyurethane

The equipment paint color shall be the Supplier's standard paint colors:

• Two (2) coats of primer shall be applied to all surfaces except those that are otherwise
corrosion treated, finished or machined
• One (1) finish coat minimum, gloss finish, paint shall be applied

All metallic surfaces shall be treated to prevent corrosion.

No drilling, filing, welding or other work that could damage the coatings may be employed after
the final paint application. The Supplier shall supply touch up paint for minor handling damage

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of the equipment at the Client's site.

3. EXECUTION

The project execution is expected to be realized as described in the following sub-sections order.

3.1. PROJECT MANAGEMENT

After Receipt of Order (ARO), the Supplier shall provide his Project Schedule for review and
approval by client.

3.2. DESIGN

During the engineering design phase, the Supplier shall create all necessary documentation for
the equipment for review and approval by client or designated delegate:

• Drawings
• Calculations (if required)
• Material Documentation (e.g. BOM, cut sheet, MSDS, etc.)

The Supplier shall not start any manufacturing work until he receives the approval of client.

3.3. PURCHASING

Once the engineering design phase is completed, the Supplier shall start the purchasing of all
necessary materials to manufacture the equipment.

3.4. MANUFACTURING

Manufacturing shall conform to the Technical Specification and all Supplier's drawings
provided and approved. Weld metal spatter and all sharp edges shall be removed.
All manufacturing welding work performed by the Supplier shall be:

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Filton, Bristol, UK

• The work of certified welders

• Made in compliance with certified CWB and/or AWS procedures.

Field assembly and the equipment installation at Client's site shall be kept to the minimum and
shall be shown on the Supplier's drawings.

3.4.1. Inspection
At the Supplier's Shop, regular inspections shall be done as deemed required by client.

3.4.2. Factory Acceptance Test (FAT)

The equipment shall be subject to a final FAT carried by the Supplier with the presence of the
client or his Representative before shipment from the Supplier's Shop. The factory acceptance
tests shall include, without limiting to:

• Verify and ascertain that:

 All components have been factory tested
 Each system shall be operational prior to its shipment
• Submit the equipment to an operation test:
 No load
 With maximum load
 At minimum speed
 At maximum speed
• Validate through a routine test the complete control system and electrical system
• Measure electrical wiring isolation with mega-ohmmeter
• Measurement of components noise level
• Measurement of equipment's total weight

Any non-conformities, corrections required and open actions resulting from the FAT shall be
corrected by the Supplier and accepted by client prior to shipment.

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KMK Consulting Engineers Ltd

Filton, Bristol, UK

3.5. SHIPPING, HANDLING AND STORAGE

After Receipt of Order (ARO), the equipment shipping destination shall be confirmed by client.
The Supplier shall arrange the shipment to client depot at Rotterdam port in Europe.

3.6. INSTALLATION

After Receipt of Order (ARO), the Supplier shall:

• Provide a detailed list of the machinery (e.g. lifting equipment, handling equipment,
forklift, etc.), materials, tools and qualified labor recommended for the installation of
the equipment;
• Provide the installation instruction for his secondary structural components for review
and approval by client.

4. OPERATIONS AND MAINTENANCE

The equipment shall be built to minimize maintenance time, repair time and overall costs over its
life. For maintainability and component reliability, the equipment shall include:
• Local built-in test points
• Fault and status indicators

The equipment shall be maintained by client in relationship to the specified maintenance

program for each equipment system and component from the Supplier.

4.1. MANUALS

The Supplier shall provide as options the different manuals (e.g. in MS Word and PDF format) for
his equipment. If possible, one (1) complete manual can be supplied by the Supplier with the
following minimum sections:
• System Functional Description;
• Operation Instructions;

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Filton, Bristol, UK

• Maintenance Instructions, including:

• Proposed Preventive Maintenance Inspection Schedule, for example:
 Daily
 Weekly
 Monthly
 Annually

• Maintenance Instructions
• Components Installation Instructions
• Components Testing Instructions
• Cleaning Instructions
• Troubleshooting Instructions:
 Electrical Troubleshooting Guide
 Mechanical Troubleshooting Guide
 Troubleshooting Schematics
• Lowest Replaceable Units (LRU) (i.e. Spare Parts)

4.2. RECOMMENDED SPARE PARTS

The Supplier shall provide as an option his recommended spare parts (i.e. minimum quantity, unit
price, delivery time, etc.)

for the equipment for review by client:

• Spare Parts List

• Special Tools List
• Lubricating Oils List
• Consumables List

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KMK Consulting Engineers Ltd

Filton, Bristol, UK

5. WARRANTY AND AFTER WARRANTY SERVICES

The Supplier shall provide the following Warranty and After Warranty Services options in his bid
proposal.

5.1. WARRANTY

The Supplier's standard warranty shall extend over a minimum period of at least twelve {12)
months from approved date by client.

The minimum warranty against corrosion on all metallic components shall be five (5) years from
the commissioning date.

5.2. EXTENDED WARRANTY

The Supplier shall list as a separate optional line items in his Bid Proposal for extended warranty
options beyond the standard warranty included in his base Bid Proposal. The extended warranty
options shall include the:

• Components affected
• Terms
• Cost (e.g. this information can be expressed as a percentage (%) of equipment cost). At a
minimum, the extended warranty options shall be for 36 months after FAT.

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