PARADIP PORT TRUST

OFFICE OF SUPERINTENDING ENGINEER,

IRON ORE HANDLING PLANT

ELECTRICAL & MECHANICAL DEPARTMENT

PARADIP PORT TRUST

TENDER DOCUMENT FOR

Design, Manufacture, Supply, Erection & Commissioning of one 3200 TPH
slewing, luffing Bucket Wheel Reclaimer for
Iron Ore Handling Plant (IOHP)

VOLUME – I

SALE OF TENDER DOCUMENT : 07.07.06 TO 28.07.06

DATE OF PREBID MEETING : 01.08.06
LAST DATE OF SUBMISSION OF BIDS : 08.08.06 at 13.00 Hrs
 PARADIP PORT TRUST
ELECTRICAL & MECHANICAL DEPARTMENT

FILE NO.: EM/IOHP/ESTG-11/06(VOL-II)

TCN NO.: EM/IOHP-24/06

1. Name of the work : Design, Manufacture, Supply, Erection

Commissioning of one 3200 TPH slewing,
luffing Bucket Wheel Reclaimer for
Iron Ore Handling Plant (IOHP)

2. Cost of Tender Paper : Rs. 10,000.00

3. Demand Draft Details :

4. Purchased by / Down Loaded by : M/s.________________________

________________________

________________________

PLEASE NOTE THAT THIS TENDER DOCUMENT IS NOT TRANSFERABLE AND IS

TO BE SUBMITTED ONLY BY THE BIDDER TO WHOM IT WAS SOLD or THE
BIDDER WHO HAS DOWN LOADED THE DOCUMENT.

Superintending Engineer,
Iron Ore Handling Plant
Paradip Port Trust
 PARADIP PORT TRUST
ELECTRICAL & MECHANICAL DEPARTMENT
IRON ORE HANDLING PLANT

File No.: EM/IOHP/ESTG-11/06 (VOL-II)/1004 Date: 30.06.06

TENDER CALL NOTICE (TCN) No.: EM/IOHP-24/06

SECTION – I
TENDER CALL NOTICE

1. The Board of Trustees, Paradip Port Trust (the Purchaser) invites sealed bids
from eligible bidders for “Design, Manufacture, Supply, Erection &
commissioning of one 3200 TPH slewing luffing bucket wheel Reclaimer
for Iron Ore Handling Plant (IOHP)” at Paradip.

2. Bidders with the following eligibility criteria only may participate.

I.
A. The Bidder must have Designed, Manufactured, Supplied,
Erected and Commissioned Reclaimer/Stacker-cum-Reclaimer for
handling Iron Ore or coal in the last 7 (seven) years
a) At least one no. of 3200 TPH or more capacity
OR
b) At least two nos of 1500 TPH or more capacity each.
B. The equipment must have operated satisfactorily for a
period of 2 (two) years.

II. The Bidders must have an average annual turnover of

minimum of Rs.5.0 Crore (Rupees Five Crore) only or more during the last
3 (three) financial years.

3. Interested eligible bidders may obtain further information from and inspect
and inquire the bidding documents at the office of the Superintending
Engineer, Iron Ore Handling Plant at the following address.

The Superintending Engineer,

Iron ore Handling Plant,
Paradip Port Trust, Dist:- Jagatsinghpur, Orissa, Pin;- 754142
India
Tel:- 06722-222735
Fax:- 06722-222034
 4. A complete set of bid documents may be purchased by interested eligible
bidders on submission of a written application to the purchaser at the above
address and upon payment of a non-refundable fee of Rs. 10,000/- (Rupees
Ten Thousand) only payable by crossed demand draft in favour of Financial
Advisor and Chief Accounts officer, Paradip Port Trust and payable at Paradip
on any working day from 07.07.06 to 28.07.06.

5. Alternatively, the tender documents may be down-loaded from our web site
(i.e.,www.paradipport.gov.in) and from Tender Portal (http://tenders.gov.in) and
submit along with non-refundable demand draft as mentioned above in a separate
envelope subscribed as “Cost of Tender Document”.

6. All bids must be accompanied by a Earnest Money Deposit of Rs.15 Lakhs

(Rupees Fifteen Lakhs) only and must be delivered to the office of the
Superintending Engineer, IOHP Division on or before 1300 Hrs. dtd.
08.08.2006.

7. There will be site visit and pre-bid meeting on 01.08.2006 at Paradip.

8. The bid will be opened in the presence of bidders representatives who choose to
attend at 1600 Hrs on 08.08.06 at the office of the Superintending Engineer,
IOHP, Paradip Port Trust.

9. Paradip Port Trust reserves the right to reject any or all the bids without
assigning any reason thereof.

Superintending Engineer,
Iron Ore Handling Plant
Paradip Port Trust
Copy forwarded to:
1. The PRO with a request to publish the TCN in the Port Gazette dt. 01.07.06.
2. The P. S. to Chairman / P. A. to Dy. Chairman / All HOD’s / Heads Of
Offices / Commandant, CISF / RAO / V.O., PPT
3. The Dy. Director, EDP Cell, PPT with a request to publish the tender
document in the PPT website w.e.f. 07.07.06 to 28.07.06.
4. Office Order Guard File / Notice Board.
 TENDER CALL NOTICE NO: EM/IOHP-24/2006

Paradip Port Trust invites sealed offers from eligible bidders for the work
“Design, Manufacture, Supply, Erection & commissioning of one 3200 TPH
slewing luffing bucket wheel Reclaimer for Iron Ore Handling Plant (IOHP)”

Sale of Tender Document : From Dt. 07.07.06 to Dt. 28.07.06.

Detailed tender document is available at the web site www.paradipport.gov.in /
(http://tenders.gov.in) and in the office of Superintending Engineer, Iron Ore
Handling Plant, E&M Department, Paradip Port Trust, Paradip – 754142 on payment
of Rs. 10,000/- (Rupees Ten Thousand) only (Non-Refundable).
Last date of submission of tender is Dt. 08.08.06, 1300 hrs.
EMD : Rs.15,00,000.00 (Rupees Fifteen Lakhs) only
 INSTRUCTIONS TO BIDDERS ( ITB )
INDEX
Clause No. Description
1.0 Scope of Bid
2.0 Eligible Bidders
3.0 E M D ( Bid Security )
4.0 Bid Price & Bid Validity
5.0 Contents of the Tender Document
6.0 Submission of Bids
7.0 Bid Opening
8.0 Bid Evaluation
9.0 Award of Contract
10.0 Initial Security Deposit
11.0 Performance Security Deposit
12.0 Techno Commercial Information & Eligibility
13.0 Taxes & Duties
14.0 Site Conditions
15.0 Equipment Operation & Maintenance
16.0 Supply of Goods
16 a Goods & Services
16 b Goods Shall Confirm to Standard
16 c Supplier to Indemnify against III Party Claim
16 d Guarented Performance
16 e Packing of the Goods
16 f Delivery of Goods
16 g Insurance
16 h Transportation
16 i Incidental Services
16 j Prices to be Agreed in Advance
16 k Spare Parts
16 l Break-up of Prices
17.0 Health, Safety & Environment
18.0 Accomodation, Transport & Medical Facilities
19.0 Port Trust Rules
20.0 Bribes
21.0 Bank Guarantee

SECTION – II

INSTRUCTIONS TO BIDDERS (I. T.B.)

1.0 SCOPE OF BID:
Paradip Port Trust, the Purchaser, invites sealed offers from eligible
bidders for the work as specified in the Tender Call Notice.(TCN).
2.0 ELIGIBLE BIDDERS:
The bidder must satisfy all the eligibility criteria as specified in the Tender
Call Notice (TCN), fill up the data sheet at Appendix – III of the tender document
and enclose all supporting documents duly signed by the bidder. It may please
be noted that only work order or supply order shall not be accepted unless
there is documentary evidence to support the satisfactory execution of the
work order or supply order.
The bidders may please note that submission of forged / fraudulent /
illegible copies of documents and/or wrong information may result in
disqualification of the bidder to participate in any tender of Electrical &
Mechanical Department and/or Paradip Port Trust for a period of six months to
two years and/or forfeiture of the EMD or Security Deposit. The bidder shall not
be permitted to purchase the tender paper in future if he fails to participate in
tender in three (3) occasions after purchasing the Tender Document.

3.0 EMD (BID SECURITY):

The bidder shall deposit an amount as specified in the Tender Call Notice
in shape of Demand Draft of a nationalised bank drawn in favour of FA & CAO,
Paradip Port Trust. Bids not accompanied by EMD may be rejected. The EMD of
unsuccessful bidder will be returned promptly after deciding the tender for which,
the bidder shall submit pre-receipted bills in duplicate duly stamped. The EMD of
the successful bidder shall be returned after the bidder furnishes security
deposit. The EMD may be forfeited in the following cases:

a) If the bidder withdraws his bid during the period of bid

validity.
b) In the case of successful bidder, if he fails to sign the
agreement and/or fails to furnish the required Security
Deposit and/or does not agree to carry out the work as per
the work order.
c) In case of submission of fraudulent documents and/or wrong
information.
However, EMD may not be applicable in the event of emergency
works being taken up on short/spot tender basis and also in case of
invitation of tenders for any rate contract unless otherwise specified.

4.0 BID PRICE & BID VALIDITY:

The bid price is to be indicated in the “Bill of Quantity” and shall be firm and
valid for 90 days from the last date of submission of the “Price Bid”. Conditional
price offer may be rejected. The bid price must include all kinds of taxes, duties,
 all types of cess, insurance, transportation up to Paradip Port Trust and all other
incidental costs, fees, cost of staging, cost of tools & tackles and all such
requirements necessary for satisfactory execution of the work under this contract
and shall be valid for the contract period till successful completion and
acceptance of the works and/or services. No escalation shall be admissible
during the execution of the contract except for variation in taxes and duties etc.
due to change in regulation during the period starting from 15 days prior to the
last date of submission of the bids and up to the original date of completion of
the work. In case of changes in regulation during the extension period, no
escalation shall be admissible if the extension is due to the fault of the Supplier.

5.0 CONTENTS OF THE TENDER DOCUMENT:

VOL-I
a) Tender Call Notice (TCN)
b) Instruction to Tenderers (IT)
c) General Conditions of Contract (GCC)
d) Special Conditions of Contract (SCC)
e) Schedule of Requirements
f) Bill of Quantity (BOQ)
g) Bill entry format – Appendix - I.
h) Techno-commercial information - Appendix-II
i) Eligibility Information - Appendix-III.
j) BG Format for EMD – Appendix-IV.
k) BG Format for ISD – Appendix-V.
l) BG Format for warranty performance deposit – Appendix-VI.
m) BG Format for Advance Payment – Appendix – VII.
n) Corporate Guarantee Format – Appendix –VIII.
o) Performa Certificate of Commissioning of Goods– Appendix –IX
p) Letter of Intent & Work Order Format– Appendix –X
VOL-II

TECHNICAL SPECIFICATIONS
VOL-III

SITE HEALTH AND SAFETY MANNUAL

6.0 SUBMISSION OF BIDS:

All the pages of the Tender documents including the supporting documents
enclosed by the bidder shall be duly signed by the bidder. Overwriting and/or
erasures may result in disqualification of the offer. All the corrections must be
initialed by the bidder.
 If the bid document has been down loaded from the web site of PPT, the
bidder must enclose a Demand Draft drawn in favor of FA&CAO, Paradip Port
Trust payable at Paradip towards the cost of the Tender document as mentioned
in the TCN and Special Conditions of Contract (SCC). The sealed envelope must
be superscripted with the name of the works and the TCN number.

The completed Bid shall be submitted as per the instructions specified in the
Tender Call Notice. Late receipt of bids shall not be accepted. Bids may be
submitted by registered post, but PPT shall not be responsible for any postal
delay. Hand delivery of the bid shall not be allowed. Bids must be put in the
specified Tender Box before the box is closed. Any attempt to tamper with the
Tender Box by any bidder in any manner may disqualify the bidder for
participating in any tender of Electrical & Mechanical Department /PPT for a
period of six months to two years and/or forfeiture of EMD, if any.

The bidder shall not attempt to influence the bidding process in any manner
till the completion of the bid evaluation and award of the work. Any such attempt
by the bidder to influence the bidding process may result in dis-qualification of
the bidder to participate in any tender of Paradip Port Trust for a period of 6
months to 2 years and/or forfeiture of the EMD.

7.0 BID OPENING:

The bids shall be opened as per the schedule specified in the Tender Call
Notice. Where the Price Bid is submitted in a separate envelope, the date of
opening of the Price Bid shall be fixed later. The bidder shall produce the
originals of the documents submitted by him in support of his eligibility for
verification on the date of technical bid opening and the originals shall be
returned to the bidder after verification on the same day. Failure to produce the
originals for verification may result in rejection of the bid. The bidder must depute
it’s authorized representative conversant with the tender requirements as well as
the bidder’s offer so that the bidder’s representative can clarify the queries, if
any, on his offer . The deviation statement submitted by the bidder in the
prescribed format shall be read out to all the bidders present at the time of
bid opening.

8.0 BID EVALUATION:

(a) The price bids of only those eligible bidders who satisfy all the technical
and commercial conditions as mentioned in the tender document shall be
evaluated. The financial evaluation shall be made on the basis of the total
price as indicated by the bidder in the “Bill of Quantity”, unless otherwise
specified. Conditional offers may not be considered. In case of single
cover system, the price offers of bidders who do not satisfy the eligibility
criteria or do not meet the technical & commercial requirements as
specified in the tender document may be declared as “invalid offer” and
may not be taken into consideration.
In case of “Rate Contract”, the offers submitted by the eligible
bidders only shall be considered and the lowest offer for individual
items shall be considered for acceptance. The bidders who accept
all the item-wise lowest rates shall be permitted to enter into rate
contract with PPT.

In a situation where a bidder has quoted the lowest rate for an item
which is abnormally low and not acceptable to other bidders, PPT
reserves the right to award that item in favor of the lowest bidder
and in the event the bidder does not perform as per the contract in
carrying out the work for that particular item, PPT may de-list the
bidder from the rate contract and disqualify the bidder from
participating in any tender of PPT for a period of six months to two
years. It is therefore strongly advised that the bidder must assess
the exact nature of the work, the prevailing conditions and quote a
realistic offer for each individual item in a responsible manner. Such
failure by any bidder may also result in forfeiture of his security
deposit, if any. Also, PPT reserves the right to delete any item from
the Bill of Quantity in case the rate quoted by the bidders is
abnormally high or low.

(b) To assist in the examination, evaluation and comparison of bids

the purchaser may, at its discretion, ask the bidder for a
clarification of its bid. The request for clarification and the
response shall be in writing and no change in the price or
substance of the bid shall be sought, offered or permitted.

(c) The Purchaser reserves the right to invite all the bidders for
a clarification of their technical bids jointly and may make
alterations in the scope of the bid in shape of addendum in
order to bring all the eligible bidders to a common platform.
In such cases where there is alterations in the technical
scope, all the bidders shall be given opportunity to submit
supplementary price bid with respect to the item in which
alterations have been made. The price quoted in the
supplementary price bid shall either be added to or
subtracted from the original price quoted for that particular
item where alterations have been made. Both the original as
well as the supplementary bid shall be evaluated jointly.
9.0AWARD OF CONTRACT:
9.1 The contract shall be awarded in favour of the successful bidder.
9.2 First, a Letter of Intent (LoI) shall be issued intimating the successful
bidder (hereinafter called the “Supplier”) to furnish the Security Deposit
and fulfil other formalities like furnishing non-judicial stamp papers worth
Rs. 5/- in three sheets for drawal of agreement etc.
9.3 After completion of all other formalities, the work order shall be issued.
9.4 The Supplier shall be provided with a form of Agreement along with the
acceptance of his Bid for execution of the Agreement. The Agreement
shall have to be signed within 15 (Fifteen) days of issue of Letter of Intent.
9.5 The Board of Trustees of Paradip Port Trust is not bound to accept the
financially lowest bidder as the successful bidder. Paradip Port Trust
reserves the right to split the work and award in favor of two or more
bidders.
9.6 In case of “Rate Contract”, the work shall be awarded in favor of those
bidders who have entered into “Rate Contract” with PPT and the award of
work shall be in turn. As far as practicable, the bidders shall be given
equal opportunities to carry out the works under the “Rate Contract”.
However, PPT is not bound to award work in favor of any or all the bidders
who have signed the “Rate Contract”. The work shall be awarded only
when the need arises, and when awarded, approved rate of the “Rate
Contract” shall apply. For deciding the panel of the Suppliers entering in to
the “Rate Contract”, the total price quoted in the “ Bill of Quantity “ shall be
the criterion, i.e. the Bidder whose total price quoted in the “Bill of
Quantity” is the lowest shall be placed at Sl. No.1 in the panel and so on.
9.7 The Supplier who enters in to the “Rate Contract” shall maintain a Register
and record the details of the work orders issued in his favor under the
“Rate Contract” like the Work Order No. / Date & value, date of
Commencement & Completion of the Work and produce the same to the
EIC on request.

10.0 INITIAL SECURITY DEPOSIT (I.S.D.):

Unless otherwise specified, within 15 (Fifteen) days of receipt of Letter of

Intent, the Supplier shall furnish 5 % of the total Contract price in form of Bank
Guarantee drawn in favour of FA & CAO, PPT. The Security Deposit (I.S.D.)
shall be retained by the Port Trust till successful completion of the contract. The
Initial Security Deposit may be forfeited in the event of failure on the part of the
Supplier to fulfill the contractual obligations in all respect. The I. S. D. shall be
returned within 30 days after successful completion and acceptance of the work .
11.0 PERFORMANCE SECURITY DEPOSIT:
Performance security deposit shall be retained from the bills of the Supplier @
5% of the bill amount, unless otherwise specified. The performance security
amount shall be released after successful completion of the warranty period. The
supplier may furnish BG of equivalent amount in which case 100% payment shall
be released.

In case of “Rate Contract”, either a fixed Security Deposit shall be taken

from the bidders who have entered into “Rate Contract” with PPT or 5 % of the
bill amount shall be deducted towards Security Deposit. The mode of Security
Deposit shall be specified in the special conditions of contract. In the event it is
not specified, then 5 % deduction from the bill shall apply.

12.0 TECHNO-COMMERCIAL INFORMATION AND ELIGIBILITY

REQUIREMENTS:
All the items in the Techno-commercial information and Eligibility
Requirement sheets shall be duly filled in by the bidder and submitted with all
documentary evidences wherever applicable. Incomplete sheets may result in
rejection of the offer. The supporting documents must be signed by the bidder.
The Bidder must correctly fill up the information required in these sheets as the
evaluation shall be made on the basis of the data given in these sheets along
with documentary evidences and any deficiency may result in return of the price
bid un-opened or rejection of the price bid. The deviation statement must be
filled up by the bidder. In case the bidder accepts all the commercial as
well as technical requirements as laid down in the tender document, then
“NIL” statement should be mentioned in the deviation statement.

13.0 TAXES AND DUTIES:

It shall be entirely the responsibility of the bidder to include all the taxes,
cess, fees, stamp duties and all other statutory services like excise duties, octroi,
insurance & transport of goods and other incidental charges in the “Bill of
Quantity”. However, price adjustment shall be allowed only in the event of
changes in the legislation during the period commencing from 15 days prior to
the last date of submission of bids and up to the original date of completion of
the works under the contract in all respects and only if such change has effect on
the quoted price. The Supplier shall promptly notify PPT about such changes in
regulation with all supporting documents and its claim statement with proper
justification. Price adjustment shall not be allowed after the original date of
completion. However, Price Adjustments due to changes in the regulation during
the extended period shall be allowed only if the Purchaser is solely responsible
for the subject extension.
14.0 SITE CONDITIONS:
The bidder, at his own risk and cost, shall assess the site condition and
the exact nature of the work prior to submission of bids. No additional cost on
account of site conditions and nature of work shall be permissible at a later
stage.

15.0 EQUIPMENT OPERATION AND MAINTENANCE:

Where the Contract obligations include operation and / or maintenance of
any machines/equipment, it shall be the responsibility of the Supplier to engage
experienced and competent operators & technicians who can diligently deliver
the intended services. Engagement of incompetent workmen for such type of
work shall be treated as default on the part of the Supplier and may lead to
termination of contract. The Engineer Incharge shall have the right to
examine/test the competency of such workmen and if found
unsuitable/unacceptable for the purpose, it shall be the responsibility of the
Supplier to arrange for suitable replacement within a specific period as
mentioned in the notice to this effect.

16.0 SUPPLY OF GOODS:

(a) Goods and Services: Where the Contract obligations include supply of goods,
the goods shall mean all of the equipment, machinery and / or other materials
such as design, drawing, manuals and all such documents which the Supplier is
required to supply to the purchaser under the contract. The services shall mean
services ancillary to the supply of the goods such as transportation and
insurance, installation, commissioning, technical assistance during installation
and commissioning, training and other similar obligations of the Supplier and any
other incidental services covered under the contract.
(b) Goods shall Confirm to Standard: The goods supplied under the contract shall
conform to the standard mentioned in the technical specification. When no
applicable standard is mentioned, it shall conform to the authoritative and latest
standard appropriate to the goods.
(c) Supplier to Indemnify against third Party Claim: The Supplier shall indemnify
the purchaser against all third party claims of infringement of patent, trademark
or industrial design rights arising from the use of the goods or any part thereof by
the purchaser.
(d) Guaranted Performance: In case of supply of goods, the bidder shall state the
guaranteed performance or efficiency in response to the technical specification.
Equipment / goods having performance / productivity less than that specified in
the technical specification may be rejected.
(e) Packing of the Goods: The Supplier shall provide such packing of the goods as
is required to prevent their damage or deterioration during transit to their final
destination as indicated in the contract. The packing shall be sufficient to
 withstand, without limitation, rough handling during transit and exposure to
extreme temperatures, salt and precipitation during transit and open storage.
Packing case size and weights shall take into consideration, where appropriate,
the remoteness of the goods, final destination and the absence of heavy
handling facilities at all points in the transit.
The packing, marking and the documentation within and outside the packages
shall comply strictly with such special requirements as shall be expressly
provided for in the contract or any subsequent instruction ordered by the
purchaser pursuant to Change Order: Clause 2.0 of SECTION-III (General
Conditions of Contract).
(f) Delivery of the Goods: Delivery of the goods shall be made by the Supplier in
accordance with the terms specified by the purchaser in the contract. The
Supplier shall provide 3 sets of instruction manuals for operation and
maintenance of the equipment and also 3 sets of all technical drawings and
documents which shall be necessary during the operation and maintenance.
(g) Insurance: The goods supplied under the contract shall be fully insured by the
Supplier at his own cost against loss or damage incidental to
manufacture or acquisition, transportation, storage and delivery in the
manner specified in the contract.
(h) Transportation: The Supplier shall be responsible to deliver the goods at its
final destination as specified in the contract.
(i) Incidental Services: Incidental services shall inter-alia include the following:
• Performance and supervision of on-site assembly and/ or start-off of the supplied
goods;
• Performance or supervision or maintenance and / or repair of the supplied goods
for a period of time agreed by the parties, provided that this service shall not
relieve the Supplier of any warranty obligations under this contract.
• Conduct of training for the purchaser’s personnel, at the Supplier’s plant and / or
on site in assembly, start-off, operation, maintenance and/or repair of the
supplied goods.
(j) Prices to be Agreed in Advance: Prices charged by the Supplier for the above
incidental services, if not included in the contract price for the goods, shall be
agreed upon in advance by the parties and shall not exceed the prevailing rates
charged to other parties by the Supplier for similar services.
(k) Spare parts: The Supplier may be required to provide materials pertaining to
spare parts manufactured or distributed by the Supplier. Purchaser may elect to
purchase spare parts from the Supplier provided that this election shall not
relieve the Supplier of any warranty obligations under the contract. In the event
of termination of production of spare parts, the Supplier shall notify the purchaser
about the termination sufficiently in advance to permit the purchaser to procure
the needed requirements. The Supplier shall, following such termination, furnish
to the purchaser, at no cost, the blue prints, drawings and specifications of the
spare parts if and when requested.
 (l) Break-up of Price: In case of supply of goods, the Supplier shall furnish a
break-up of the landing cost of the goods clearly indicating the base cost, various taxes
and duties including RD cess – if any, transport, insurance and other incidental for
reference & record of the purchaser. However, the total landing cost of the goods
indicated in the Bill of Quantity shall be considered for financial evaluation.

17. HEALTH, SAFETY AND ENVIRONMENT:

The Supplier shall be solely responsible for carrying out the works having the
highest regards for the safety of workers, persons at or in the vicinity of the site,
the works and the property of the third parties. The Supplier shall take all
necessary precautions to protect the environment and the Supplier shall also
ensure that all the statutory regulations issued by any Government bodies or any
statutory bodies in connection with environment protection are complied
promptly.
18. ACCOMODATION, TRANSPORT AND MEDICAL FACILITY:
The Supplier, at his own cost, shall arrange for the accommodation,
transport, gate pass and medical treatment of his staff.

19. PORT TRUST RULES:

The Supplier shall observe all the conservancy rules relating to the Harbor and
shall comply with all the working rules of Paradip Port Trust as issued from
time to time.

20. BRIBES:

The Supplier shall refrain from giving or offering to give to any person any bribe,
gift, gratuity or commission to influence the contract in any manner. Any such
attempt by the Supplier may result in termination of the Contract and/or forfeiture
of the initial security deposit, if any.

21. BANK GUARENTEE:

The Supplier shall ensure that the Bank Guarantee shall bear the Tender Call
Notice No. as the reference number and the reference number must be used in
all the correspondences related to the Bank Guarantee to avoid delay.

***********************************

GENERAL CONDITIONS OF CONTRACT ( GCC )

INDEX
Clause No Description
1.0 Use of Contract Document
2.0 Change Orders
3.0 Sub-Contracts
4.0 Responsibility of the Supplier
4.1 Supplier to Pay all Taxes
4.2 Supplier to Act with due diligence
4.3 Supplier to Protect interst of Purchaser
4.4 Supplier to follow Metric System
4.5 Design to Perform intended functions
4.6 Supplier to Re-perform
4.7 Supplier’s Responsibility for Total Project Management
4.8 Supplier to plan timely Completion
4.9 Supplier to utilize Economical Concepts
4.10 Supplier to co-ordinate with Govt. Agencies
4.11 Care of Works
4.12 Opportunity for Other Suppliers
4.13 Site free from Obstruction
4.14 Site Account of Materials
5.0 Execution and Timely Completion
6.0 Liquidated Damage
7.0 Tests and Inspection
8.0 Acceptance
9.0 Warranty
10.0 Payment
11.0 Extension in Supplier’s Performance
12.0 Termination for Default
13.0 Resolution of Dispute
14.0 Force Majeur
15.0 Insurance
16.0 Compliance with Statute
17.0 Indemnification
18.0 Deduction
19.0 Variations in Conditions
20.0 Variation in Price
21.0 Supply of Materials & Equipment
22.0 Idle Charges
23.0 Personal Protective Equipment
24.0 Conduct
25.0 Accident
26.0 Watch and Ward
27.0 Engineer – in – Charge
28.0 Undertaking by Supplier
 SECTION – III

GENERAL CONDITIONS OF CONTRACT(GCC)

1.0 USE OF CONTRACT DOCUMENT:

The Supplier shall not, without prior consent, make use of any document
except for the purpose of performing this contract.

2.0 CHANGE ORDERS:

At any time during the execution of the contract, by a written notice to the
Supplier, changes may be made in the general scope of contract.

The Engineer Incharge (EIC), with due approval of competent authority,

may make any changes in the quality and/or quantity of the work or any part
thereof that may, in his opinion, be necessary and for that purpose the Engineer
Incharge shall have the power to order the Supplier to do and the Supplier shall
do any of the following:
a) Increase or decrease or split the quantity of work included in the contract,
b) Omit any such work,
c) Change the character, quality or kind of any such work,
d) Change the dimensions of any such work,
e) Execute additional work of any kind necessary for completion of the work
under the contract,
and no such change shall in any way vitiate or invalidate the contract but the
cost, if any, arising out of all such changes shall be taken into account in
ascertaining the total amount of the contract price. Where the rate is
available in the contract and the same is applicable to the additional work,
in the opinion of the EIC, the cost of the additional work shall be
determined as per this available rate. But, if the rate for additional work is
not available in the contract, the same shall be determined by the EIC
taking into account the market rate and labour cost at the site for similar
works and shall be final.

3.0 SUBCONTRACTS:
The Supplier shall not sub-contract all or any part of this contract without
getting PPT’s approval in writing and the Supplier shall guarantee that the sub-
Supplier, for any part of the work under this contract will comply fully with the
terms and conditions of the contract.
4.0 RESPONSIBILITIES OF THE SUPPLIER

4.1 Supplier to Pay all Taxes: The supplier shall pay all taxes, duties , fees, levies , RD
Cess and all other imposition imposed by or under any authority in India as well as
abroad in respect of all services, equipment, materials, goods and all other supplies.

4.2 Supplier to act with due diligence: The supplier shall carry out the obligations
under the contract with due diligence and efficiency and in conformity with sound
engineering, administrative and financial practices.

4.3 Supplier to Protect the interests of Purchaser: The supplier shall act at all times
so as to protect the interests of the purchaser and will take reasonable steps to keep
all the expenses to a minimum consistent with sound economic and engineering
practices.

4.4 Supplier to follow Metric System: The supplier shall prepare all specifications and
design using the metric systems incorporating the current design criteria.

4.5 Design to perform Intended function: The supplier shall undertake that the design
will be suitable to achieve the objectives of the project and will perform the intended
function for which it is designed.

4.6 Supplier to re-perform: The supplier shall, at its own cost and expense , upon
request of the purchaser, re-perform the services in the event of supplier’s failure to
exercise the skill and care required under sound engineering, administrative and
financial practices.

4.7 Supplier ‘s Responsibility for Total Project Management: The supplier’s

responsibility shall, inter alia , include total project management including detailed
designs , drawings, specifications, construction, supervision, testing and
commissioning of the project.

4.8 Supplier to Plan Timely Completion: The supplier shall plan the construction and
procurement programme properly so as to achieve economical and timely
completion of the project.

4.9 Supplier to utilize economical Concepts: The supplier shall at all times utilize the
most economical, effective and widely accepted engineering concepts and design
standards consistent with the project objectives.

4.10 Supplier to co-ordinate with Govt. Agencies: The supplier shall consult and co-
oordinate with the concerned government agencies/local authorities especially
relating to the construction and/or other associated works.

4.11 Supplier Responsible for Care of Works: The supplier shall take full responsibility
for the care of the works and materials and plant from the commencement date until
the date of issue of the taking over certificate for the whole of the works when the
responsibility of the said care shall pass to the purchaser.
4.12 Opportunity to Other Suppliers: The supplier shall, in accordance with the
requirements of the engineer afford all reasonable opportunities to other Suppliers/
suppliers employed by the purchaser for carrying out their work. This opportunities
shall also be extended to the workmen of the purchaser or the workmen of any duly
constituted authorities who may be employed in the execution on or near the site of
any work not included in the contract or of any contract which the purchaser may
enter into in connection with or ancillary to the works. Pursuant to the above, the
supplier shall on the written request of the engineer:-

a) Make available to any such other supplier or to the purchaser or any such
authority, any roads or ways for the maintenance of which the supplier is
responsible or
b) Permit the use of any such temporary works or supplier’s equipment on the
site or
c) Provide any other services of what so ever nature.

For providing the above, if requested by the Supplier, the engineer shall
determine a reasonable addition to the contract price and shall notify the supplier
accordingly.

4.13 Supplier to keep site free from Obstruction: During execution of work the supplier
shall keep the site reasonably free from all unnecessary obstructions and shall
store or dispose any supplier’s equipment and surplus materials and clear
away and remove from the site any wreckage , rubbish or temporary works no
longer required for the work.

4.14 Supplier to maintain Site Account of Materials: The supplier shall maintain site
account of materials clearly indicating relevant information such as description of
the material, source, date of delivery at site, date of consumption at site. The
supplier shall forward a copy of monthly site account of materials to the Engineer in
Charge at the end of every month. On completion of the work under the contract,
the Supplier shall submit to the Engineer in Charge a copy of the site account of the
materials from the date of commencement to completion of the work in all respect.

5.0 EXECUTION AND TIME OF COMPLETION:

5.1 The work must be executed diligently to the full satisfaction of the Engineer
Incharge, strictly observing punctuality and discipline.

5.2 The Supplier shall plan the work in consultation with the designated Engineer
Incharge so that there is least interruption in operation of the Port. In case the
work has to be stopped intermittently for the aforementioned reasons or any
other important activity of the Port, the Supplier shall not claim idle charges.

5.3 The work shall be completed in all respects within the time schedule as
mentioned in the Tender Call Notice or as specified in the LoI / Work
Order.
5.4 The Supplier shall commence the work in time, ensure the progress of the
work, till completion in all respects, as per the agreed schedule failing which it shall
 be considered as a failure on part of Supplier to discharge it’s obligations under
the Contract.

6.0 LIQUIDATED DAMAGE: (L. D.)

Unless otherwise specified, in case of delay in completing the work,
liquidated damage shall be charged to the Supplier at the rate of 1.0% of the
contract value for a delay of one week or part thereof subject to a maximum of
10 % of the contract value if the original execution period is 90 days or more.
Where the original execution period is less than 90 days, liquidated damage
shall be charged to the Supplier at the rate of 0.5% of the contract price for a
delay of one day or part thereof subject to a maximum of 10% of the contract
value. Where the liquidated damage amount exceeds the maximum limit, the
Purchaser reserves the right to terminate the contract and forfeit the Security
Deposit. The L.D. cost shall be recovered from the bills of the Supplier. Where
any deduction clause is provided, the deduction on account of defaults shall be
evaluated independently and recovered from the bills.

7.0 TESTS & INSPECTIONS:

7.1 Purchaser’s Right to Inspect: The Board or its representative shall have the
right to inspect the work being carried out in this contract and to test the goods or
services to ascertain their conformity to the specifications. The Board shall notify
the Supplier, in writing, of the identity of any representative retained for this
purpose. However, the Engineer Incharge shall have the right to test and inspect
the work as a whole.

7.2 Supplier to Assist the Inspector: The inspections and the tests may be
conducted in the premises of the Supplier during the work in progress and at the
point of delivery. All reasonable facilities and assistance, including access to
drawings and production date, shall be furnished to the inspectors by the
Supplier.

7.3 Purchaser’s Right to Reject: If any inspected or tested goods and/or services fail
to conform to the specifications, the Board may reject them, and the Supplier
shall either replace them or make all necessary alterations to meet the
requirements of the specifications, free of cost to the Board.

7.4 Purchaser’s Right to Reject at Site : The Board’s right to inspect, test, and where
necessary, reject the goods and/or services after arrival at the site of installation,
shall in no way be limited or waived by reason of the goods or services having
been previously inspected, tested and passed by the Board or its representative
prior to the despatch of goods.
7.5 Purchaser’s Right to Verify the Authenticity: The Board may conduct inspection
to ascertain the authenticity of the technical offers made by the Supplier. In the
event of any document submitted by the Supplier or any information provided by
the bidder found, during the execution of the contract, to be fraudulent or forged
or false, the contract may be terminated and/or the Supplier may be debarred
from participating in any tender of Electrical & Mechanical Department for a
period of six (6) months to two (2) years and the EMD and/or Security Deposit
may be forfeited.

7.6 Nothing in this Clause 6.0 shall in any way release the Supplier of any warranty or
other obligations under this contract.

8.0 ACCEPTANCE:
Upon completion of work under this contract, the Board may accept the
works and/or services after installation, if defects or shortcomings are not
considered essential and, the Supplier agrees to make good the deficiencies in
confirmation with this contract. No work shall be accepted before the Supplier
clears the site of scraps, unused materials, work shed, equipment and all such
materials which were used for execution of the work and not required any more
at the work site. Also, the Supplier has to submit all the documents and final “as
built ” drawings as per the contract agreement without which no work shall be
treated as complete.

9.0 WARRANTY:
9.1 The warranty period shall be valid up to six / twelve months (6 months for repairs
and 12 months for new works including supplied items) with effect from the date
of acceptance of the work and/or services, unless otherwise specified in the
scope of work / Special Conditions of Contract (SCC).

9.2 The Supplier shall warrant the Board that the goods and services under this contract
will comply strictly with the contract, shall be first class in every particular case
and, shall be free from defects. The Supplier shall further warrant the Board that
all materials, equipment and the supplies furnished by him will be new and fit for
their intended purposes.

9.3 The Board shall promptly notify the Supplier in writing of any claim arising under this
Warranty. Upon receipt of such notice, the Supplier shall promptly repair or
replace the defective goods and/or services at no cost to the Board.

9.4 If the Supplier, having been notified, fails to remedy the defects in accordance with
the contract, the Board may proceed to take such remedial action as may be
necessary, at the Supplier’s expense.
10.0 PAYMENT TERMS:
10.1 The Supplier shall submit pre-receipted bills in duplicate as specified in the Work
Order / Letter of Intent.

10.2 Completed Bill Entry Format issued by the Engineer In-charge and the warranty
certificate issued by the Supplier shall be attached to the bills.

10.3 Unless otherwise specified, 95 % of the contract price shall be released for
payment within 15 days of submission of bills completed in all respects and the
balance 5 % of the contract price shall be released within 30 days after
successful completion of the warranty period. The Supplier may submit Bank
Guarantee, valid up to 30 days after the warranty period, for the balance 5 % in
which case 100 % of the contract price shall be released for payment.

10.4 Payment shall be made for the actual quantity executed.

11.0 EXTENSIONS IN THE SUPPLIER’S PERFORMANCE:

The Supplier may claim extension of the time limits in case of:
(a) Changes ordered by the Board pursuant to Cl. 2.0 of this Section;
(b) Delay in supply of any materials or services which are to be
provided by the Board (Services by the Board shall be interpreted to
include all approvals as well as access to the site);
(c) Force Majeure;
(d) Delay in performance of work caused by orders issued by Board.
The Supplier shall submit the claim clearly indicating the justification for such
extension and with necessary documentary evidence.

12.0 TERMINATION FOR DEFAULT:

12.1 The Board may, without any prejudice to any other remedy for breach of
contract, by written notice of default sent to the Supplier, terminate the contract
in whole or in part:

(i) if the Supplier fails to execute the work within the period as
specified in the contract, or any extension granted by the Board;
(ii) if the Supplier fails to perform any other obligation under the
contract and if the Supplier does not cure, after receipt of a notice of
default, its failure within the time specified in the notice. The notice of
default shall specify the nature of default as well as the time within which
the default has to be cured by the Supplier.

12.2 In the event of Board’s termination of the contract in whole or in part, the Board
may execute the remaining work or procure goods similar to those undelivered
 by the Supplier, and the Supplier shall remain liable to the Board for any excess
cost for such works or goods and risks, if any.

12.3 The Board will pay the Supplier, for all the items that are completed and ready
for delivery, within 30 days after the Supplier’s receipt of notice of termination
and, cancel the remainder and pay the Supplier an agreed amount for partially
completed goods and for materials previously procured by the Supplier for the
purpose of the contract, together with a reasonable allowance for overhead and
profit. The payment shall be made only after all the afore-mentioned goods are
supplied to and accepted by Paradip Port Trust.

12.4 In case of termination of contract for default by the Supplier, the Board may not
permit the Supplier to participate in any of the tender of Port Trust for a period of
six (6) months to two (2) years from the date of termination.

12.5 In case of a Rate Contract, the Supplier may be de-listed and the Rate Contract
may be terminated by PPT if the performance of the Supplier is found to be
unsatisfactory.

12.6 The contract may be terminated by either party on mutual agreement by

giving written notice to the other, at least 30 days in advance and neither
party shall have any right of any claim on the other on account of such
termination.

13.0 RESOLUTION OF DISPUTE:

The Board and the Supplier shall make every effort to resolve amicably,
by direct informal negotiations, any disagreement or dispute arising between
them in connection with the contract. However, in case of failure of negotiation,
the matter shall be referred to the Chairman, PPT whose decision shall be final
and binding on both the parties. Neither party shall have the right to commence
Arbitration to resolve any dispute and all such disputes which could not be
settled shall be subjected to the jurisdiction of Courts at Jagatsinghpur. The
contract shall be governed by The Indian Contract Act, 1872.

14.0 FORCE MAJEURE:

14.1 In the event that the Supplier is delayed in performing its obligations in the
contract, and such delay is caused by force majeure including war, civil
resurrection, strikes (other than the strike solely by the Supplier’s men), fire,
flood, epidemics, earthquakes, extremely adverse climatic conditions, such
delay may be excused and the period of such delay may be added to the time of
performance of the obligations without any addition to the contract price.
14.2 If a force majeure situation arises, the Supplier shall promptly notify the Board in
writing of such condition and the cause thereof, but not later than 7 days from it’s
occurrence. Unless otherwise directed by the Board in writing, the Supplier shall
continue to perform its obligations under the contract as far as reasonably
practicable. The Supplier shall demonstrate to the Board’s satisfaction that it has
used its best endeavours to avoid or overcome such causes of delay and the
parties will mutually agree upon remedies to mitigate or overcome such causes
of delay without having any right to any claim on account of such force majeure.

14.3 In any other situation, which is beyond the reasonable control of the Supplier in
the opinion of the Engineer Incharge, and the Supplier has promptly notified the
Board in writing about such situation, it may be considered as “Force Majeure”
situation.

15.0 INSURANCE:
15.1 All the men/women to be deployed by the Supplier for performing the contract
shall be insured against accidents/death, by the Supplier at his own cost. The
Supplier shall make arrangement to take the workers inside the prohibited area
at his own cost.

15.2 The Supplier shall indemnify the Board against all losses and claims in case of
death or injury to any person engaged by him during the execution of the work.

16.0 COMPLIANCE WITH STATUTES, REGULATIONS:

The Supplier shall comply in all respects, with all statutes and regulations
as may be necessary, including clearance from State/Central Govt. authorities,
labour enforcement and local authorities.

The Supplier shall, at all times during the continuance of the contract, so
far as it may be necessary, comply with all existing enactments including Central
and State legislation as well as any by-laws of any local authorities regarding
labour, particularly the Minimum wages Act, Factories Act, Workmen’s
Compensation Act, Employees’ Provident Fund and Family Pension Fund Act,
Employees’ State Insurance Act, Contract Labour (Regulation and Abolition) Act,
Payment of Wages Act, Maternity Benefit Act, National and Festival Holidays
Act, Shop and Establishment Act, The Apprentice Act and keep the Employer
indemnified against any loss or claim arising out of contravention of the
provisions of the above said enactments by the Supplier. The price quoted by
the Supplier in the Bill of Quantity shall be deemed to include all expenses
whatsoever the Supplier may be required to incur for the compliance with the
provisions of the above said legislation. The Supplier shall make necessary
arrangements for the Employer to witness the payment made by the Supplier to
his staff and labour.
17.0 INDEMNIFICATION:

The Supplier shall indemnify, protect and defend at its own cost, Paradip
Port Trust and its agents and employees from and against any and all actions,
claims, losses or damages arising out of

(a) any violation by the Supplier in course of its execution of the

contract of any legal provisions or any right of third parties;
(b) Supplier’s failure to exercise the skill and care required for
satisfactory execution of the contract.
18.0 DEDUCTION:

18.1 Deduction of taxes at source shall be made from the bill of the Supplier in
accordance with the prevailing rules of Paradip Port Trust.

18.2 While performing under the contract, the damages caused by the Supplier or his
workmen to any of the Port Trust property shall be promptly made good by the
Supplier at his own cost. In case the Supplier fails to repair/replace the damage,
Paradip Port Trust shall have the right to take steps to make good the damages
and all the cost on this account shall be recovered from the bills of the Supplier
or any money due to the Supplier from this contract or any other contract or any
other transaction. In determination of the damage, the opinion of the Engineer
Incharge (EIC) shall be conclusive.

18.3 Any dues arising out of failure on the part of the Supplier to carry out any
obligation under the contract shall be deducted from the bills of the Supplier or
from any money due to the Supplier from this contract or any other contract.

18.4 In case of dispute between the Supplier and its sub-Supplier, PPT shall have the
right to withhold adequate money from the dues of the Supplier till the Supplier
settles the dispute with its sub-Supplier and submits documentary evidences in
support of such settlement. PPT shall also have the right to make payment to the
sub-Supplier directly for that part of the sub-Supplier’s claim which has been
certified for payment by the Supplier but not paid.

19.0 VARIATION IN CONDITIONS OF CONTRACT :

In case of any variation in Instructions to Bidders (ITB), General
Conditions of Contract (GCC) and Special Conditions of Contract (SCC), the
Special Conditions of Contract – if any, shall prevail. But in case of any
requirement / condition specified in the Scope of Work, it shall prevail over all
other conditions. In case of any variation in the tender document which was sold
to the bidder and which was down loaded by the bidder from the web site, the
 former shall prevail. For Agreement purpose, the tender document which is sold
by the Department shall be used.

20.0 VARIATION IN PRICE OFFER:

There should not be any overwriting, erasure and corrections in the price
offer. In case of variation between the amount quoted in words & figures, the
amount quoted in words shall prevail and in case of variation between rate and
amount, the quoted rate shall prevail.

21.0 SUPPLY OF MATERIALS AND EQUIPMENT:

On request of the Supplier, Port Trust may supply materials and/or
provide equipment to the Supplier for the work subject to availability and
Supplier’s acceptance of the prevailing Port Trust conditions.
On request of the Purchaser (PPT), to avoid delay, the Supplier shall
supply materials / spares which are not available with PPT and not included in
the scope of the Supplier and payment for such supply shall be made by PPT as
per actual on the basis of documentary evidences like purchase vouchers etc.

22.0 IDLE CHARGES:

All efforts shall be made for timely supply of materials and/or equipments
where it is included in the scope of Paradip Port. However, the Supplier shall not
be entitled to any idle charges for delay in supply of materials and/or equipment
by the Port Trust. Further, in case of any delay due to stoppage of work ordered
by the Port Trust to avoid interruption in other important activities of Port Trust,
the Supplier shall not claim any idle charges.

23.0 PERSONAL PROTECTIVE EQUIPMENT: (PPE)

The Supplier shall be solely responsible, at his own cost, for the supply of
required PPE to his workers and staff and he shall also ensure the use of PPE
such as helmets, nose masks, hand gloves etc. by his staff at site.

24.0 CONDUCT:
The Supplier, at all times during execution of the contract, shall take all
measures to prevent any unlawful, riotous or disorderly conduct by or amongst
his staff at the site and for the preservation of peace and protection of persons
and property at the work site as well as in the neighbourhood of the works.
25.0 ACCIDENT:
The Supplier shall, within 24 hours of the occurrence of any accident, at
or about the work site or in connection with execution of the contract, report such
 accidents to the Engineer Incharge giving all the details. He shall also provide
additional information about the accident as requested by the EIC.
26.0 WATCH AND WARD:
During the execution of the contract, it shall be the responsibility of the
Supplier to arrange watch and ward of the work including the raw materials,
machineries and equipment used for the work at his own cost till the contract is
completed in all respects and accepted by PPT.
27.0 ENGINEER INCHARGE: (EIC)

The EIC of this contract shall be as specified in the LoI / Work Order.

28.0 UNDERTAKING BY THE SUPPLIER:

Having understood all the terms and conditions of the tender document
and having assessed the site conditions, we hereby confirm that the price
offered by us is a firm price and includes all the taxes, duties, fees, Cess etc.
and all other incidental charges.

Seal: SIGNATURE OF THE BIDDER

Date:
 SECTION- IV: SPECIAL CONDITION OF CONTRACT
INDEX

Clause DESCRIPTION
no.
1. BID SUBMISSION PROCEDURE
2. DOWNLOADING BID DOCUMENT FROM THE WEBSITE
3. PRE-BID MEETING
4. DATE OF COMMENCEMENT & COMPLETION OF WORK
5. TIME IS THE ESSENCE OF THE CONTRACT
6. PURCHASER’S RIGHT TO AMEND TENDER DOCUMENT
7.0 PURCHASER’S REPRESENTATIVE
7.1 &7.2
PURCHASER’S REPRESENTATIVE’S DEFN. DUTIES AND
AUTHORITY
7.3 NOMINEE OF PURCHASER’S REPRESENTATIVE
7.4 PURCHASER’ S REPRESENTATIVE AUTHORITY TO
DELEGATE
7.5 INSTRUCTION’S IN WRITING
7.6 PURCHASER’S REPRESENTATIVE TO ACT IMPARTIALLY
8.0 DESIGN AND DOCUMENTATION
8.1 DESIGN
8.2 CONFORMITY WITH DESIGN
8.3 SUPPLY OF DOCUMENTS BY PURCHASER
8.4 DISCREPANCIES
8.5 DESIGN AND DOCUMENTATION SUBMISSION
8.6 DIMENSIONS
8.7 AVAILABILITY OF DOCUMENTS
9.0 MISCELLANEOUS CONDITIONS
9.1 ASSIGNMENT OF SUB-SUPPLIERS’ OBLIGATION
9.2 SITE OPERATIONS AND METHODS OF CONSTRUCTION
9.3 INSPECTION OF SITE
9.4 ACCESS TO DATA
9.5 CASH FLOW ESTIMATE TO BE SUBMITTED
9.6 SUPPLIER’S SUPERINTENDENCE
9.7 LANGUAGE ABILITY OF SUPPLIER’S REPRESENTATIVE
9.8 SUPPLIER’S EMPLOYEES
9.9 PURCHASER’S REPRESENTATIVE AT LIBERTY TO OBJECT
9.10 LANGUAGE-ABILITY OF SUPERINTENDING STAFF
9.11 EMPLOYMENT OF LOCAL PERSONNEL
9.12 COMPLIANCE WITH STATUTES AND REGULATIONS
9.13 PATENT RIGHTS
9.14 INTERFERENCE WITH TRAFFIC AND ADJOINING
PROPERTIES
9.15 WATERBORNE VESSELS OR CONSTRUCTIONAL PLANT
9.16 AVOIDANCE OF DAMAGE TO ROADS
9.17 TRANSPORT OF SUPPLIER’S EQUIPMENT OR TEMPORARY
WORKS:
9.18 TRANSPORT OF MATERIALS OR PLANT
8.19 OPPORTUNITIES FOR OTHER SUPPLIERS:
9.20 FACILITIES FOR OTHER SUPPLIER
9.21 SUPPLIER TO KEEP SITE CLEAR
9.22 CLEARANCE OF SITE ON COMPLETION
9.23 COST OF TESTS
9.24 COST OF TESTS NOT PROVIDED FOR
9.25 INSPECTION AND TESTING
9.26 DATES FOR INSPECTION AND TESTING
9.27 REJECTION
9.28 REMOVAL OF IMPROPER WORKS, MATERIALS OR PLANT
9.29 SUSPENSION OF WORK
9.30 PURCHASER’S REPRESENTATIVE’S DETERMINATION
FOLLOWING SUSPENSION
9.31 SUSPENSION LASTING MORE THAN 84 DAYS
9.32 RESTRICTION ON WORKING HOURS
9.33 DAY WORK
9.34 NOTICE OF CLAIMS
9.35 CONTEMPORARY RECORDS
9.36 SUBSTANTIATION OF CLAIMS
9.37 FAILURE TO COMPLY
9.38 PAYMENT OF CLAIMS
9.39 SUPPLIER’S EQUIPMENT, TEMPORARY WORKS AND
MATERIALS, EXCLUSIVE USE FOR THE WORKS:
9.40 CUSTOMS CLEARANCE
9.41 RE-EXPORT OF SUPPLIER’S EQUIPMENT
9.42 DEFINITION OF “NOMINATED SUB-SUPPLIERS”
9.43 NOMINATED SUB-SUPPLIERS : OBJECTION TO NOMINATION
9.44 PAYMENTS TO NOMINATED SUB-SUPPLIERS
9.45 CERTIFICATION OF PAYMENTS TO NOMINATED SUB-
SUPPLIERS
9.46 DEFAULT OF SUPPLIER & TERMINATION
9.47 VALUATION AT DATE OF EXPULSION
9.48 PAYMENT AFTER EXPULSION
9.49 URGENT REMEDIAL WORK
9.50 OUTBREAK OF WAR
9.51 REMOVAL OF SUPPLIER’S EQUIPMENT ON TERMINATION
9.52 PAYMENT IF CONTRACT TERMINATED
9.53 PAYMENT IN THE EVENT OF RELEASE FROM
PERFORMANCE
9.54 DEFAULT OF PURCHASER DUE TO INSULVENCY
9.55 BRIBES
9.56 JOINT AND SEVERAL LIABILITY
9.57 DETAILS TO BE CONFIDENTIAL
9.58 DRAWINGS AND PHOTOGRAPHS OF THE WORKS
9.59 THE APPRENTICES ACT 1961
9.60 SUPPLY OF PLANT, MATERIALS AND LABOUR
9.61 GATE PASSES
10.0 WORKPLACE HEALTH AND SAFETY
10.1 GENERAL REQUIREMENTS
10.2 HEALTH AND SAFETY PLANS
10.3 SITE HEALTH AND SAFETY MANUAL FOR SUPPLIERS
11.0 SITE FACILITIES
11.1 FACILITIES SUPPLIED BY THE SUPPLIER
11.2 FACILITIES SUPPLIED BY PURCHASER
12.0 PROGRAMMING
12.1 PROGRAMMS
12.2 PROGRESS REPORTING
13.0 RECEIPT OF MATERIAL AT SITE
14.0 PURCHASE ORDERS
15.0 PROTECTION OF THE ENVIRONMENT
16.0 CO-OPERATION WITH OTHER SUPPLIER
17.0 RESTORATION OF OTHER SUPPLIER/SUPPLIERS’ WORKS
18.0 EXISTING SERVICES
19.0 PORT TRUST RULES
20.0 PURCHASER’S SUPPLIED EQUIPMENT
21.0 PROVISIONAL SUMS
22.0 COMPLIANCE WITH LABOUR REGULATIONS
23.0 CHANGES IN COST AND LEGISLATION
23.1 PRICE ADJUSTMENT
23.2 OTHER CHANGES IN COST
23.3 SUBSEQUENT LEGISLATION
24.0 GENERAL OBLIGATIONS OF THE SUPPLIER
25.0 ANNUAL MAINTENANCE & OPERATION OF THE MACHINE
FOR 5 YEARS
26. PAYMENT
27. DEDUCTION ON DEFAULT
28. FINAL INSPECTION, ACCEPTANCE & PAYMENT
29. SUPPLY OF SPARES
30. SUPPLY OF CONSUMABLES
31. PERSONAL PROTECTIVE EQUIPMENT (P.P.E)
32. CONDUCT
33. ACCIDENT
34. WATCH AND WARD
 SECTION - IV

SPECIAL CONDITIONS OF CONTRACT (SCC)

1. BID SUBMISSION PROCEDURE.
1.1 The Bidder shall enclose EMD of specified amount in specified shape, copies of
documents in support of their eligibility with Eligibility Information Sheet (Appendix-
III) duly filled up and Techno-Commercial Information Sheet with Deviation
Statement (Appendix-II) duly filled up in the envelope No. 1.
1.2 The technical offer along with tender document signed on all the pages by the
bidder except the Bill of Quantity must be enclosed in the envelope No.2.
1.3 Only the Bill of Quantity shall be enclosed in the envelope No.3. All the 3 envelopes
must be enclosed and sealed in an outer envelope and submitted to the address as
given in the Tender Call Notice.
1.4 On each of the envelopes the Tender Call Notice No., Name of the work and the
bidder’s mailing address must be clearly written.
1.5 On the date of bid opening the bidder’s representative shall identify the documents
in support of the bidder’s eligibility and deviation statement, if any.
1.6 Paradip Port Trust reserves the right to verify the original documents of the bidders
as and when necessary. If the No. 1 envelope does not contain the EMD, copies of
the documents in support of eligibility and deviations statement, then the No. 2 and
No. 3 envelopes may be returned unopened.
1.7 In case of no deviation, it may please be noted that the bidder must submit a NIL
deviation statement duly signed by the authorized signatory of the bidder.

2. DOWNLOADING BID DOCUMENT FROM THE WEBSITE :

The bidders who intend to download the tender document from the website must
keep track of the tender in the website at their own risk and down load any
corrigendum and/or addendum or any change in the schedule or any other relevant
information issued in respect of the subject tender. The Bidders who intend to
participate in the tender by downloading the bid document must enclose the cost of
the tender document in shape of a Demand Draft drawn in favour of FA&CAO,
Paradip Port Trust, payable in any Nationalised bank at Paradip. The Demand Draft
towards the cost of the tender documents shall be enclosed in the envelope No.1.
3. PRE-BID MEETING :
For pre-bid meeting, the bidder must depute its authorized and responsible
representative to participate in the pre-bid discussion so that any ambiguities in
interpretation of the tender conditions/requirements may be clarified for smooth
evaluation of the bids. The pre-bid meeting is scheduled to be held at 1530 hrs on
01.08.06 in the chamber of Superintending Engineer, IOHP, PPT. The Bidders
are advised to visit the site on 01.08.06 at 1000 hrs to assess the exact nature of
work.

4. DATE OF COMMENCEMENT & COMPLETION OF WORK :

The date of commencement shall be treated from the date of issue of LOI and shall
be completed within 20 months including Sundays & holidays from the date of issue
of LOI. The work at site shall be planned and executed in such a manner that no
hindrance to the operation of the plant will occur. Shutdown , if any, required for
erection work, shall be planned to the minimum extent possible and it must be
approved by the Port Trust in advance. The number of days for which the work shall
be hampered due to non-availability of the above mentioned shut down of the plant,
the same will not be counted towards the above stipulated days specified for
completion of work. No other compensation will be given to the supplier for non-
availability of the shut down for final erection due to any reason.

5 TIME IS THE ESSENCE OF THE CONTRACT :

Time is the essence of the contract and the supplier shall ensure that all the
obligations under the contract shall have to completed within the specified time,
failing which, the supplier shall be responsible for compensating any loss suffered
by the purchaser due to the delay caused by non-performance by the supplier. This
shall, inter alia, include the business loss to the purchaser. Unless otherwise
specified, any time extension granted to the supplier shall not absolve the Supplier
from the responsibility of compensating the purchaser for all kind of losses suffered
by the Purchaser because of the non-performance by the supplier.

6. PURCHASER’S RIGHT TO AMEND TENDER DOCUMENT :

Purchaser reserves the right to incorporate amendments to the tender document on

the basis of the outcome of the joint pre-bid discussion including extension of last
date of submission of bids.
7. PURCHASER’S REPRESENTATIVE

7.1 The Purchaser’s Representative is any Engineer / Officer authorized by PPT in

the letter of intent (LOI) and / 0r Work Order.

7.2 Purchaser’s Representative’s Duties and Authority.

(a) The Purchaser’s Representative shall carry out the duties specified in the
Contract.
(b) The Purchaser’s Representative may exercise the authority specified in or
necessary to be implied from the Contract with the specific approval of the
Purchaser.
(c) Except as expressly stated in the Contract, the Purchaser’s
Representative shall have no authority to relieve the Supplier of any of his
obligations under the Contract.

7.3 NOMINEE OF PURCHASER’S REPRESENTATIVE

The Nominee shall be appointed by and be responsible to the Purchaser’s

Representative and shall carry out such duties and exercise such authority as
may be delegated to him by the Purchaser’s Representative.

7.4 PURCHASER’S REPRESENTATIVE AUTHORITY TO DELEGATE

The Purchaser’s Representative may from time to time delegate to the Nominee
of the Purchaser’s Representative any of the duties and authorities vested in the
Purchaser’s Representative and he may at any time revoke such delegation. Any
such delegation or revocation shall be in writing and shall not take effect until a
copy thereof has been delivered to the Purchaser and the Supplier.

Any communication given by the Nominee to the Supplier in accordance with

such delegation shall have the same effect as though it had been given by the
Purchaser’s Representative provided that

(a) any failure of the Nominee to disapprove any work, materials or

plant shall not prejudice the authority of the Purchaser’s
Representative to disapprove such work, materials or plant and to
give instructions for the rectification thereof.
(b) if the Supplier questions any communication of the Nominee he
may refer the matter to the Purchaser’s Representative who shall
confirm, reverse or vary the contents of such communication.

7.5 INSTRUCTIONS IN WRITING

Instructions given by the Purchaser’s Representative shall be in writing provided

that if for any reason the Purchaser’s Representative considers it necessary to
give any such instruction orally the Supplier shall comply with such instruction.
Confirmation in writing of such oral instruction given by the Purchaser’s
Representative, whether before or after carrying out of the instruction shall be
deemed to be an instruction within the meaning of this sub-clause. Provided
further that if the Supplier, within 7 days, confirms in writing to the Purchaser’s
 Representative any oral instruction of the Purchaser’s Representative and such
confirmation is not contradicted in writing within 7 days by the Purchaser’s
Representative it shall be deemed to be an instruction of the Purchaser’s
Representative.

The provisions of this sub-clause shall equally apply to instructions given by the
Nominee.

7.6 PURCHASER’S REPRESENTATIVE TO ACT IMPARTIALLY

Whenever, in the Contract, the Purchaser’s Representative is required to

exercise his discretion by :

(a) giving his decision, opinion or consent or

(b) expressing his satisfaction or approval or
(c) determining value or
(d) otherwise taking action which may affect the rights and obligations of the
Purchaser or the Supplier.

he shall exercise such discretion impartially within the terms of the Contract and
having regard to all of the circumstances.

7.7 The Purchaser’s Representative shall obtain the specific approval of the
Purchaser before taking any of the following actions :

(a) approving subletting of any part of the supply and services.

(b) certifying additional cost.
(c) Determining an extension of time.
(d) Issuing a variation (except in an emergency situation, as reasonably
determined by the Purchaser’s Representative).
(e) fixing rates or prices.

8. DESIGN AND DOCUMENTATION

8.1 DESIGN

The Supplier warrants to the Purchaser that the Supplier shall exercise
proper professional skill, care and due diligence in all design work, design
development and documentation to ensure that the Goods and services
comply with all of the requirements of the Contract and are fit for their
intended purposes.

Notwithstanding that the Purchaser, the Purchaser’s Representative or their

respective employees, agents or suppliers may be given copies of or approve
any conceptual design, the correctness of the design, development,
documentation, manufacture, fabrication, installation, erection or construction
documents shall be the sole responsibility of the Supplier.
8.2 CONFORMITY WITH DESIGN

When the work under the Contract includes design, the Supplier shall exercise
proper professional skill, care and due diligence in the superintendence,
administration, design, manufacture, fabrication, supply, transportation,
installation, erection, construction, testing and commissioning of the work under
the Contract so as to ensure that the works are in accordance with the contract
and are fit for their intended purposes.

8.3 SUPPLY OF DOCUMENTS BY PURCHASER

The Purchaser shall provide the Supplier with the documents comprising the
Contract.

The Purchaser shall supply to the Supplier the number of copies of such
documents stated in the contract or, if no number is stated, then 2 copies.

The Supplier shall not use, copy or reproduce the documents provided by the
Purchaser for any purpose other than the work under the Contract.

The documents supplied by the Purchaser shall remain the property of the
Purchaser and shall be returned by the Supplier to the Purchaser upon the
Purchaser’s Representative’s written demand.

8.4 DISCREPANCIES

Immediately upon becoming aware of any significant ambiguity, error, omission

in or conflict or discrepancy between any of the documents provided by the
Purchaser including without limitation the Technical Specification or the
Drawings, which affects the Supplier’s ability to carry out the work under the
Contract in accordance with the requirements of the contract, the Supplier shall
give written notice thereof to the Purchaser’s Representative.

The Purchaser’s Representative shall direct the Supplier as to the interpretation

to be followed. If the direction causes the Supplier to incur more or less cost than
the Supplier could have reasonably anticipated at the time of tendering, the
difference shall be valued under Clause 17.2
( Valuation of Variation) of General Conditions of Contract.

8.5 DESIGN AND DOCUMENTATION SUBMISSION

The Supplier shall provide the Purchaser’s Representative with the design
documentation and any other documentation required by the Contract including
documents to be used for manufacture, fabrication, supply, transportation,
installation, erection, construction, testing and commissioning by the dates or
within the periods stated in the contract or if no dates or periods are stated
before proceeding with the work under the contract to which such documents
and other things relate.
 It shall be the Supplier’s responsibility to make submissions to the Purchaser’s
Representative in sufficient time to avoid delay and disruption to the work under
the Contract, making due allowance for the potential for rejection and the
requirement for re-design, re-documentation and re-submission by the Supplier.

The Supplier shall comply with any specific requirements for submissions set out
in the Contract in connection with submission of the above documentation.

(a) within 14 days after receipt of the submission, the Purchaser’s

Representative shall inform the Supplier whether it has any comments on
the submission, or whether additional time or information is required in
which to reach a decision.

(b) acceptance and or approval of submission by the Purchaser’s

Representative shall in no way release the supplier from any obligation
under the contract or relieve the supplier from responsibility for the
correctness of the submissions.
(c) the Purchaser’s Representative’s approval, review, comments or failure to
approve, review or make any comments shall not relieve the Supplier
from responsibility for the Supplier’s errors or omissions or from
compliance with the requirements of the Contract.

(d) if the Purchaser’s Representative rejects part or all of a submission, the

Supplier shall promptly make an amended or new submission, and
(e) the contract price and the date for commissioning of goods shall all be
regarded as containing adequate allowance for
(i) any cost, loss, expense or damage incurred by the Supplier in
making submission to the Purchaser’s Representative and
(ii) any delay or disruption in or in connection with fulfilling the
Purchaser’s Representative’s requirements.

including without limitation for any re-design, re-documentation, or re-

submission process and any delay in connection therewith.

8.6 DIMENSIONS

Where any discrepancy exists between figured and scaled dimensions, the
figured dimensions shall prevail.

8.7 AVAILABILITY OF DOCUMENTS

During the execution of the work under the contract, the Supplier shall have,
available at all times at the Site and other locations where the work under the
contract is carried out, a complete set of documents which relate to the work
under the contract carried out at each location for reference by the Purchaser’s
Representative and other persons nominated in writing by the Purchaser’s
Representative.
9. MISCELLANEOUS CONDITIONS

9.1 ASSIGNMENT OF SUB-SUPPLIERS’ OBLIGATIONS

In the event of a Sub-Supplier having undertaken towards the Supplier in respect

of the work executed, or the goods, material, plant or services supplied by such
Sub-Supplier, any continuing obligation extending for a period exceeding that of
the warranty period under the contract, the Supplier shall at any time, after the
expiration of such period, assign to the Purchaser, at the Purchaser’s request,
the benefit of such obligation for the un-expired duration thereof.

9.2 SITE OPERATIONS AND METHODS OF CONSTRUCTION

The Supplier shall take full responsibility for the adequacy, stability and safety of
all Site operations and methods of construction. Provided that the Supplier shall
not be responsible (except as stated hereunder or as may be otherwise agreed)
for the design or specification of Permanent Works or for the design or
specification of any Temporary Works not prepared by the Supplier. Where the
Contract expressly provides that part of the Permanent Works shall be designed
by the Supplier, he shall be fully responsible for that part of such Works
notwithstanding any approval by the Purchaser’s Representative.

The Supplier shall promptly notify the Purchaser and the Purchaser’s
Representative of any error, omission, fault or any other defect in the design of
or specifications for the works which he discovered when reviewing the contract
documents or in the process of execution of the works.

9.3 Inspection of site

The Supplier shall be deemed to have inspected and examined the Site and its
surroundings and obtained all information available in connection therewith and
to have satisfied himself (so far as is practicable having regard to considerations
of cost and time) before submitting his Tender as to :

(a) the form and nature of the site , including the sub-surface conditions.
(b) the hydrological and climatic conditions.
(c) the extent and nature of work and materials necessary for the execution
and completion of the Works and the remedying of any defects therein,
and
(d) the means of access to the Site and the accommodation he may require
and in general shall be deemed to have obtained all necessary
information, as to risks, contingencies and all other circumstances which
may influence or affect his tender.

9.4 Access to data

Available data with the Purchaser may be inspected at The Office of Chief
Electrical and Mechanical Engineer, Paradip Port Trust, Paradip.
9.5 Cash-Flow Estimate to be Submitted

The Supplier shall within 28 days after the date of the Notification of Award,
provide to th Purchaser’s Representative for his information a detailed cash flow
estimate, in quarterly periods of all payments to which the Supplier will be
entitled under the Contract and the Supplier shall subsequently supply revised
cash flow estimates at quarterly intervals, if required to do so by the Purchaser’s
Representative. The cash flow estimate to be submitted by the Supplier must
clearly indicate the activities based on which it has been prepared.

9.6 Supplier’s Superintendence

The Supplier shall provide all necessary superintendence during the execution of
the Works and as long thereafter as the Purchaser’s Representative may
consider necessary for the proper fulfilling of the Supplier’s obligations under the
Contract. The Supplier or a competent and authorized representative approved
by the Purchaser’s Representative, which approval may at any time be
withdrawn, shall give his whole time to the superintendence of the Works. Such
authorized representative shall receive, on behalf of the Supplier, instruction
from the Purchaser’s Representative or, subject to the provisions of clause 1.4 of
SCC the Nominee of the Purchaser’s Representative.

If approval of the representative is withdrawn by the Purchaser’s Representative,

the Supplier shall, as soon as is practicable, having regard to the requirement of
replacing as hereinafter mentioned, after receiving notice of such withdrawal,
remove the representative from the Works and shall not thereafter employ him
again on the Works in any capacity and shall replace him by another
representative approved by the Purchaser’s Representative.

9.7 Language Ability of Supplier’s Representative

If the Supplier’s authorised representative is not in the opinion of the Purchaser’s
Representative, fluent in English language, the Supplier shall have available on
Site at all times a competent interpreter to ensure the proper transmission of
instructions and information. It is strongly advised that the representative should
have basic knowledge of the local language.

9.8 Supplier’s Employees

The Supplier shall provide on the Site in connection with the execution and
completion of the Works and the remedying of any defects therein

(a) only such technical assistance as are skilled and experienced in their
respective callings and such foremen and leading hands as are
competent to give proper superintendence of the Works and
(b) such skilled, semi skilled and unskilled labour as is necessary for the
proper and timely fulfilling of the Supplier’s obligations under the Contract.

9.9 Purchaser’s Representative at Liberty to Object

The Purchaser’s Representative shall be at liberty to object to and require the

Supplier to remove forthwith from the Works any person provided by the Supplier
 who in the opinion of the Purchaser’s Representative, misconducts himself, or is
incompetent or negligent in the proper performance of his duties or whose
presence on Site is otherwise considered by the Purchaser’s Representative to
be undesirable and such person shall not be again allowed upon the Works
without the consent of the Purchaser’s Representative. Any person so removed
from the Works shall be replaced as soon as possible.

9.10 Language-Ability of Superintending Staff

A reasonable proportion of the Supplier’s superintending staff shall have a

working knowledge of the English language or the Supplier shall have available
on Site all times a sufficient number of competent interpreters to ensure the
proper transmission of instructions and information.

9.11 Employment of Local Personnel

The Supplier is encouraged to the extent practicable and reasonable to employ

staff and labour from local sources within India.

9.12 Compliance with Statutes and Regulations

The Supplier shall conform in all respects, including payment of fees and issue
of notices to

a) any National or State Statute, Ordinance or other law or any regulation or

by-law of any local or other duly constituted authority in relation to the
execution and completion of the Works and the remedying of any defects
therein and

b) the rules and regulations of all public bodies and companies whose
property or rights are affected or may be affected in any way by the
Works.

and the Supplier shall keep the Purchaser indemnified against all penalties and
liability of every kind for breach of any such provisions. Provided always that the
Purchaser shall be responsible for obtaining any planning, zoning or other
similar permission required for the Works to proceed and shall indemnify the
Supplier against all claims proceedings damages costs charges and expenses
arising out of any violation to the above by the Purchaser.

9.13 Patent Rights

The Supplier shall save harmless and indemnify the Purchaser from and against
all claims and proceedings for or on account of infringement of any patent rights,
design trademark or name or other protected rights in respect of any Supplier’s
Equipment, materials or Plant used for or in connection with or for incorporation
in the works and from and against all damages, costs, charges and expenses
whatsoever in respect thereof or in relation thereto.
9.14 Interference with Traffic and Adjoining Properties

All operations necessary for the execution and completion of the works and the
remedying of any defects therein shall, so far as compliance with the
requirements of the contract permits, be carried on so as not to interfere
unnecessarily or improperly with

(a) the convenience of the public, or

(b) the access to, use and occupation of public or private roads and footpaths
or of properties whether in the possession of the Purchaser or of any
other person.

The Supplier shall save harmless and indemnify the Purchaser in respect of all
claims, proceedings, damages, costs, charges and expenses whatsoever arising
out of, or in relation to, any such matters insofar as the Supplier is responsible
therefor.

9.15 Waterborne Vessels or Constructional Plant

If any plant (floating or otherwise) belonging to or hired by the Supplier or any

Sub-Supplier or any person employed by the Supplier or by any sub-Supplier or
any materials or things therein or therefrom sink (in water or unstable ground)
from any cause whatsoever, it shall immediately be reported by the Supplier to
the competent authorities and the Purchaser’s Representative, and Supplier
shall forthwith, at his cost raise and remove any such plant, materials or things or
otherwise deal with the same as the Purchaser may direct.

The fact that such sunken plant, materials or things are insured or have been
declared a total loss or do not represent any further value shall not absolve the
Supplier from his obligations under this clause to raise and remove the same.

Until such sunken plant or materials or things have been raised and removed,
the Supplier shall set such buoys or markers as appropriate and display at night
such lights and do all such things for the safety as may be required by the
competent authorities or by the Purchaser’s Representative.

In the event of the Supplier not carrying out the obligations imposed on him by
this clause, the Purchaser may cause to set buoy or markers and display at night
light on such plant and raise and remove the same without prejudice to the right
of the Purchaser to hold the Supplier liable and all expenses and consequences
thereon and incidental thereto shall be borne by the Supplier and shall be
recoverable from him by the Purchaser as a debt or may be deducted by the
Purchaser from any moneys due or which may become due to the Supplier. In
such cases an overhead up to 20% may be added to the actual expenditure and
recovered from any money due or to be come due to the Supplier.

9.16 Avoidance of Damage to Roads:

The Supplier shall use every reasonable means to prevent damage to any of the
roads or bridges communicating with or on the routes to the site from being
damaged or injured by any traffic of the Supplier or any of his sub-Supplier and
 in particular, shall select routes, choose and use vehicles and restrict and
distribute loads so that any such extraordinary traffic as will inevitably arise from
the moving of materials, Plant, Supplier’s Equipment or Temporary Works from
and to the Site shall be limited, as far as reasonably possible, and so that no
unnecessary damage or injury may be occasioned to such roads and bridges.

9.17 Transport of Supplier’s Equipment or Temporary Works:

Save insofar as the contract otherwise provides, the Supplier shall be

responsible for and shall pay the cost of strengthening any bridges or altering or
improving any road communicating with or on the routes to the site to facilitate
the movement of Supplier’s Equipment or Temporary Works and the Supplier
shall indemnify and keep indemnified the Purchaser against all claims for
damage to any such road or bridge caused by such movement, including such
claims as may be made directly against the Purchaser, and shall negotiate and
pay all claims arising solely out of such damage.

If it is found necessary for the Supplier to move one or more loads of heavy
constructional plant and equipment, materials or pre-constructed
units or parts of units of work over roads, highways, bridges on which such
oversized and overweight items are not normally allowed to be moved, the
Supplier shall obtain prior permission from the concerned authorities. Payments
for complying with the requirements, if any, for protection of or strengthening of
the roads, highways or bridges shall be made by the Supplier and such
expenses shall be deemed to be included in his contract price.

9.18 Transport of Materials or Plant

If, notwithstanding clause 3.18, any damage occurs to any bridge or road,
communicating with or on the routes to the site arising from the transport of
materials or Plant, the Supplier shall notify the Purchaser’s Representative with a
copy to the Purchaser, as soon as he becomes aware of such damage or as
soon as he receives any claim from the authority entitled to make such claim and
the Supplier shall make all efforts to promptly settle the claim and avoid any
delay and the Purchaser shall not be liable for any cost. In the event the Supplier
fails to settle the claim promptly, the Purchaser reserves the right to settle the
claim and recover all the expenses from any money due or to become due to the
Supplier.

9.19 Opportunities for Other Suppliers:

The Supplier shall, in accordance with the requirement of the Purchaser’s

Representative afford all reasonable opportunities for carrying out their work to

(a) any other Supplier employed by the Purchaser and their workmen.
(b) The workmen of the Purchaser and
(c) The workmen of any duly constituted authorities who may be employed in
the execution on or near the Site of any work not included in the Contract
or of any contract which the Purchaser may enter into in connection with
or ancillary to the Works.
9.20 Facilities for Other Supplier

If, however pursuant to Clause 3.19 the Supplier shall on the written request of
the Purchaser’s Representative :

(a) make available to any other Supplier, or to the Purchaser or any such
authority any roads or ways for the maintenance of which the Supplier is
responsible or

(b) permit the use of any such Temporary Works or Supplier’s Equipment on
the Site or

(c) provide any other service of whatsoever nature

the Purchaser’s Representative shall determine an addition to the

Contract Price in accordance with Clause 17 of the General Conditions of
Contract ( Change Orders ) and shall notify the Supplier accordingly with
a copy to the Purchaser.

9.21 Supplier to Keep Site Clear

During the execution of the Works the Supplier shall keep the Site reasonably
free from all unnecessary obstruction and shall store or dispose of any Supplier’s
Equipment and surplus materials and clear away and remove from the Site any
wreckage, rubbish or Temporary Works no longer required.

9.22 Clearance of Site on Completion

Upon the issue of any Certificate of Commissioning the Supplier shall clear away
and remove from that part of the Site to which such certificate relates all
Supplier’s Equipment, surplus material, rubbish and Temporary Works of every
kind, and leave such part of the Site and Works clean and in a workmanlike
condition to the satisfaction of the Purchaser’s Representative. Provided that the
Supplier shall be entitled to retain on Site, until the end of the Warranty Period,
such materials. Supplier’s Equipment and Temporary Works as are required by
him for the purpose of fulfilling his obligations during the Warranty Period.

In the event, the supplier does not clear the site with in 30 days of issue of the
commissioning certificate, the purchaser shall have the right to clear the site and
deduct the cost of clearing the site with a 20% overhead added to the cost from
any monies due or to become due to the Supplier. The Supplier shall have no
claim whatsoever on this matter.

9.23 Cost of Tests

The cost of making any test shall be borne by the Supplier if such test is

(a) clearly intended by or provided for in the Contract, or

(b) appropriate to ascertain the design of any finished or semi-finished work

is fit for the intended purpose.
9.24 Cost of Tests not provided for

If any test required by the Purchaser’s Representative which is not covered

under (a) and (b) of Clause 3.23 above or if the Purchaser’s Representative
requires any test to be carried out at any place other than the site or place of
manufacture, fabrication or preparation of the material and plant, then the
Purchaser’s Representative after due consultation with the Supplier shall
determine

(a) any extension of time to which the Supplier is entitled under clause 22 of
the General Conditions of Contract and

(b) the amount of such costs, which shall be added to the Contract Price, and
shall notify the Supplier accordingly with a copy to the Purchaser.
However, if the test results shows that the material or plant or workmanship is
not in accordance with the Contract then the cost of such test and all other
related costs shall be borne by the Supplier and the Supplier shall not be entitled
to any extension of time on this account.

9.25 Inspection and Testing

The Purchaser’s Representative shall be entitled, during manufacture,

fabrication or preparation to inspect and test the materials and Plant to be
supplied under the Contract. If materials or Plant are being manufactured,
fabricated or prepared in workshops or places other than those of the Supplier,
the Supplier shall obtain permission for the Purchaser’s Representative to carry
out such inspection and testing in those workshops or places. Such inspection or
testing shall not release the Supplier from any obligation under the Contract.

9.26 Dates for inspection and Testing

The supplier shall agree with the Purchaser’s Representative on the time and
place for the inspection or testing of any materials or Plant as provided in the
Contract. The Purchaser’s Representative shall give the Supplier not less than
24 hours notice of his intention to carry out the inspection or to attend the tests. If
the Purchaser’s Representative or his duly authorized representative does not
attend on the date agreed, the Supplier may, unless otherwise instructed by the
Purchaser’s Representative, proceed with the tests, which shall be deemed to
have been made in the presence of the Purchaser’s Representative. The
Supplier shall forthwith forward to the Purchaser’s Representative duly certified
copies of the test readings. If the Purchaser’s Representative has not attended
the tests, he shall accept the said readings as accurate.

9.27 Rejection

If, at the time and place agreed in accordance with Clause 3.26, the materials or
Plant are not ready for inspection or testing or if as a result of the inspection or
testing referred to in this Clause, the Purchaser’s Representative determines that
the materials or Plant are defective or otherwise not in accordance with the
Contract, he may reject the materials or Plant and shall notify the Supplier
 thereof immediately. The notice shall state the Purchaser’s Representative’s
objections with reasons. The Supplier shall then promptly make good the defect
or ensure that rejected materials or Plant comply with the Contract. If the
Purchaser’s Representative so requests, the tests of rejected materials or Plant
shall be made or repeated under the same terms and conditions. Costs, if any,
incurred by the Purchaser by the repetition of the tests shall, after due
consultation with the Purchaser and the Supplier, be determined by the
Purchaser’s Representative and shall be recovered from the Supplier by the
Purchaser and may be deducted from any monies due or to become due to the
Supplier and the Purchaser’s Representative shall notify the Supplier
accordingly, with a copy to the Purchaser.

9.28 Removal of Improper Works, Materials or Plant

The purchaser’s Representative shall have authority to issue instructions from

time to time for

(a) The removal, from the Site, within such time or times as may be specified
in the instruction, of any materials or Plant which, in the opinion of the
Purchaser’s Representative, are not in accordance with the Contract.

(b) the substitution of proper and suitable materials or Plant and

(c) the removal and proper re-execution, notwithstanding any previous test
thereof or interim payment thereof, of any work which, in respect of
(i) materials, Plant or Workmanship or
(ii) design by the Supplier or for which he is responsible
is not, in the opinion of the Purchaser’s Representative, in accordance
with the Contract.

9.29 Suspension of Work

The Supplier shall, on the instructions of the Purchaser’s Representative,

suspend the progress of the works or any part thereof for such time and in such
manner as the Purchaser’s Representative may consider necessary and shall,
during such suspension, properly

protect and secure the works or such part thereof so far as is necessary in the
opinion of the Purchaser’s Representative. Unless such suspension is :

(a) otherwise provided for in the Contract, or

(b) necessary by reason of some default of or breach of contract by the
Supplier or for which he is responsible, or
(c) necessary by reason of climatic conditions on the Site, or
(d) necessary for the proper execution of the works or for the safety of the
works or any part thereof (save to the extent that such necessity arises
from any act or default by the Purchaser or Purchaser’s Representative).
then Clause 3.30 shall apply.
9.30 Purchaser’s Representative’s Determination Following Suspension

Where, pursuant to Clause 3.29, this Clause applies, the Purchaser’s

Representative shall, after due consultation with the Purchaser and the Supplier,
determine.

(a) any extension of time to which the Supplier is entitled under Clause 22.5
of the General Conditions of Contract, and
(b) the amount, which shall be added to the Contract Price, in respect of the
cost incurred by the Supplier by reason of such suspension.

and shall notify the Supplier accordingly, with a copy to the Purchaser.

9.31 Suspension Lasting More than 84 Days

If the progress of the works or any part thereof is suspended on the written
instructions of the Purchaser’s Representative and if permission to resume work
is not given by the Purchaser’s Representative within a period of 84 days from
the date of suspension, then, unless such suspension is within paragraph (a),
(b), (c) or (d) of Clause 3.29, the Supplier may give notice to the Purchaser’s
Representative requiring permission, within 28 days from the receipt thereof to
proceed with the works or that part thereof in regard to which progress is
suspended. If, within the said time, such permission is not granted, the Supplier
may, but is not bound to, elect to treat the suspension, where it affects part only
of the works as an omission of such part under Clause 3.29 by giving a further
notice to the Purchaser’s Representative to that effect, or, where it affects the
whole of the works, treat the suspension as an event of default by the Purchaser
and terminate his employment under the Contract in accordance with the
General Conditions of Contract.

9.32 Restriction on Working Hours

Subject to any provision to the contrary contained in the Contract, none of the
works shall, save as hereinafter provided, be carried on during the night or on
locally recognized days of rest without the consent of the Purchaser’s
Representative, except when work is unavoidable or absolutely necessary for
the saving of life or property or for the safety of the works, in which case the
Supplier shall immediately advise the Purchaser’s Representative provided that
the provisions of this clause shall not be applicable in the case of any work which
it is customary to carry out by multiple shifts.

Unless otherwise provided in the contract, the Supplier shall have the option to
work continuously day and night on 3 shifts basis and on locally recognized
holidays or days of rest (except national holidays).
9.33 Day work

Only where provision exists in the Price Schedule / Bill of Quantity, the
Purchaser’s Representative may, if in his opinion it is necessary or desirable,
issue an instruction that any varied work shall be executed on a day work basis.
The Supplier shall then be paid for such varied work under the terms set out in
 the Price Schedule / Bill of Quantity. If any provision is available under “
Contingency Head “ in the Bill of Quantity, it may also be used for meeting the
day work expenses, provided approval to this effect has been obtained from the
Purchaser’s Representative.

The Supplier shall furnish to the Purchaser’s Representative such receipts or

other vouchers as may be necessary to prove the amounts paid and before
ordering materials, shall submit to the Purchaser’s Representative quotations for
the same for his approval.

In respect of such of the works executed on a day work basis, the Supplier shall,
during the continuance of such work, deliver each day to the Purchaser’s
Representative an exact list in duplicate of the names, occupation and time of all
workmen employed on such work and a statement, also in duplicate, showing
the description and quantity of all materials and Supplier’s Equipment used
thereon or therefore. Representative and returned to the Supplier.

At the end of each month the Supplier shall deliver to the Purchaser’s
Representative a priced statement of the labour, materials and Supplier’s
Equipment used and the Supplier shall not be entitled to any payment unless
such list and statements have been fully and punctually rendered. Provided
always that if the Purchaser’s Representative considers that for any reason the
sending of such lists or statements by the Supplier, in accordance with the
foregoing
provision, was impracticable he shall nevertheless be entitled to authorize
payment for such work, either as day work, on being satisfied as to the time
employed and the labour, materials and Supplier’s Equipment used on such
work, or at such value therefor as shall, in his opinion, be fair and reasonable.

9.34 Notice of Claims

Notwithstanding any other provision of the Contract, if the Supplier intends to

claim any additional payment pursuant to any Clause of these Conditions or
otherwise, he shall give notice of his intention to the Purchaser’s Representative,
with a copy to the Purchaser, within 28 days after the event giving rise to the
claim has first arisen. The notice must give the particulars of the event and
justification for the intended claim.

9.35 Contemporary Records

Upon the “happening of the event referred to in Clause 3.34, the Supplier shall
keep such contemporary records as may reasonably be necessary to support
any claim he may subsequently wish to make. Without necessarily admitting the
Purchaser’s liability, the Purchaser’s Representative shall, on receipt of a notice
under Clause 3.34, inspect such contemporary records and may instruct the
Supplier to keep any further contemporary records as are reasonable and may
be material to the claim of which notice has been given. The Supplier shall
permit the Purchaser’s Representative to inspect all records kept pursuant to this
Clause and shall supply him with copies thereof as and when the Purchaser’s
Representative so instructs.
9.36 Substantiation of Claims

Within 28 days or such other reasonable time, as may be agreed by the

Purchaser’s Representative, of giving notice under Clause 3.34, the Supplier
shall send to the Purchaser’s Representative an account giving detailed
particulars of the amount claimed and the grounds upon which the claim is
based. Where the event giving rise to the claim has a continuing effect, such
account shall be considered to be an interim account and the Supplier shall, at
such intervals as the Purchaser’s Representative may reasonably require, send
further interim accounts giving the accumulated amount of the claim and any
further grounds upon which it is based. In cases where interim accounts are sent
to the Purchaser’s Representative, the Supplier shall send a final account within
28 days of the end of the effects resulting from the event. The Supplier shall, if
required by the Purchaser’s Representative , forward copies, to the Purchaser,
of all accounts sent to the Purchaser’s Representative pursuant to this Clause.

9.37 Failure to Comply:

If the Supplier fails to comply with any of the provisions of Clauses – 3.34, 3.35
& 3.36 in respect of any claim which he seeks to make, his entitlement to
payment in respect thereof shall not exceed such amount as the Purchaser or
any arbitrator / arbitrators or any court of law appointed pursuant to Clause 27
( Resolution of Dispute ) of the General Conditions of Contract assessing the
claim considers to be fair, based on the contemporary records.

9.38 Payment of Claims

The Purchaser’s Representative, after verification of the claims made by the

Supplier pursuant to Clause-3.36 may determine the claim amount due to the
Supplier provided that the Supplier has supplied sufficient particulars to enable
the Purchaser’s Representative to determine the amount due. If such particulars
are insufficient to substantiate the whole of the claim, the Supplier shall be
entitled to payment in respect of such part of the claim as such particulars may
substantiate to the satisfaction of the Purchaser’s Representative. The
Purchaser’s Representative shall notify the Supplier of any determination made
under this Sub-Clause, with a copy to the Purchaser.

9.39 Supplier’s Equipment, temporary Works and Materials, Exclusive Use for
the Works:
All Supplier’s Equipment, temporary Works and materials provided by the
Supplier shall, when brought on to the Site, be deemed to be exclusively
intended for the execution of the Works and the Supplier shall not remove the
same or any part thereof, except for the purpose of moving it from one part of the
Site to another, without the consent of the Purchaser’s Representative. Provided
that consent shall not be required for vehicles engaged in transporting any staff,
labour, Supplier’s Equipment, temporary Works, Plant and materials to or from
the Site.
9.40 Customs Clearance

The Purchaser will use his best endeavors in assisting the Supplier, where
required, in obtaining clearance through the Customs of Supplier’s Equipment,
materials and other things required for the Works and all the cost shall have to
be borne by the Supplier.

9.41 Re-export of Supplier’s Equipment

In respect of any Supplier’s Equipment which the Supplier has imported for the
purposes of the Works, the Purchaser will use his best

endeavors to assist the Supplier, where required, in procuring any necessary

Government consent to the Re-export of such Supplier’s Equipment by the
Supplier upon the removal thereof pursuant to the terms of the Contract. The re-
export cost as well as all incidental expenses shall have to be borne by the
Supplier.

9.42 Definition of “Nominated Sub-Suppliers”

All specialists, merchants, tradesmen and others, engaged by the Supplier and
approved by the Purchaser, who are executing any work or supplying any goods,
materials, Plant or services under this contract shall be treated as “ Nominated-
Sub Supplier”.

9.43 Nominated Sub-Suppliers : Objection to Nomination

The Supplier shall not be required by the Purchaser’s Representative or the

Purchaser or be deemed to be under any obligation, to employ any nominated
Sub-Supplier against whom the Supplier may raise reasonable objection, or who
declines to enter into a subcontract with the Supplier .

9.44 Payments to Nominated Sub-Suppliers

For all Work executed or goods, materials, Plant or services supplied by any
nominated Sub-Supplier, the Supplier shall make payment to the sub-supplier. In
case of any dispute between the Supplier and it’s Sub-Supplier, the Purchaser
reserves the right to make payment to the Sub-Supplier directly for that part of
the claims for which the bills of the sub-supplier have been certified for payment
by the Supplier and recover the same from any money due or to become due to
the Supplier. In all other cases of sub-suppliers claim, the Supplier shall make all
efforts to settle the claim with in a reasonable period as determined by the
Purchaser’s Representative failing which the Purchaser reserves the right to with
hold adequate amount from any money due or to become due to the Supplier till
the Supplier settles the dispute and submits documentary evidence to this effect.
9.45 Certification of Payments to Nominated Sub-Suppliers.

Before issuing, under Clause 15 of the General Conditions of Contract, any

certificate, which includes any payment in respect of work done or goods,
materials, plant or services supplied by any nominated Sub-Supplier, the
Purchaser’s Representative shall be entitled to demand from the Supplier
reasonable proof that all payments, less retentions,

included in previous certificates in respect of the work or goods, materials, Plant

or services of such nominated Sub-Supplier have been paid or discharged by
the Supplier. If the Supplier fails to supply such proof then, unless the Supplier

(a) satisfies the Purchaser’s Representative in writing that he has reasonable

cause for withholding or, refusing to make payments, and

(b) produces to the Purchaser’s Representative reasonable proof that he has

so informed such nominated Sub-Supplier in writing.

the Purchaser shall be entitled to pay to such nominated Sub-Supplier direct,

upon the certificate of the Purchaser’s Representative, all payments, less
retentions, provided for in the nominated subcontract, which the Supplier has
failed to make to such nominated Sub-Supplier and to deduct by way of set-off
the amount so paid by the Purchaser from any sums due or to become due from
the Purchaser to the Supplier.

Provided that, where the Purchaser’s Representative has certified and the
Purchaser has paid direct as aforesaid, the Purchaser’s Representative shall, in
issuing any further certificate in favour of the Supplier, deduct from the amount
thereof the amount so paid, direct as aforesaid, but shall not withhold or delay
the issue of the certificate itself when due to be issued under the terms of the
contract.

9.46 Default of Supplier and Termination:

Should the Supplier, default under any of the Clauses of the Contract then the
Purchaser may after giving 14 days’ notice to the Supplier, enter upon the Site
and the works and terminate the employment of the Supplier without thereby
releasing the Supplier from any of his obligations or liabilities under the Contract,
or affecting the rights and authorities conferred on the Purchaser or the
Purchaser’s Representative by the contract, and may himself complete the
works or may employ any other Supplier to complete the works. The Purchaser
or such other Supplier may use for such completion so much of the Supplier’s
Equipment, Temporary works and materials as he or they may think proper.

9.47 Valuation at Date of Expulsion:

The Purchaser’s Representative shall, as soon as may be practicable after any

such entry and expulsion by the Purchaser, fix and determine ex-party, or after
 reference to the parties or after such investigation or enquiries as he may think fit
to make or institute, and shall certify

(a) what amount (if any) had, at the time of such entry and expulsion, been
reasonably earned by or would reasonably accrue to the Supplier in
respect of work then actually done by him under the contract, and
(b) the value of any of the said unused or partially used materials, any
Suppliers’ Equipment and any Temporary works.

9.48 Payment after Expulsion

If the Purchaser shall enter and expel the Supplier under Clause 3.48, he shall
not be liable to pay to the Supplier any further amount (including damages) in
respect of the Contract until the expiration of the warranty period and thereafter
until the costs of execution, completion and remedying of any defects, damages
for delay in completion (if any) and all other expenses incurred by the Purchaser
have been ascertained and the amount thereof certified, by the Purchaser’s
Representative. The Supplier shall then be entitled to receive only such sum (if
any) as the Purchaser’s Representative may certify would have been payable to
him upon due completion by him after deducting the said amount. If such amount
exceeds the sum which would have been payable to the Supplier on due
completion by him, then the Supplier shall, upon demand, pay to the Purchaser
the amount of such excess and it shall be deemed a debt due by the Supplier to
the Purchaser and shall be recoverable accordingly.

9.49 Urgent Remedial Work

If, by reason of any accident, or failure, or other event occurring to in, or in

connection with the works, or any, part thereof, either during the execution of the
works, or during the warranty period, any remedial or other work is, in the
opinion of the Purchaser’s Representative, urgently necessary for the safety of
the works and the Supplier is unable or unwilling at once to do such work, the
Purchaser shall be entitled to employ and pay other persons to carry out such
work as the Purchaser’s Representative may consider necessary. If the work or
repair so done by the Purchaser is work which, in the opinion of the Purchaser’s
Representative, the Supplier was liable to do at his own cost under the contract,
then all costs consequent thereon or incidental thereto shall, after due
consultation with the Purchaser and the Supplier, be determined by the
Purchaser’s Representative and shall be recoverable from the Supplier by the
Purchaser and may be deducted by the Purchaser from any monies due or to
become due to the Supplier and the Purchaser’s Representative shall notify the
Supplier accordingly with a copy to the Purchaser. Provided that the Purchaser’s
Representative shall as soon after the occurrence of any such emergency as
may be reasonable, practicable, notify the Supplier thereof.

9.50 Outbreak of War

If, during the currency of the Contract, there is an outbreak of war, whether war
is declared or not in any part of the world which, whether financially or otherwise,
materially affects the execution of the works, the Supplier shall, unless and until
the contract is terminated under the provisions of this clause, continue to use his
 best endeavors to complete the execution of the works. Provided that the
Purchaser shall be entitled, at any time after such outbreak of war, to terminate
the Contract by, giving notice to the Supplier and, upon such notice being given,
the contract shall, except as to the rights of the parties under this clause and to
the operation of clause 27 ( Resolution of Disputes ) of the General Conditions of
Contract, terminate, but without prejudice to the rights of either party in respect
of any antecedent breach thereof.

9.51 Removal of Supplier’s Equipment on Termination

If the contract is terminated under the provisions of Clause 3.50 of the Special
Conditions of Contract the Supplier shall, with all reasonable dispatch, remove
from the site all Supplier’s Equipment and shall give similar facilities to his Sub-
Suppliers to do so.

9.52 Payment if Contract Terminated

If the contract is terminated in accordance with sub-clause 3.50, the Supplier

shall be paid by the Purchaser, insofar as such amounts or items have not
already been covered by payments on account made to the Supplier, for all work
executed prior to the date of termination at the rates and prices provided in the
Contract and in addition.

(a) The amounts payable in respect of any preliminary items referred to in the
Bill of Quantities, so far as the work or service comprised therein has
been carried out or performed, and a proper proportion of any such items
which have been partially carried out or performed.

(b) The cost of materials, Plant or goods, reasonably, ordered for the works
which have been delivered to the Supplier or of which the Supplier is
legally liable to accept delivery of such materials, plant or goods
becoming the property of the Purchaser upon such payments being made
by him.’

(c) A sum being the amount of any, expenditure reasonably incurred by the
Supplier in the expectation of completing the whole of the works insofar
as such expenditure has not been covered by any other payments
referred to in this sub-clause.

(d) Such proportion of the cost, as may be reasonable, taking into account
payments made or to be made for work executed, of removal of Supplier’s
Equipment under Clause 3.51 of the Special Conditions of Contract and, if
required by the Supplier, return thereof to the Supplier’s main plant yard in
his country of registration or to other destination at no greater cost.

(e) The reasonable cost of repatriation of all the Supplier’s staff and workmen
employed on or in connection with the works at the time of such
termination.

Provided that against any payment due from the Purchaser under this Sub-
Clause, the Purchaser shall be entitled to be credited with any outstanding
 balances due from the Supplier for advances in respect of Supplier’s Equipment,
materials and Plant and any other sums which, at the date of termination, were
recoverable by the Purchaser from the Supplier under the terms of the contract.
Any sums payable under this sub-clauses shall, after due consultation with the
Purchaser and the Supplier, be determined by the Purchaser’s Representative
who shall notify the Supplier accordingly, with a copy to the Purchaser.

9.53 Payment in the Event of Release from Performance:

If any circumstance outside the control of both parties arises after the issue of
the Notification of Award which renders it impossible or unlawful for either party
to fulfill his contractual obligations or under the law governing the contract the
parties are released from further performance, then the sum payable by the
Purchaser to the Supplier in respect of the work executed shall be the same as
that which, would have been payable under Clauses 3.50 to 3.52 if the contract
had been terminated under the provisions of clauses 3.50 to 3.52.

9.54 Default of Purchaser Due to insolvency

In the event of purchaser becoming bankrupt or, being a company, going into
liquidation, other than the purpose of a scheme of reconstruction or
amalgamation, the Supplier shall be entitled to terminate his employment under
the contract by giving notice to the Purchaser, with a copy to the Purchaser’s
Representative. Such termination shall take effect 14 days after the giving of the
notice.

9.55 Bribes

If the Supplier, or any of his Sub-Supplier, agents or servants gives or offers to

give to any person any bribe, gift, gratuity or commission as an inducement or
reward for doing or forbearing to do any action in relation to the contract or any
other contract with the Purchaser, or for showing or forbearing to show favour or
disfavour to any person in relation to the contract or to any other contract with
the Purchaser, then the Purchaser may enter upon the Site and the Works and
expel the Supplier and the provisions of Clause 23 ( Termination for Default ) of
the General Conditions of Contract hereof shall apply as of such entry and
expulsion had been made pursuant to that clause.

9.56 Joint and Several Liability

If the Supplier is a joint venture of two or more persons, all such persons shall be
jointly and severally bound to the Purchaser for the fulfillment of the terms of the
contract and the lead partner, as nominated and agreed with the Purchaser
during the Pre-qualification process, shall act as a leader with authority to bind
the joint venture. The composition or the constitution of the joint venture shall not
be altered without the prior consent of the Purchaser.

9.57 Details to be Confidential

The Supplier shall treat the details of the contract as private and confidential,
save insofar as may be necessary for the purposes thereof, and shall not publish
 or disclose the same or any particulars thereof in any trade or technical paper or
elsewhere without the previous consent in writing of the Purchaser or the
Purchaser’s Representative. If any dispute arises as to the necessity of any
publication or disclosure for the purpose of the contract the same shall be
referred to the decision of the Purchaser whose award shall be final.

9.58 Drawings and Photographs of the Works

The Supplier shall not disclose details of drawings furnished to him and works on
which he is engaged without the prior approval of the Purchaser’s
Representative in writing. No photograph of the works or any part thereof or
plant employed thereon shall be taken or permitted by the Supplier to be taken
by any of his employees or any employees of his Sub-Suppliers without the prior
approval of the Purchaser’s Representative in writing and no such photographs
shall be published or otherwise circulated without the approval of the
Purchaser’s Representative in writing.

9.59 The Apprentices Act 1961

The Supplier shall duly comply with the provisions of the Apprentices Act 1961
(III of 1961) the rules made thereunder and the orders that may be issued from
time to time under the said Act and the said Rules and on his failure or neglect to
do so he shall be subject to all liabilities and penalties provided by the said Act
and said Rules.

9.60 Supply of Plant, Materials and Labour

Except where otherwise specified, the Supplier shall at his own expense supply
and provide all the Constructional Plant, Temporary Works, materials both for
temporary and permanent works, labour (including the supervision thereof),
transport to or from the Site and in and about the works and all other things of
every kind required for the complete construction and maintenance of the works.

9.61 Gate Passes

For entry/exit within the Port area the Supplier shall arrange at his own cost for
the issue of gate passes as required for the work for labour and materials.

10.0 WORKPLACE HEALTH AND SAFETY

10.1 General Requirements

10.1.1 Responsibility
The Supplier shall be solely responsible for carrying out the works having
the highest regard for the safety of workers, persons at or in the
vicinity of the Site, the Works and the property of third parties.
10.1.2 Design

Where the Works include design/detail work to be undertaken by the Supplier,

statutory requirements for health and safety shall be incorporated into the
 design/detail and subsequently to the Works. When statutory requirements do
not adequately cover particular areas of work then international health and
safety requirements normally applied to such work shall prevail.

10.1.3 Work on Site

For the Supplier to comply with its obligations under Clause 4.1.1 above the
Supplier shall be required to undertake the following as a minimum

 Active promotion of safety among employees.

 Hold regular safety meetings with employees (tool box meetings)
 Supplier’s management to be involved in overall Site safety meetings which
shall be attended by all Suppliers/suppliers on Site.
 Carry out regular safety audits of the work Site and correct/rectify areas
identified as unsafe or that may cause a health risk to the Supplier’s
employees or others.
 Provision and maintenance of all necessary safety equipment for employees
e.g. safety hats, safety footwear, eye protection etc.
 Employment of personnel with either a positive prior safety performance
record or who are capable of meeting the safety goals set for the
Supplier/Site.
 Training of Supplier’s personnel for particular/difficult erection or construction
sequence or process.
 Carry out inductions of Supplier’s workforce covering particular site rules,
regulations and safety requirements prior to commencement of work on Site.
 Enforce safety rules and statutory regulations.
 Carry out assessment of work methods for operation involving specific
hazards.
 Ensure all equipment being used by the Supplier is appropriate to the task
and can operate in a safe manner.
 Conducts investigations into and provide written reports for all lost time injury
accidents and/or incidents which may have caused a lost time injury.
 Provide statistics for the number of personnel employed, hours worked and
the number of minor, medical treatment, lost time injuries etc.
 Provide list of hazardous substance brought to the Site and ensure
storage/use in accordance with the material safety data sheet (MSDS).
Provide the Purchaser’s Representative with a copy of all safety data sheets.
 Ensure Supplier’s visitors to the work Site comply with specific safety
inductions prior to being allowed access to the Site.
 Provision of adequate first aid equipment and facilities to cover minor injuries
sustained at the work Site.
 Implementation of a danger/out of service tag (lockout) system for work on
live equipment/machinery.
 Specify accountability for safety within the Supplier’s Site Organisation
structure.
 Implement fire safety requirements to the work Site by provision of adequate
fire extinguishers etc. And storage of flammable/dangerous substances in
accordance with statutory rules and regulations.
  Complying with legislation on health and safety as applied to carry out work
in India.
 Provision of adequate security to ensure compliance with the above
requirements.
 Housekeeping of the Site to promote hazard removal, proper storage,
tidiness and cleanliness.
 Ensure clean up of Site at the end of the Contract.
 Carryout/implement all safety/health instruction and/or procedures issued by
the Purchaser’s Representative.

For the purpose of this Sub-Clause the word employees shall include the
Supplier’s Sub-Suppliers and their employees.

10.2 Health and safety Plan

The Supplier shall develop, implement and administer a Health and safety Plan
specific to the Services performed on the Site. The plan shall be in writing and
shall be submitted to the Purchaser’s Representative prior to the
commencement of the services on the Site.

10.3 Site Health and Safety manual for Suppliers

The Supplier shall comply with the requirements of Site Health and safety
manual for contractors which forms part of Section IV Special Conditions of
Contract and is included in the contract documents as volume-III. The Health
and safety plan produced by Supplier in accordance with Sub-Clause 10.2
above shall embody the requirements of this manual.

11.0 SITE FACILITIES

11.1 Facilities Supplied by the Supplier

The Supplier shall supply all services, amenities, temporary structures including
security fencing and storage compounds, machinery, buildings and construction
equipment necessary for the proper execution of the Services at Site except for
the items specified in Sub-Clause 5.2 below, which will be provided by the
Purchaser.

11.2 Facilities Supplied by the Purchaser

The Purchaser will make available to the Supplier the following services on
chargeable basis as per the prevailing terms and conditions of Paradip Port
Trust:

(a) Supply of land for Supplier’s site establishment and laydown areas:

The Purchaser will make available to the Supplier a prepared hardstand

area for the reclaimer and an undeveloped area for the Supplier to locate
its Site facilities and to use as a lay down and erection area. The Supplier
 shall restrict its Site facilities to the nominated area and not use any other
area on the Site without written approval of the Purchaser.

Applicable Rents in force at present:

(i)Outside Customs Barrier Rs.75.00 per 200m2 per month

(ii)Inside Customs Barrier (open)Rs.200.00 per 200m2 per month

(b) Construction Water

The Purchaser will provide a reasonable quantity of construction water at

one point adjacent to the Supplier’s work area. Any further reticulation to
the Supplier’s individual facilities shall be the Supplier’s responsibility and
cost.

The Supplier shall be required to pay for water usage at the following
rates.

(i) Rs.12.00 per MT, where a meter is fixed for 12 mm ferrule

connection.
(ii) Rs.1800.00 per month, if a ferrule connection is provided.

(c) Electric Power

The Purchaser will provide electric power at one point adjacent to the
Supplier’s work area on production of a clearance from the Electrical
inspectorate, Govt. of Orissa. Any further reticulation to the supplier’s
individual facilities shall be the Supplier’s responsibility and cost.
Up to 100 kVA
Power will be provided at 400V 3 phase 50 cycles. The monthly charges
shall be demand charges at Rs.90.00 per kVA of the demand plus energy
charges at RS.1.65 per unit.

Monthly minimum charges shall be calculated on a demand of 80% of the

contract demand and of units calculated on a power factor of 0.9 and a
load factor of 20% of the contract demand. The contract demand can only
be increased once and reduced once by the Supplier during the contract
period. The Supplier shall also pay towards the cost of the development of
the power supply into the Supplier’s premises at actual cost.

Two months consumption charges shall be collected in advance as a

security deposit. No interest shall be paid on this deposit.

The Purchaser does not guarantee the continuity of supply. In the event of
a power failure the Supplier shall be required to make its own
arrangement for the provision of electric power.
12.0 PROGRAMMING

12.1 Programmes

12.1.1 General
The Supplier shall prepare and submit in it’s technical bid the following
programmes ( 2 sets ) clearly indicating the activities so as to complete the
contractual obligations in all respect.
(a) Critical path Network (henceforth called “the network)

(b) Time Scaled Bar Chart (henceforth called “the bar chart”)

12.1.2 Programme Activities

Each activity shall be –

 a continuous item of work.

 measurable.

The list of activities given in the Bid Document is preliminary only. After award of
the Contract the activity list will be reviewed by the Purchaser’s Representative
and the Supplier and extended to allow for the proper management and
programming of the Contract.

12.1.3 Critical Path Network (“Network”)

The Supplier shall prepare and submit to the Purchaser’s Representative a

critical path, network. The network shall clearly indicate the logic and sequence
of activities necessary to complete the Works and shall include but not be limited
to the following :

(a) The duration of each activity.

(b) Early start, late start, early finish, late finish of each activity.
(c) The critical path.
(d) Precedence relationships between activities.
(e) Date of the issue of the Notification of Award.
(f) Dates of submission of documents requiring review to the Purchaser’s
Representative.

(g) Statutory approval dates.

(h) Date of commencement of the Services on the Site.
(i) Date for completion of the Contract separable portions of the Contract.
(j) Manufacture and delivery durations for the Goods.
(k) Dates by which Purchaser supplied items, if any, are required by the
Supplier.

Activity duration shall be in multiples of one week, allowing for public holidays or
other non-working days.
12.1.4 Time Scaled Bar Chart (“Bar Chart”)

The Supplier shall, after Letter of Intent, prepare and submit to the Purchaser’s
Representative a time scaled bar chart and a critical path network for
acceptance after which the Work Order will be issued. These programmes, after
acceptance by the Purchaser’s Representative, shall be used for monitoring the
progress of the works.

(a) Activities
The activities included in the bar chart shall be the same as those in the
network Each activity shall have a separate bar on the bar chart. Each
activity shall be allocated a percentage of the total Contract Price by the
Supplier.

(b) Durations
Each activity shall be represented by a continuous bar. The length of the
bar shall represent the activity duration and start and finish dates shall be
the latest start and latest finish dates as determined by the network.

(c) Critical Path

Activities which lie on the critical path as determined by the network shall
be clearly identified.

(d) Off-Site and On-Site activities

Off-Site and on-Site activities shall be clearly defined and segregated on
the Bar chart.

(e) Calendar
The bar chart heading shall show the year, the month and the Contract
week number. The bar chart shall commence on the Date of the
Notification of Award.

12.1.5 Programme Submission

The Supplier shall submit both the network and the bar chart within 28 days of
the Date of the Notification of Award

12.1.6 Programme Revisions

The Supplier shall revise the programmes when either of the following events
occur :
 the issue of a contract change Order/variation which affects the programmes,
or
 a change in method of working adopted by the Supplier which affects the
programmes.
If the event causes a change to the critical path, the Supplier shall submit the
revised programmes to the Purchaser’s Representative within seven (7) days of
the event occurring. If however, the critical path is not changed by the event, the
Supplier shall submit the revised programmes by the end of the month in which
 the event occurs or within seven (7) days of the event occurring, whichever is the
longer period.

The revised programmes shall clearly indicate the following

 the reason for the revision.

 The difference between the revised programmes and the previously
approved programmes and
 The revision number of the revised programmes.

The Purchaser’s Representative’s written acceptance of any revised

programmes shall be required prior to the revised programmes being used to
replace the previously accepted programmes.

The revised programmes shall be prepared at the cost and expense of the
Supplier.
12.1.7 Supplementary Programmes

The Purchaser’s Representative may direct the Supplier at any time to produce
supplementary programmes to highlight a particular aspect of the works.

12.2 Progress Reporting

12.2.1 Progress Monitoring

Actual progress will be monitored monthly and shall be derived from the
Supplier’s monthly statement of the measured progress of each activity.

The Supplier shall indicate the percentage completion of each activity in

successive monthly statements.

12.2.2 Progress Report

The Supplier shall provide a written progress report with his monthly statement.
The report shall summarize progress and problems encountered during the
preceding month and shall include detailed comments with respect to the
following:
i. activities or items of work commenced and/or completed during the month.
ii. activities or items of work scheduled for commencement and/or completion
during the month but not commenced or completed with reasons for the
delay, intended remedial action and likely effect on the overall programme.
iii. status of procurement items.
iv. problems or anticipated problems.

In the event of any slippage, the Supplier shall clearly indicate the reason for
such slippage, the efforts initiated to make good the slippage and submit a
written report to this effect to the Purchaser’s Representative.
12.2.3 Photographic/ Video Record of Progress of the Works

The Supplier shall provide with the monthly progress report, or at such other
periods directed by the Purchaser’s Representative, four (4) sets of
professionally executed colour photographs showing the progress of the works
to date. The number of photographs shall be 112 mm x 67 mm (or nearest
equivalent) and shall be presented in a sturdy album. The negatives shall be
separately packed and delivered with the album.

During the course of the contract the Supplier shall maintain a video record of
the progress of the services on Site from initial site establishment to
demobilization after the issue of the Certificate of Commissioning. All the main
construction activities shall be captured on the video which shall be a minimum
of 3 hours duration and shall be recorded on new first quality video tape in the
VHS format. The completed tape shall be handed over to the Purchaser’s
Representative after the issue of the certificate of commissioning of goods. The
Purchaser’s representative may at any time and from time to time view the video
tape during the course of the contract.

13.0 RECEIPT OF MATERIALS ON SITE

The Supplier shall maintain detailed records of all materials and equipment
received on the Site and into the Suppliers store and shall make such records
available to the Purchaser’s Representative at the

Purchaser’s Representative’s request. However, the Supplier shall submit a

statement of materials at site every month to the Purchaser’s Representative
clearly indicating the description of the material, it’s origin, date of receipt at the
site, date of use at the site etc.

14.0 PURCHASE ORDERS

The Supplier shall submit to the Purchaser’s Representative unpriced copies of

all Purchase Orders issued for the supply of materials or equipment to be used
in the works.

The Purchase Order shall be submitted within 28 days of the Purchase Order
being awarded.

15.0 PROTECTION OF THE ENVIRONMENT

The Supplier shall take all responsible steps to minimize the destruction of flora
and pollution of the environment caused by the performance of the Services on
Site. The Supplier shall observe all directions issued by the Purchaser’s
Representative from time to time on the subject. The Supplier shall ensure that
its employees and Sub-Suppliers are made aware of all such directions.
The Supplier shall perform the Services on Site in an environmentally
responsible manner and shall minimize damage to the areas in which the
 Services are performed. Equipment movements shall be restricted to those
areas essential for performing the Works.

The Supplier shall provide suitable facilities to prevent the introduction from the
Supplier’s work area of any substance or material into any well, stream, river,
lake, ocean or other watercourse which may pollute the water or be deleterious
to fish and other wildlife.

The Supplier shall comply with statutory regulations issued by the Government
of India Ministry of Environment and Forest and any other Governmental bodies
having jurisdiction over the Site and with the Purchaser’s Representative’s
direction with respect to the discharge into the atmosphere of smoke, dust or
other contaminants or the creation of undue noise.

The Supplier shall preserve and protect all cultivated and planted areas and
vegetation such as trees, plants, shrubs etc on or adjacent to the Site which do
not interfere with the performance of the Contract.

The Site drainage system shall not be used to dispose of waste materials other
than those for which it was designed.
The Supplier shall immediately notify the Purchaser’s Representative of any
spillage of oil, grease or other hazardous substance. The Purchaser’s
Representative shall advise the Supplier of the required method of disposal. The
Supplier shall dispose of all pollutants and clean up any spillage at its own cost
and to the satisfaction of the Purchaser’s Representative.

16.0 CO-OPERATION WITH OTHER SUPPLIERS

During the progress of the Services on Site work may be progressing on other
Contracts in locations that directly affect this Contract. The Supplier shall make
due allowance for access by other Suppliers/Suppliers for the delivery and
storage of their materials and the execution of their work, and shall properly
connect and co-ordinate his work with the work of other Suppliers under the
overall control of the Purchaser’s Representative.

If any part of the Supplier’s work depends for proper execution upon results of
the work of another contract, the Supplier shall inspect and promptly report to the
Purchaser’s Representative any defect in such work that render it unsuitable for
such proper execution of Supplier’s work. Failure to inspect and report shall
constitute an acceptance of the other Supplier’s work as fit and proper for the
reception of his work except for defects which may develop in the other
Supplier’s work after the execution of the Supplier’s work carried out under this
Contract.

The Supplier shall carry out the services in such a manner as to minimize
inconvenience to other Suppliers on the Site.

17.0 RESTORATION OF OTHER SUPPLIER’S/SUPPLIER’S WORKS

 Where during the course of performing the Services, the Supplier disturbs or
damages the completed or semi-completed work of another Supplier it shall be
the Supplier’s responsibility to return the work to the original state.

This requirement shall apply irrespective of whether the disturbance or damage

is accidental or is necessitated by the normal course of work.

Where existing earthworks or road formation are disturbed and existing

protective coating or paintwork are damaged, these shall be restored by the
Supplier to the standards specified in the Contract or, where not specified, in
accordance with a specification issued by the Purchaser’s Representative.

The cost of all restoration work shall be borne and paid by the Supplier with out
any liability to the Purchaser.

18.0 EXISTING SERVICES

Prior to commencement of the Services on Site, the supplier shall satisfy himself
as to the location and/or depth of all utility mains and customer services and
shall guard and protect the services from damage during the Contract.

Any damage to existing services, whether or not shown on drawings, shall be

repaired without delay by the Supplier, to the satisfaction of the Purchaser’s
Representative and at the Supplier’s cost.

19.0 PORT TRUST RULES

The Supplier shall observe the conservancy rules relating to the Harbour and
shall comply with the working rules and regulations of the Port Trust as issued
from time to time.

20.0 PURCHASER SUPPLIED EQUIPMENT

The Purchaser shall provide the track line for traveling of the reclaimer, access
to the site, power and water at the site as per the provision of the contract with
in 3 weeks of receipt of requisition from the Supplier.

21.0 PROVISIONAL SUMS

Provisional sum shall mean a contingency provision, if provided in the

Bill of Quantity, to meet unforeseen expenses during the continuance of
the contract. Such provisions, where available in the Bill of Quantity
may be utilized for the supply of goods or services on the instruction of
the purchaser’s representative. The amount so spent for the supplier’s
goods or services shall be due to the supplier as per the actual
supported by sufficient documentary evidences acceptable to the
purchaser’s representative.

22.0 COMPLIANCE WITH LABOUR REGULATIONS

The Supplier and all the Suppliers’ Sub-Suppliers shall abide by the laws and
regulations governing labour on the site.
23.0 CHANGES IN COST AND LEGISLATION

23.1 Price Adjustment

Prices and rates charged by the Supplier for Goods delivered and Services
performed under the Contract shall not vary from the prices and rates quoted by
the Supplier in its Bid unless otherwise specified. No price adjustment shall be
allowed except for variation in taxes, duties, cess etc. arising out of changes in
regulation pursuant to Clause No.23.3 of SCC. However, for Operation and
Maintenance price adjustment shall be allowed as per the formula given below:
Pr = P0 (0.20 + 0.80 L1/L0) where
Pr = Revised Price after price adjustment.
P0 = Original Price quoted for the 1st year.
L0 = Consumer price Index Number for Industrial Workers at
Bhubaneswar issued by Govt. of India, Ministry of Labor as on the base date,
that is the last date of submission of Bid.
L1 = Consumer price Index Number for Industrial Workers at
Bhubaneswar issued by Govt. of India, Ministry of Labor as on the 1 st day of the
1st year, 2nd year, 3rd year and so on. For Example, for the 1st year Pr = P0 (0.20
+ 0.80 L1/L0) where L1 will be the consumer price index Number for industrial
workers on the 1st day of 1st year of O&M and L0 will be the consumer
price index for industrial workers on the base date. The price adjustment shall
be made once in a year. L0 shall not vary during the period of O&M Contract.

23.2 Other Changes in Cost

Unless specifically provided in this contract, the contract sum shall be deemed to
include amounts to cover the contingency of all other rise or fall of cost.

23.3 Subsequent Legislation:

If, between 28 days prior to the latest date for submission of the tender and the
original date of completion of the work, there is any change in taxes, duties and
cess arising out of changes to any National or State statute, Ordinance, Decree
or other law or any regulation or bye-law of any local or any duly constituted
authority and such changes cause additional or reduced cost to the Supplier in
the execution of the contract, such additional or reduced cost shall, after due
consultation with the Supplier and the Purchaser, be determined by the
Purchaser’s representative and such cost shall be added to or subtracted from
the Contract Price. Changes in Legislation occurring after the original date of
completion of the work shall not be considered.

24.0 GENERAL OBLIGATIONS OF THE SUPPLIER:

24.1 The supplier shall pay all taxes, duties , fees, levies , RD Cess and all other
imposition imposed by or under any authority in India as well as abroad in respect of
all services, equipment, materials, goods and all other supplies.

24.2 The supplier shall carry out the obligations under the contract with due diligence and
efficiency and in conformity with sound engineering, administrative and financial
practices.
24.3 The supplier shall act at all times so as to protect the interests of the purchaser and
will take reasonable steps to keep all the expenses to a minimum consistent with
sound economic and engineering practices.

24.4 The supplier shall prepare all specifications and design using the metric systems
incorporating the current design criteria.

24.5 The supplier shall undertake that the design will be suitable to achieve the objectives
of the project and will perform the function for which it is designed.

24.6 The supplier shall, at its own cost and expense , upon request of the purchaser, re-
perform the services in the event of supplier’s failure to exercise the skill and care
required under sound engineering, administrative and financial practices.

24.7 The supplier’s responsibility shall, inter alia , include total project management
including detailed designs , drawings, specifications, construction, supervision,
testing and commissioning of the project.

24.8 The supplier shall plan the construction and procurement programme properly so as
to achieve economical and early completion of the project.

24.9 The supplier shall at all times utilize the most economical, effective and widely
accepted engineering concepts and design standards consistent with the project
objectives.

24.10 The supplier shall consult and co-operate with the concerned government
agencies/local authorities especially relating to the construction and/or other
associated works.

24.11 The supplier shall take full responsibility for the care of the works and materials and
plant from the commencement date until the date of issue of the taking over
certificate for the whole of the works when the responsibility of the said care shall
pass to the purchaser.

24.12 The supplier shall, in accordance with the requirements of the engineer afford all
reasonable opportunities to other Suppliers/ suppliers employed by the purchaser for
carrying out their work. This opportunities shall also be extended to the workmen of
the purchaser or the workmen of any duly constituted authorities who may be
employed in the execution on or near the site of any work not included in the contract
or of any contract which the purchaser may enter into in connection with or ancillary
to the works. Pursuant to the above, the supplier shall on the written request of the
engineer:-

a) Make available to any such other supplier or to the purchaser or any such
authority, any roads or ways for the maintenance of which the supplier is
responsible or
b) Permit the use of any such temporary works or supplier’s equipment on the
site or
c) Provide any other services of what so ever nature.
 For providing the above, if requested by the Supplier, the engineer shall
determine a reasonable addition to the contract price and shall notify the
supplier accordingly.

24.13 During execution of work the supplier shall keep the site reasonably free from all
unnecessary obstructions and shall store or dispose any supplier’s equipment and
surplus materials and clear away and remove from the site any wreckage , rubbish or
temporary works no longer required for the work.

24.14 The supplier shall maintain site account of materials clearly indicating relevant
information such as description of the material, source, date of delivery at site, date of
consumption at site. The supplier shall forward a copy of monthly site account of materials
to the Engineer in Charge at the end of every month. On completion of the work under the
contract, the Supplier shall submit to the Engineer in Charge a copy of the site account of
the materials from the date of commencement to completion of the work in all respect.

25.0 OPERATION AND MAINTENANCE (O&M)

25.01 Period of O&M Contract :

The period of Operation Maintenance shall be 5 years from the date of
acceptance of the machine by PPT including the warranty period. Paradip Port
reserves the right to vary the period of the O&M Contract giving 60 days notice
to the Supplier.

25.2 Notice for Operation :

The machine shall be used for reclaiming as per the requisition made by
PPT. The operation in-charge shall serve 4 hrs. notice to the Supplier to
keep the machine ready for operation and the Supplier shall ensure that
the machine is positioned and ready for operation by the end of 4hrs.
notice. A register shall be maintained by the Supplier to record all the
operational parameters date wise such as :
• 4 hrs. Notice received at _______ hrs.
• Machine positioned and on stand-by at ______ hrs.
• Operation commenced on Plot No. ______ at ______ hrs.
• Operation Completed at _____ hrs.
and so on.
The register may also record other important data such as load, important
temperatures, pressures, levels etc. and other vital data observed during the
operation.

25.3 Efficient Operation :

The Supplier must ensure that the machine is operated in the most efficient
manner without sacrificing any safety aspect and giving due regards to the
health of the machine as well as personnel.

25.4 Experienced Staff :

The Supplier must engage trained and experienced staff for O7M of the
machine.
25.5 Watch & Ward
During the O&M contract watch and ward and house keeping shall be the
responsibility of the Supplier at his own cost.

25.6 Maintenance Plan :

The Supplier shall prepare a maintenance plan acceptable to PPT and ensure
timely maintenance of the machine as per the plan. A monthly report is to be
submitted by the Supplier on maintenance of the machine. In case of any failure
by the Supplier to carryout the maintenance as per the schedule, it shall be
treated as a default and may attract a deduction from the Bills of the Supplier up
to 10% of the monthly bill. While deciding on the schedule maintenance plan, the
manufacturer’s recommendations should be followed.
However, the schedule may be amended later, if necessary and in consultation
with the Engineer-in-charge with a view to make it more appropriate to meet the
site needs.

25.7 Spare Parts & Consumables :

All the spare parts shall be supplied by PPT whereas all the consumables such
as cleaning materials etc. shall be supplied by the Supplier without any
additional cost to PPT. However, during the warranty period, if any spare is
required to be used on the machine, then the Supplier shall have to bear the
cost.

25.8 Co-ordination with Operation in-Charge :

The Supplier shall ensure that the machine is operated in close co-ordination
with the IOHP operation in-charge. In case of any maintenance, planning shall
have to be done by the Supplier in advance and in consultation with the
operation in-charge so as to make the best use of the idle period.

25.9 Written Clearance :

Where the maintenance period is expected to exceed 4 hrs., the Supplier must
obtain written clearance, in a format acceptable to PPT, from the operation in-
charge clearly indicating the nature of maintenance intended to be undertaken,
expected time of commencement and completion.

25.10 Advance Notice for Spares :

The Supplier shall keep PPT informed of the spares requirement well in advance
so as to avoid long machine down time.

25.11 Supplier to Provide Spares on request :

In the event, the spares/materials required is not available with PPT and the
requirement is urgent, PPT may request the Supplier in writing to arrange for the
same and the Supplier shall arrange to supply the spare/materials for which the
expenses shall be borne by PPT as per actual on submission of documentary
evidences. The Supplier shall ensure that the spare parts so procured by him are
genuine and either from the maker or from their authorized agents.

25.12 Supplier to Provide Consumables :

 The Supplier shall provide all consumables necessary for house keeping, routine
checking and maintenance such as cotton rags, cleaning agents, hose pipes,
general tools and tackles.

25.13 PPT to Supply Spares, Steel :

Paradip Port shall supply all the spares, steel materials, hard wares such as nuts
and bolts, Paints etc.

25.14 Maintenance of Records :

The Supplier shall maintain the following records :
a) Operation Register/Log Book
b) Scheduled maintenance Register/Log Book
c) Break Down Maintenance Register/Log Book
d) Site Inspection Register.
e) Site Materials Accout Register.
The format of the above Log Books shall be as per the requirement of the
Engineer-in-charge.

25.15 Monthly Reports ;

The Supplier shall submit the following monthly reports in a format acceptable to
PPT along with the Bills a) Extract of Operation, b) Extract of Scheduled
maintenance, c) Extract of Break Down maintenance d) Inspection Report on
House keeping e) Spares Consumption Report. Without these reports Bills shall
not be released for payment.

25.16 Periodic Inspection :

The Supplier shall have to arrange for periodic inspection of specialized
equipment such as control and automation system, hydraulic system etc. once in
a 6 month by the manufacturer’s experts to assess the health of the systems and
make suitable recommendations to maintain the reliability of the system. The
cost of such inspections to be conducted by the experts shall have to be borne
by the Supplier without any additional financial liability to the Purchaser. A copy
of the inspection report shall be forwarded by the Supplier to the Engineer-in-
charge.

25.17 Improvement Plans :

During the course of the O&M Contract, the Supplier may suggest improvement
plans to make the machine more reliable and efficient and PPT shall examine
such plans and if such plans are acceptable to PPT, PPT reserves the right to
implement the plan either by engaging the Supplier or any other agency. In such
cases, the Supplier shall extend all co-operation to PPT for implementation of
any modification plan with least interruption to the site activities. In case the
Supplier is entrusted with the modification work, the Supplier shall have to carry
out the work without discontinuing the on-going O&M Contractual obligations in
any manner.

25.18 Operation Modes :

The machine shall be manned for O&M on 3 shift basis a day and 365 days a
year. The machine shall be used for reclaiming as per the requirement of the
operation-in-charge. The Supplier shall not be entitled to any additional payment
on account of working on 3 shift basis and 365 days a year.
25.19 In the event of any break down maintenance, the Supplier shall put in it’s best
effort to promptly attend the break down and bring the machine to an operating
condition as early as possible . If necessary, the Supplier shall arrange and
deploy more manpower to reduce the break down period. Also, if the Services of
any expert are required, the Supplier shall arrange the same in the most
expeditious manner at his own cost. After each Break Down, a joint inspection
shall be conducted to assess the cause of the failure. In the event the joint
inspection report established that the failure is due to negligence on the part of
the Supplier, all the costs of repair including the cost of materials, spares and the
services shall be borne by the Supplier. In all other cases PPT shall borne the
expenses. When the machine is under break down, the Supplier’s workmen shall
be deployed for carrying out repairs of the machine. In case the break down
repair is being done by PPT or some other Supplier, the Supplier’s workmen shall
assist in the repair, if so required by the EIC.

25.20 Warranty :
The Supplier shall ensure that the O7M of the machine is carried out with due
diligence, skill and care following sound engineering, financial and administrative
practices. The Supplier shall ensure that the obligations under the O&M contract
are carried out as per the terms and conditions of this contract. After
commissioning and testing of the machine, the machine shall be taken over by
the Purchaser and again handed over to the Supplier for O&M. the relevant
conditions of this contract shall also apply during the O&M period.

25.21 CORE PERSONNEL:

The Supplier shall indicate the names of the core personnel who would be in
charge of the O&M. the over all in-charge nominated by the Supplier shall co-
ordinate with PPT in all matters related to O&M as well as the warranty
obligations during the 1st year. The Supplier shall have to deploy at least 1
Mechanical Engineer and 1 Electrical & Automation Engineer is to be submitted
to the Purchaser for acceptance. The Engineers so deployed must have
adequate experience in their respective fields preferably in any Bulk Material
Handling Plant. Besides Engineers, the Supplier shall deploy adequate
experienced work men such as operators, electricians etc. so as to discharge all
the obligations under the contract efficiently.

25.22 SAFETY PRECAUTIONS

The Supplier shall observe all applicable regulations regarding safety on the
machine.

25.23 Authority for Access

No persons other than Supplier’s Personnel shall be allowed on the machine

except with the consent of PPT. The employees of the Supplier must possess
proper identity card having their photographs.

25.24 COMPLIANCE WITH STATUTES, REGULATIONS :

 In performing the work, the Supplier shall comply in all respect with all
Applicable Laws of any duly constituted authority in the country.
The Supplier shall keep PPT indemnified against all penalties and liability of
every kind for breach of laws relating to compliance with environmental, health,
safety, and similar laws.

26.0 PAYMENT

26.1 The total contract price for payment purpose under this clause shall not
include the price quoted for operation and maintenance of the machine.
Payment for operation and maintenance of the machine shall be made on
monthly basis on successful completion of the operation and maintenance
for the preceding month. Payment of the contract price shall be made in
the following manner.

(a) 10% of the total Contract Price as an interest free advance payment after
• the execution of the Form of Agreement by the parties
• the provision of the required performance security, and
• the provision of an unconditional bank guarantee in a form and by a
bank acceptable to the Purchaser in amounts and currencies equal to
the advance payment.
• Invoice.

26.2 GOODS

(a) 50% of the Price quoted for the Goods shall be paid, after:

for Imported Goods:

• receipt of the following documents by the bank.

• Full set of original negotiable clean on-board

bills of lading drawn or endorsed to the order of the Purchaser and
marked “freight pre paid”.
• Copy of insurance certificate for 110% of the
invoice value, showing claims payable at the destination covering Institute
Cargo Clauses (A), Institute War Clauses (Cargo) and Institute Strikes
Clauses (Cargo).
• Inspection Certificate issued by the
Purchaser’s Representative, if any.
• Manufacturer’s warranty certificate, if
applicable.
• Certificate of Origin issued by Chamber of
Commerce.
• Packing List.
• Invoice showing the total CIF value of the
goods delivered.
 • Supplier’s certificate that the amounts in the
invoice are correct in terms of the Contract and that all terms and
conditions of the Contract have been complied with.

for Domestic Goods

• Receipt by the bank of the following documents.

• Railway or transport receipt.
• Insurance certificate.
• Manufacturer’s/supplier’s guarantee certificate.
• Inspection certificate issued by the
Purchaser’s Representative, if any.
• Packing list
• Certificate of Origin issued by Chamber of
Commerce.
• Invoice showing the total CIF value of the
goods delivered.
• Supplier’s certificate that the amounts in the
invoice are correct in terms of the Contract and that all terms and
conditions of the Contract have been complied with.

(b) 30% of the price quoted for the goods shall be paid on installation & erection
of the goods on the machine.

(c) 20% of the price quoted for the goods shall be paid on satisfactory final testing
& commissioning of the goods.

26.3 DESIGN, DRAWINGS AND DOCUMENTS:

(i) 40% of the price quoted in the BOQ for drawing & documents shall
be paid on submission of drawings certified as “good for construction” of
the machine.
(ii) 20 % of the price quoted in the BOQ for drawing & documents shall
be paid on submission of “Construction Drawings” of the machine up to
Slewing deck level.
(iii) 20 % of the price quoted in the BOQ for drawing & documents shall
be paid on submission of “Construction Drawings” of the machine
complete with the upper structure, operator’s cabin etc.
(iv) 20 % of the price quoted in the BOQ for drawing & documents shall
be paid on submission of “As Built Drawings” , all manuals and
documents as per the contract.

26.4 INSTALLATION & ERRECTION – ELECTRICAL:

(i) 40 % of the price quoted in the BOQ for installation &erection -

Electrical shall be paid on successfully completion of installation &
erection of all Electrical Equipments except cabling.
 (ii) 40% of the price quoted in the BOQ for installation & erection-
Electrical shall be paid on successfully completion of cabling of all the
equipment as per the approved drawings.

(iii) 20% of the price quoted in the BOQ for installation & erection -
Electrical shall be paid on successfully completion of final testing &
commissioning of the machine.

26.5 INSTALLATION & ERRECTION – MECHANICAL:

(i) 40 % of the price quoted in the BOQ for installation &

erection - Mechanical shall be paid on successfully completion of
installation & erection of all Mechanical Jobs up to the lower
frame. Lower frame means up to the landing platform of slew
bearing.
(ii) 40% of the price quoted in the BOQ for installation & erection -
Mechanical shall be paid on successfully completion of installation &
erection of the superstructure/ upper frame i.e inclusive of all the
mechanical erection jobs.
(iii) 20% of the price quoted in the BOQ for installation & erection -
Mechanical shall be paid on successfully completion of final testing &
commissioning of the machine.

26.6 TESTING & COMMISSIONING:

80% of the price quoted in the BOQ for Testing and Commissioning shall be paid
on successful completion of “ NO LOAD TESTS “ as per the terms and
conditions of the Contract.

20% of the price quoted in the BOQ for Testing and Commissioning shall be paid
on successful completion of “ LOAD TESTS “ as per the terms and conditions
of the Contract.

26.7 INITIAL SPARES

50% of the price quoted for the initial spares shall be paid on dispatch of the
documents and further 30% shall be released after the spares are delivered at
Paradip Port Trust and 20 % shall be released on acceptance of the Spares.

26.8 In case of staggered procurement of goods and initial spares, the payment
shall also be staggered in the same manner but the schedule as mentioned in
this clause shall apply.

26.9 Prior to final payment, the Supplier shall submit an irrevocable Bank
Guarantee of 10% of the total contract value ( excluding the price
quoted for Operation & Maintenance ) towards Warranty Obligations under
the contract.
26.10 Recovery of Advance Payment:
The advance payment made to the Supplier shall be adjusted @10% of each
Invoice till the full amount is recovered. The Supplier may adjust the Bank
Guarantee accordingly under intimation to the Purchaser’s Representative.

SUMMARY OF PAYMENT CLAUSE: 26

Stage Amount Remarks
On signing of 10% of Total Contract Amount O&M price offered in the
agreement etc. against a B.G. of equivalent BOQ not to be included
amount. in the total contract price
GOODS
On despatch of 50% of the cost of the goods In case of procurement
documents of the quoted in the BOQ. in phase, payment shall
goods. also be made in phases.
On erection & 30% of the cost of goods quoted In case of erection &
installation of the in the BOQ. installation in phase
goods . payment shall also be
made in phases.

On final testing& 20% of the cost of goods quoted In case of testing &
commissioning of in the BOQ . commissioning in phase,
the goods . payment shall also be
made in phases.
DESIGN, DRWINGS & DOCUMENTS::

Drawing & Document

on submission of 40% of the cost of drawings & Drawing must be good
drawings “good for document . for manufacturer .
construction” of the
machine.
On submission of 20% of the cost of drawings and To be supplied timely in
construction documents line with the work
drawings up to slew progress.
deck level including
slew bearing
landing platform
On submission of 20% of the cost of drawings and To be supplied timely in
balance constru- documents line with the work
ction drawings for progress.
completion of the
work
On submission of 20% of the cost of drawings & Complying clause no:
“As built” drawings documents . 6.7, volume-2, page
of the machine , no:38
manuals and
documents.
Installation & erection ( Electrical )
On successful 40% of the cost of installation &
completion of all erection- Electrical
electrical equipment
except cabling
On successful 40% of the cost of installation &
completion of erection – Electrical.
cabling of all the
equipment as per
the approved
drawings.
On successful 20% of the price quoted for
completion of final installation & erection - Electrical
testing &
commissioning

Installation & Erection _ Mechanical

On successful 40% of the cost of installation &
completion of all erection- Mechanical
mechanical jobs up
to the lower frame
On successful 40% of the cost of installation &
completion of all erection – Mechanical
the balance
mechanical jobs.
On successful 20% of the price quoted for
completion of final installation & erection
testing & -Mechanical
commissioning
Testing & commissioning
On successful 80% of the price quoted for
completion of testing & commissioning of the
testing & machine.
commissioning of
the machine on NO
LOAD.
On successful 20% of the price quoted for
completion of final testing & commissioning of the
testing & machine.
commissioning of
the machine ON
LOAD.
INITIAL SPARES
On dispatched of 50% of the price quoted for initial
the documents of spares .
initial spares
On delivery of initial 30% of the price quoted for
spares at site . initial spares
On Acceptance 20% of the price quoted for
initial spares

27. DEDUCTION ON DEFAULT

The Supplier shall ensure that the machine is available on demand all the
time. Failure on the part of the Supplier to meet the demand at 95% and
above shall attract a deduction on account of underperformance. The
availability shall be calculated as under :

Availability of Plant

a= Total demand raised

b= Demand met
% of availability = a – b X 100
a

Non-availability of the machine due to the following shall not be considered.

i) Non-availability of power supply from the PPT supply source.

ii) Force maejure.

iii). Any other cause which is beyond the reasonable control of the Supplier
for which the Supplier has promptly notified Port Trust with sufficient
justification acceptable to the Engineer-in-charge designated by PPT. In
case of disagreement in determining whether the cause is beyond the
reasonable control of the Supplier or not, the decision of the CE&ME, PPT
shall be final and binding.

a) Deduction for under availability.

The availability of the machines should be normally 100% of

the demand. However, there shall be a grace zone up to 95%.
Availability below 95% shall attract a penalty as mentioned
under :

Equipment Availability Deductions from the monthly bill

95% and above Nil

90% and above 2%
85% and above 4%
 80% and above 6%
75% and above 8%
70% and above 10%

Availability below 70% shall be treated as failure by the

Supplier to fulfill the contractual obligation and action will be
initiated against the Suppliers as per the terms and conditions
of the contract.

b. Deduction on Poor Maintenance.

If the maintenance works carried out by the Supplier is not up to

satisfaction of Engineer in charge in any month , deduction upto 10% will
be recovered from corresponding monthly bill.

c. Deduction due to poor cleanliness/house keeping.

The machines is to be kept in a reasonable cleaned condition. In case the

level of cleanliness and house keeping is not up to satisfaction of a joint
Committee comprising of one officer from IOHP, one officer nominated by
CE&ME and one Supplier’s representative, the Supplier shall initiate
immediate steps to undertake cleaning work failing which the Supplier
shall be liable for a penalty of Rs.10,000/- only for 1 st violation, and
Rs.20,000/- for 2nd violation, the Supplier shall be liable to be debarred
from the execution of contract. The level of cleanliness and house
keeping is to be checked at least once in every month. In the event the
Supplier is found to be negligent in house keeping it may result in
termination of the O&M Contract pursuant to Clause No. 12 of GCC
(Termination for Default).

28. FINAL INSPECTION, ACCEPTANCE AND PAYMENT.

The Supplier shall, three months prior to the expiration of the Contract Period,
notify the Employer in writing to take-over the machine.

The Purchaser shall make a final inspection within 45 days of receiving such
Notice from the Supplier and take over the machine on expiry of the O&M
Contract. Normal wear & tear shall be acceptable to the Purchaser. In case of
any defect or abnormality observed during inspection the same shall be made
good by the Supplier at his own cost with a reasonable period failing which the
final payment shall be withheld.

Upon receipt of the certificate of final acceptance, the Supplier will make
application to PPT for final payment within 30 days.

PPT shall make payment to the Supplier within 30 days after receiving the final
payment application, complete in all respect.

29. Supply of Spares etc.

All the mechanical & electrical spares, steel materials, all type of lubricants
,hardware & electrical power etc. required for operation, routine maintenance &
breakdown maintenance are to be supplied by the department.
30. Supply of Consumables :

Consumables like cleaning agent, Fasteners, Tools and plants, Special tools like
hydraulic jacks, torque wrench, welding machine, chain pulling, heavy duty
pullers, lifting and pulling tackles, testing equipment, scaffolding, welding
electrodes, industrial gas, high pressure hose for DA & Oxygen, cutting set with
regulator, welding cable, holder, screen, scrapping & cleaning hand tools, cotton
waste/rags etc. required for operation and maintenance shall be arranged by the
Supplier. However, mobile equipment and cranes will be supplied by the
department at free of cost depending on availability.

31. PERSONAL PROTECTIVE EQUIPMENT: (PPE)

The Supplier shall be solely responsible for the supply of required PPE to his
workers and staff and he shall also ensure the use of PPE such as helmets,
nose masks, hand gloves etc. by his staff at site.

32. CONDUCT:
The Supplier, at all times during execution of the contract, shall take all
measures to prevent any unlawful, riotous or disorderly conduct by or amongst
his staff at the site and for the preservation of peace and protection of persons
and property at the work site as well as in the neighborhood of the works.

33. ACCIDENT:
The Supplier shall, within 24 hours of the occurrence of any accident, at or about
the work site or in connection with execution of the contract, report such
accidents to the Engineer-In-charge giving all the details. He shall also provide
additional information about the accident as requested by the EIC.

34. WATCH AND WARD:

During the execution of the contract, it shall be the responsibility of the Supplier
to arrange watch and ward of the work including the raw materials, machineries
and equipment used for the work at his own cost till the contract is completed in
all respects and accepted by PPT.
SECTION-V SCHEDULE OF REQUIREMENTS.

1. TECHNICAL INFORMATION
2. SCHEDULE OF SUPPLEMENTARY INFORMATION
 1. TECHNICAL INFORMATION
A) Characteristics of materials to be handled :

Material Approx. Size Bulk Density Angle of

Repose
Iron Ore Lumps– 10-200 mm 1800-2250 38 degree
Fines – Up to10 mm kg./Cu.mtr.

B) Stack-Pile Details :
i) Shape : Trapezoidal
ii) Length : 900 mtr.
iii) Base Width : 36.5 mtr.
iv) Height : 12 mtr.(11 Mtr above the rail level
& 1 Mtr below the rail level )

C) Existing Yard Conveyor Details :

Track gauge : 6706 MM(22 Ft)
Track rail size : 52 Kg. rail
Belt type : Steel Cord Belt
Belt Width : 1200 mm
Troughing Angle : 45 degree
Belt Speed : 200 mtrs./min.
Rated Capacity : 3000 MTPH
Deck height : 1070 mm.
[ Height of top of middle roller of troughing idler set from bottom of rail]

GENERAL TECHNICAL SPECIFICATION:

A.
i) Reclaiming : 3200 MT/Hr. (Guaranteed)
ii) Boom Length : 36 mtrs.
iii) Maximum Travel : 800 mtr.
iv) Maximum wind velocity
a) Service Condition : 72 km./hr.
b) Storm Condition : 200 km./hr.
v) Maximum wheel load : 20 tonne
vi) Counter weight : of Cast iron block each not
Exceeding 6 ton.
vii) Power supply : 3.3kV, 3 PH, 50 Hz, AC.
viii) Total machine weight : To be filled up by the bidder
ix) Total power demand : To be filled up by the bidder

Mechanical Requirement

B. Bucket Wheel :
i) Type : Cell-less
ii) Drive : Electro-mechanical drive.
 iii) Gear reducer : Planetary with hollow output
sleeve.
iv) Motor : TEFC Squirrel cage induction
motor
v) Brake : Electro hydraulic thruster
operated drum type.
vi) Bucket wheel pillow block : Preferably split type.

C. Boom Conveyor.
i) Belt Width : 1200 mm, provision to use 1400
mm, if required in future.
ii) Troughing Angle : 45 degree.
iii) Take up : Hydraulic type with adjusting
length 1.5 mtr.
iv) Drive : Electro-mechanical drive
v) Gear reducer : Bevel helical / helical type.
vi) Motor : TEFC Squirrel cage induction
motor
v) Brake : Electro hydraulic thruster
operated drum type.
N.B: Transmission of power shall be through gear coupling both on high speed and
low speed side of the gear reducer. There shall be also an alternative
arrangement for incorporation of fluid coupling, if required.

D. Luffing
Hydraulic System : Electrically driven hydraulic
Power pack.
Minimum /Maximum inclination of
boom to horizontal : To be filled up by the bidder
Boom luff cylinder
Type/Designation : Clevis mounted heavy duty
Repairable construction type.
No of cylinder : Twin
Piston rod : Piston rods shall be hard
Chromed to 60 Micron, induction
Hardened medium carbon steel
Or stainless steel.
Power pack
pump type : Variable displacement pump shall
be of axial piston type or fixed
displacement pumps shall be of gear
type.

E. Boom Slewing
i) Arrangement and : Left to designer to meet
bearing type guaranteed capacity of the machine
ii) Slewing range : 360 degree
 iii) Slewing Speed : As per design to meet
guaranteed capacity along with
speed control speed.
iv) No of Drives : Three
v) Drive : Electro-mechanical Drive
with VVVF type speed control.
vi) Gear reducer : Planetory/Heliworm reducer.
vii) Motor : TEFC Squirrel cage induction
motor suitable for VVVF drive.
vii) Brake : Electro Hydraulic Thruster
Operated disc type/ Electro magnetic
operated disc brake.
F. Long Travel
i) Travel Speed : 20 mtr./min. (max) (variable
speed)
ii) Wheels : Approximate ground clearance
300mm above rail level.
iii) Drive : Electro Mechanical drive with
VVVF type speed control.
iv) Gear reducer : Bevel helical / Helical with
individual lubrication type.
(Geared Motors can be used)
v) Motor : TEFC Squirrel cage induction
motor suitable for VVVF drive.
vii) Brake : Electro Hydraulic Thruster
Operated disc type/ Electro
Magnetic operated disc brake
G. Power Cable Reeling Drum
Voltage : 415 V, 3 ph, 50 Hz
Motor : Stall torque type
Drum : Barrel type to accommodate
entire trailing cable.

H. Central Lubrication System.

The Central lubrication for the machine consists of 4 separate system.
a. Under carriage lubrication system
b. Superstructure lubrication system.
c. Conveyor lubrication system.

Each system is constructed from the following elements:

a. Lubricating oil pump with a lubricant vessel, powered by a built-in electric
engine with capacity control of each output
b. Pipes and flexible conduits
c. connections
d. Required lubricating points.
e. Distributor with visual operation monitoring (tappet)

Electrical Requirement:
 1. The machine is fed from a land mounted 3.3 KV Junction Box located at
midpoint of travel through 3.3 KV flexible trailing cable and onboard barrel type
CRD for reeling and unreeling of the trailing cable while the machine is traveling.
The CRD feeds 3.3 KV Power to on machine 3.3 KV switch gear (VCB) located
inside the onboard E house and in turn to the Dry cast Resin (AN) transformer
with Class F insulation. The transformer shall be located outside the E house but
provided with suitable enclosure with proper ventilations. The transformer steps
down the 3.3 K.V. power to 415V +/- 10% and the L.T. power is fed to the MCC
located inside the electric house.
NB: PPT will provide 3.3 KV supply at midpoint of the long travel from a 3.3KV
supply Junction Box.

2. 3.3 KV Switch gear shall be vacuum circuit Breaker panel.

3. All the motors required for running of the machine as well as allied auxiliary is
fed from MCC through a combination of Armored and flexible cables.

4. MCC Panel (Non drawn out type)

Sl. Description Type of Type of Type of overload

No. switch gear Starter protection
1 Incomer MCCB - With shunt trip and
E/F module
2 Conveyor MCCB DOL With Microprocessor
based Motor
protection relay
3 Bucket Wheel MCCB DOL With Microprocessor
based Motor
protection relay
4 Boom Luffing MCCB DOL Bi-metallic thermal
type overload relay
with single phasing
preventor.
5 Long Travel MCCB VVVF Bi-metallic thermal
Control type overload relay
with single phasing
preventor.
6 Slewing MCCB VVVF Bi-metallic thermal
Control type overload relay
with single phasing
preventor.
7 Other drives like MCCB DOL Bi-metallic thermal
DSS, Centralized type overload relay
lubrication system with single phasing
etc. preventor
8 Lighting transformer SFU
9 Welding sockets SFU
10 Control transformer MCCB( For
incoming and
outgoing
both)
5. Voltage and power supply conditions:

Low voltage supply

• Voltage(V) : 415V
• Voltage fluctuations % : +/- 10%
• Frequency : 50 Hz
• Frequency fluctuations : +/- 4%
• Phases : 3
• Neutral : Earthed through earth shoe on
both side rails.
• Auxiliary voltages : 230 +/- 10%
• Control (V) : 230 V, 48V DC
• Lighting (V) : 230 V
• Solenoid valves (V) : 48V DC
• Electronic equipment (V) : 48V DC(PLC)
• Control voltages : 48V DC
• Digital I/O(V) : 48V DC
• Signal lamp (V)/Field devices : 48V DC

6. Degree of protection:
All outdoor panels : IP 65
All indoor panels : IP 54
All field devices : IP 65
All Motors : IP 65

7. Operation of the machine is achieved by a PLC system having a Central

processing Unit located inside the electric house and a remote I/O panel located
inside the operator’s cabin connected by a RIO Link cable for communication.
PLC system is considered to be Non-redundant.

8. The machine is controlled by an operator control desk having joysticks

and push buttons and HMI.

9. Hardware signal exchange between the reclaimer machine and the Central
Control room of the Plant is achieved through a control trailing cable and control
CRD to the land mounted control Junction Box. The land mounted control
Junction Box shall be supplied by PPT.

10. Operational and safety limits of the drives and their motions are cut off by a no.
of limit switches located strategically all over the machine.

11. Long travel and slew drives of the machine are controlled through variable
voltage variable frequency( VVVF) converters located inside the Electric house
for wide range of speed control.

12. Communication within the machine and with Central control station is achieved
via telephone and wireless system.
13. Belt weigher : Electronic type

2. SCHEDULE OF SUPPLEMENTARY INFORMATION

Contents

Schedule I Organization Chart

Schedule II SubSuppliers
Schedule III Tender Programme
Schedule IV Work Method Statements
Schedule V Technical Data Sheets
Schedule I : Organization Chart and Key Personnel.

1. The Supplier shall provide an organization chart or charts depicting the proposed
organization for

- Project Management
- Engineering
- Site Construction

The charts shall clearly depict the reporting relationship between the personnel
within each discipline and also the overall relationship of engineering, project
management and site construction within the corporate structure.

2. Names of the proposed personnel in the first 3 levels of the organization charts
shall be included against the respective title in the charts and Bio-data
(Curriculum Vitae) of each of the nominated personnel to be attached. The Bio-
data to include as a minimum:
- Name:
- Summary of Qualifications
- Present Occupations
- Names and Contact Phone Numbers.
In the event the Supplier makes any change in the top 3 levels, the same shall
be promptly informed to the Purchaser’s Representative and suitable
replacement, acceptable to the Purchaser, must be posted.
Schedule II : SubSuppliers.

Element of Work Approximate Name and Statement of

Value Address of Similar Works
SubSupplier previously
Executed

* Include the Owners name for whom the works were executed and the name of
the Consultant, if any.
Schedule III : Tender Programme

Bidders shall provide a tender programme in the form of a time scaled bar chart clearly
indicating the sequence and duration of the main activities required to complete the
Works within the required time schedule.

The programme shall be accompanied by detailed explanation of how the Bidder

intends to manage and control the programme to ensure that time and quality
requirements are met.

The activities covered by the programme and explanation shall include but not be
limited to

♦ Design
♦ Fabrication
♦ Delivery
♦ Erection
♦ Commissioning
Schedule IV : Work Method Statements

Construction

Bidder shall provide its proposed methodology for the construction work with particular
emphasis on the following:

♦ Sequence of erection of the machine.

♦ Handling and carnage.
♦ Temporary bracing.
♦ Co-ordination with Related and other Contracts, if any.
Schedule V : Technical Data Sheets

1.0 GENERAL

a) The Bidder shall complete the Data Sheets in this Schedule to the fullest extent
applicable to the equipment being offered. Where the space allowed in the
schedule does not permit a comprehensive response the Bidder shall insert
additional sheets which shall be cross referenced to the specific question in the
Schedule.

b) This shall be used to technically evaluate the bid and to assess its compliance
with the Specification. To the extent that the Data Sheets supplied do not
adequately describe the equipment offered the Bidder shall submit additional
sheets, brochures, drawings, sketches etc. to fully describe the technical
attributes of the equipment offered.

c) Failure to complete this schedule as required may render the bid non-
responsive.

2.0 DRAWINGS

Drawings showing the following arrangements and details and certified by

the Supplier as “ good for construction “ shall be submitted by the Supplier to the

Purchaser’s representative with in 30 days of issue of Letter of Intent (LOI) :- ( 3

sets )

- General arrangement - elevations

- General arrangement - sections

- Driven and non-driven bogie and wheel arrangement

- Boom luffing arrangement

- Slew assembly arrangement

- Bucket wheel arrangement

- Bucket wheel drive arrangement

- Circular chute and support structure arrangement

- Access Platforms, walkways, stairs including location of

lifting
 equipment.

- Arrangement of transfer points, showing chutes, deflector plates,

liners, scrapers, access and inspection doors, skirts, seals, etc.

- Outline drawings and data for all major items of electrical

plant and

components offered.

- Typical drawing of each proposed drive assembly.

- Arrangement of fire protection equipment.

- Single line diagram of power distribution.

- Switchboard, operator’s control cabin and control desk

layout

drawings.

- Surge hopper and feeder arrangement

3.0 WHEEL LOAD DATA

Wheels

Total No. of wheels - East Rails No._________________________

- West Rails No._______________ ________

Number of wheels per corner main gantry No._______________________

Wheel Diameter mm_______________________

Bogie spacing mm_______________________

Wheel Loads Unit Restricted Storm Stationery

Main Gantry (Maximum) Travel Tie Down
Vertical ---------------------------------------------------------------

Load per wheel t

-----------------------------------------------------------------------
Load per corner t
-----------------------------------------------------------------------

4.0 EQUIPMENT DATA

 4.1.1 GENERAL

Manufacturer _________________
Designer _________________
Total Machine Operating Weight _________________
Guaranteed Reclaiming Capacity _________________
(3200TPH minimum)
Design Reclaiming Capacity _________________
Total Installed Power _________________
Slew Angle Limits if any ______________deg.
Boom Length (Centre of rotation to centre of boom
Conveyor head pulley) ________________m
Boom inclination (Max/Min) ______________deg.
Can the machine service stockpile profile of 12m
at guaranteed capacity YES / NO

4.1.2 MASS OF ASSEMBLIES

Weight of structurals ________________ t
Counterweight mass ________________ t
Electrical Installations ________________ t
Bucket-wheel Assembly ________________ t
Total machine weight ________________ t
4.1.3 POWER REQUIREMENTS
Maximum Power Demand at Design
Reclaiming Rate _______________kW
Power factor at Maximum Demand _________________
Power factor and Power Demand at no load _________________
Total installed power capacity of Machine drive _________________
4.1.4 BOOM CONVEYOR.
Power Demand _______________kW
Installed Power _______________kW
Capacity (Normal/Design) _______________ t/h
Centres _______________ m
Lift (Max) _______________ m
Speed _______________ m/sec
Max/Min Inclination _______________ deg
Take up : Type _______________
Total Travel _______________

Drive Pulley
Diameter _______________mm
Type of lagging/thickness _______________mm
Shaft diameter _______________mm
Bearing Designation _______________
Housing Designation _______________
Mass (incl. Shaft and bearing housings) _______________
Manufacturer
Non-Drive Pulleys
Diameter ______________mm
Type of lagging/thickness ______________ mm
Shaft Diameter ______________ mm
Bearing designation _______________
Housing designation _______________
Mass (incl. Of shaft and bearing housings) ______________kg
Manufacturer _______________
Snub Pulley
Diameter ______________mm
Type of lagging/thickness ______________ mm
Shaft Diameter ______________ mm
Bearing designation _______________
Housing designation _______________
Manufacturer _______________
Mass ______________kg
Coupling Low Speed
Type _______________
Manufacturer _______________
Gear Reducer
Type _______________
Mounting (foot, shaft, other) _______________
 Ratio _______________
Mass ______________kg
Manufacturer _______________

Motor
Manufacturer _______________
Rated Power _______________kW
Type _______________
Synchronous Speed _______________
Brake
Type _______________
Torque rating _______________Nm
Diameter of disc _______________mm
Manufacturer _______________
Fluid Coupling
Type/Designation _______________
Size _______________
Manufacturer _______________
Mass _______________
Coupling – High Speed
Type/Designation _______________
Manufacturer _______________
Coupling – Low Speed
Type/Designation _______________
Manufacturer _______________
Belt Scrapers
Type _______________
Quantity _______________
Manufacturer _______________
4.1.5 BOOM SLEWING.
Slew Assembly (Bearing)
Type _______________
Diameter (PCD of elements) _______________mm
No. and type of rolling elements _______________
 Manufacturer _______________
Expected life _______________

Jacking points of slew assembly

No. of jacking points/pads _______________
Qty. of hydraulic jacks supplied _______________
Hydr. Jack capacity _______________
Hydr. Jack weight closed/raised _______________mm
Slew Drive
Power Demand ______________kW/RPM
Installed Power ______________kW/RPM
Number of slew drives/pinions _______________
Gear Reducer Type
Type/Designation _______________
Ratio _______________
Manufacturer _______________
Mass _______________
Brake
Designation and type _______________
Manufacturer _______________
Machine Overload Protection
Coupling Type/Designation _______________
Manufacturer _______________
Boom Slewing Drive : Hydraulic drive for the Boom slewing shall be
preferred. Provide details of the drive system.
4.1.6 BOOM LUFFING
Minimum/Maximum inclination of boom
to horizontal _________________deg
Time to luff from minimum to maximum inclination________________secs
Acceleration ________________m/sec2
Deceleration ________________m/sec2
Power Demand ________________kW
Installed Power ________________kW
 Boom Luff Cylinder
Type/Designation ______________
No. of Cylinders ______________
Bore/Rod Diameter ______________mm
Stroke ______________mm
Operating pressure ______________Mpa
Safety factor (yield) ______________
Mass _______________kg
Manufacturer _______________
Power Pack
Pump displacement _______________1/rev.
Pump type _______________
Rated pressure _______________Mpa
Tank capacity _______________Litre
Manufacture _______________
Oil used _______________
4.1.7 LONG TRAVEL EQUIPMENT
Power Demand / Speed ______________kW/RPM
Installed Power/Speed ______________kW/RPM
Long travel speed range ________________m/sec
Number of drives and driving wheels ________________
Axle Assemblies
Load Vertical/horizontal per wheel ________________kN
Tread diameter (wheel) ______________mm
Bearing designation _______________
Bearing housing type _______________
Coupling Low Speed (if required)
Type _______________
Manufacturer _______________
Speed Reducers
Type _______________
Mounting (Foot, shaft, other) _______________
Reduction ratio _______________
Mass _______________
 Manufacturer _______________
Brakes
Type _______________
Diameter of disc _______________
Manufacturer _______________
Coupling – High Speed
Type _______________
Manufacturer _______________
Jacking Points for
Portal/Equaliser/Bogie/Wheel
No. Jacking Points _______________
Qty. of hydraulic jacks supplied _______________
Hydraulic Jack capacity ______________kN
Hydraulic jack height closed/raised ______________mm
Trailer
No. of wheels _______________
Tread diameter _______________m
Bearing designation _______________
Bearing Housing Type ________________
Long Travel Buffers
Buffer Type ________________
Manufacturer ________________

4.1.8 TRAILING CABLES AND REELERS.

Power Cable
Size and type ________________
Manufacturer ________________
No. of Cores ________________
Power core size ________________
Earth core size ________________
Screen size ________________
Overall Diameter of cables ________________
Power Cable Reeler
Drum diameter _______________mm
 Reducer Designation ________________
Reducer ratio ________________
Reeling drive type ________________
Motor type ________________
Rated motor power/speed ______________kW/RPM
Power Slip ring type/designation ________________
Manufacturer(Reeler) ________________
Control Cable Reeler
Drum Diameter ________________mm
Reducer designation ________________
Reducer ratio ________________
Reeling drive type ________________
Tension control method ________________
Motor type ________________
Rated motor power/speed ______________kW/RPM
Power Slip ring type/designation ________________
Manufacturer(Reeler) ________________

4.1.9 SERVICES.
Lubricants (List of all oils and Lubricants)
Function ________________
Manufacturer and Availability in India ________________
Type of Lubricant ________________
Painting
Paint Manufacturer/s ________________
Service Hoists
No. of units ________________
Locations and Capacities ________________
Power or Hand Operated ________________
4.1.10 SWITCHBOARD. _______________Voltage
Enclosure Manufacturer _______________
Busbar current rating _______________A
Fault withstand rating _______________kA
3.3KV VCB
manufacturer _______________
type/rating _______________A
MCCB
Manufacturer _______________
- type/rating ________________A
 Sub-circuit breakers
-manufacturer _______________
- type/rating ________________A
MCC
Manufacturer ________________
Motor contactor type and model ________________
Motor protection relay ________________
Make ________________
Rating ________________
Overload Relay with single phasing prevention _________________
Make ________________
Rating ________________

4.1.11 VARIABLE SPEED DRIVES.

Travel
Manufacturer _____________________
Type _____________________
Rating _____________________
Motor Power rating ___________________kW/RPM
Degree of protection _____________________
Duty type(S number) _____________________
Slew
Manufacturer _____________________
Type _____________________
Rating _____________________
Motor Power Rating ___________________Kw/RPM
Torque nominal – max ____________________Nm
Speed at range ____________________rpm
Degree of protection ____________________
Duty type (S number) ____________________
4.1.12 PROGRAMMABLE CONTROLLERS.
MINIMUM REQUIREMENTS.
Memory size _____________________
No. of I/O blocks _____________________
No of spare I/O blocks _____________________
No. of Digital outputs _____________________
No. of Digital inputs _____________________
No. of Analogue inputs _____________________
No. of Analogue outputs _____________________
Specification _____________________
Minimum processing capabilities _____________________
Minimum memory requirements _____________________
Expected maximum operating temp of PC Assy.
Expected maximum operating temp of I/O Blocks
Constant voltage transformer rating _____________________
4.1.13 FIELD CONTROL DEVICES.
A list of all field control devices including transducers and devices are to be
provided with the following data:
♦ Purpose
♦ Expected position on Machine
♦ Manufacturer
♦ Rating / Configuration
♦ Quantity

4.1.14 LUMINAIRES
The contractor shall provide the name of the manufacturer and catalogue
number of each luminaire, including emergency lighting and number of such
shall be stated.

4.1.15 SWITCHROOM ENCLOSURE.

Air Conditioner Cooling Capacity __________________kW
Design working pressure in switch room ___________________
Design working temperature in switchroom ___________________0C
Pressuring Filter Fan Manufacturer _____________________
Model Number _____________________
Rating _____________________
4.1.16 LIGHTING LEVELS.
Boom conveyor discharge ___________________lux
Boom conveyor loading ___________________lux
Switchrooms ___________________lux
Walkways ___________________lux
Stairways ___________________lux
4.1.17 MOTORS.
A list of motors completed Motor Data Sheets
For each motor shall be supplied.
See item 9.4.1.25.
4.1.18 TRANSFORMERS.
For each power transformer a filled in Transformer
Data Sheet shall be supplied.
See item 9.4.1.26.
4.1.19 CURRENT TRANSFORMERS.
The following shall be supplied for all
Current transformers :
- Manufacturer/Make
- Class
- Ratio
4.1.20 VOLTAGE TRANSFORMER.
A list of all voltage transformers and the following
Information for each shall be supplied :
- Manufacturer/Make
- Class
- Ratio
4.1.21 MANUALS AND TRAINING.
Confirmation of the following will be as specified: -
- Testing Manuals
- Commissioning Manuals
- Maintenance Manuals
- Operating Manuals
- As Built Drawings
 - Personal Training Operations & Maintenance
4.1.22 MOTOR DATA SHEET.
The following shall be provided for each 3-phase electric motor:
- Application and quantity
- kW rating and frame size
- Locked rotor torque
- Breakdown torque
- Pull-up torque
- Speed-torque curve determined by type testing of machine
- Speed-Current curve for machine
- Permissible stall time with full voltage applied to terminals
- Temperature of stator and rotor conductors at the still
time
- Full Load Current
- Rotor moment of inertia
Type and arrangement of stator windings.
- Type and construction of rotor cage
- Place of manufacture
- Full load speed
- No of permissible starts per day
- Duty
- Degree of protection
- Insulation / Class
4.1.23 TRANSFORMER DATA SHEET
4.1.24 EQUIPMENT ITEM
1. Type of Transformer _________________
2. Number of units supplied : _________________
3. Rated Power : _________________ kVA
4. Applicable Standards transformer
complies with : _________________
5. Frequency : _________________ Hz
6. Insulation Type : _________________
7. IP Rating of Transformer enclosure : _________________
 8. Rated Voltages
a) Primary Winding : _________________ V
b) Secondary Winding : _________________ V
9. System Highest Voltages _________________ V
a) Primary Winding : _________________ V
b) Secondary Winding : _________________ V
10. Tappings Required : _________________ V
11. Method of Earthing
a) Primary Winding : _________________
b) Secondary Winding : _________________
12. Fault level primary
Fault level Secondary :
13. % Impedance __________________

14. Class of Insulation __________________

with temp rise above ambient temp.(450C)

4.1.25 BUCKETWHEEL
Power Demand _______________ kW
Installed Power _______________ kW/RPM
Type (cell-less) _______________
Diameter over buckets _______________ m
Number of buckets _______________
Bucket width _______________ mm
Bucket volume _______________ m3
Rotational Speed _______________ RPM
Rotational speed _______ buckets/minute
Peripheral cutting speed _______________ m/sec
Shaft diameter _______________ mm
Shaft/body connection type _______________
Mass of BW assembly (no chute & drive) _______________ t
Material of buckets _______________
Replaceable wear cutters _______________
 Gear Reducer – BW
Type _________________
Power rating mechanical/thermal _________________ kw
Ratio _________________
Cooling (Air/self) _________________
Lubrication (splash/forced) _________________
Breather Type _________________
Connection to Bucket wheel shaft _________________
Mass _________________ kg
Manufacturer _________________

Auxiliary Drive
Motor Power/Soeed ______________kW/RPM
Time for one BW Rotation _________________ sec
Drive Arrangement _________________
Fluid Coupling – BW
Type/Designation _________________
Stalling Torque _________________ %
Nominal slip at demand Power _________________ %
Manufacturer _________________
Mass _________________ kg
Load Cell – MW
Type _________________
Capacity _________________ kN
Manufacturer _________________
1. Model
Materials to be used _________________
Scale _________________
Machine motions modelled _________________
Slewing _______________ Yes/No
Luffing _______________ Yes/No
2. Initial Spares :

The list of Initial Spares will be finalized in the Pre Bid Meeting. The list of initial
spare, special tools etc. offered by the Supplier must be enclosed in the
Technical Bid.

5.0 TECHNO-COMMERCIAL INFORMATION SHEET: APPENDIX - II

The Supplier must fill up the techno-commercial sheet and enclose the
same in the technical bid. The bidder must enclose copies of documents in
support of the information provided in this sheet. This sheet shall be used
for technical evaluation and failure to provide correct information in this
sheet may result in rejection of the bid. The deviation statement must be
prepared carefully as the items not appearing in the deviation statement
shall be deemed to have been accepted by the bidder.

The bidder must ensure that the representative attending the pre-bid meeting /
post-bid meeting is conversant with the technical as well as commercial
requirements of the Tender Document and also conversant with the Techno-
commercial offer proposed / submitted by the bidder so that various points could
be clarified promptly to save delay.
 SECTION-VI
BILL OF QUANTITY FORMAT

Sl Items Amount

01 Total Cost of Goods – Domestic

02 Total Cost of Goods – Imported

Design, Drawing & Documents

03

04 Installation & Erection - Electrical

05 Installation & Erection - Mechanical

06 Testing & Commissioning

07 Total Cost of Initial Spares

Operation and maintenance @

08
Rs.__________ per month x 12 months

TOTAL: Rs.
(In words rupees -------------------------------------------------------------------------

--------------------------------------------------------------------------------------------- )

Having gone through the terms and conditions and understood the
requirements of the contract, we confirm that the above offered price
includes all the taxes and duties and all other incidentals and is a firm price.

Signature of the Bidder

 APPENDIX-I

BILL ENTRY FORMAT FOR E & M WORKS

(Vide F. C. no. 1534/FA dt. 09/06/03 & approval no. 2442/DCM dt. 17/06/03)

1. Name of the work :

2. Name of the Agency :
3. Work Order No. :
4. Head of Account : Capital / Revenue
5. Chargeable Head :___/___/___
6. Date of commencement :
7. Date of completion :

Sl. Description of works / materials Unit Qty. as Qty. Rate Amount

No. as per Bill of Quantity (BOQ) per BOQ Executed (Rs.) (Rs.)

(Using this format submit the information in separate sheets.)

Additional items, if any.

Accepted the above entries.

Signature of the EIC Signature of the Supplier

Certified that the Supplier has discharged all the obligations under the contract
satisfactorily.

Remarks, if any, of EIC:

C/s by Executive Engineer Signature of the Engineer Incharge

Bill No.: ______________ Date: _________________

Gross Value of the Work: Rs. __________________

Less Recoveries:
a. Rs. ______________
b. Rs. ______________
c. Rs. ______________7
Total Recoveries (-) Rs. _______________

Net amount payable: Rs. ______________

Passed for Rs.______________ (Rupees ________________________________)

Under Revenue / Capital Code No. _ _ _ _ / _ _ _ _ / _ _ _ _ .

Signature of the D.D.O.

 APPENDIX-II

TECHNO-COMMERCIAL INFORMATION

1. Name of the Bidder :

2. Present address with :

Telephone No. and name
of the contact person

3. Whether you accept all the terms

and conditions of the contract : Yes / No
(If no, indicate the details with
reasons, if any. The Deviation
Statement must be filled up in
the following format.)
DEVIATION STATEMENT

Ref No./ PPT’s Requirement Bidder ‘s Offer

Clause No.

4. Technical details of Supply items viz.

Make, Model, Capacity etc. (enclose
brochures, test certificates, if any)

SIGNATURE OF THE BIDDER

 APPENDIX - III

ELIGIBILITY INFORMATION
(To be filled up and enclosed with the Technical Bid )

1. SIMILAR EXPERIENCE:

Name of Work Work Commencement Completion Completion

the work Order Order Date Date Certificate
no. value no.

2. FINANCIAL CAPABILITY: (Average Annual Turn Over)

Financial Year: Financial Year: Financial Year:

Rs.: Rs.: Rs.:

Enclose copy of profit/loss statement certified by any Chartered Accountant.

3. OTHER ELIGIBILITY REQUIREMENTS, IF ANY, AS PER THE TCN:

We hereby confirm that copies of supporting documents for above are attached
to this sheet for reference. ( Total nos. of pages including this sheet - ________ ).
Originals shall be presented for verification on the date of opening of technical
bid.

SIGNATURE OF THE BIDDER

FOR OFFICIAL USE ONLY: Originals Verified on Date: ______________

Remarks, if any:

______________ ________________ _______________

_______________

Signature of Tender Committee Members Representatives

 APPENDIX-IV

BANK GUARANTEE FORMAT FOR BID SECURITY (EMD)

WHEREAS _______________________________________(herein after

called “the Bidder”) has/have submitted his/their bid dated _______________ for
____________________________________ (hereinafter called the “the Bid”).
KNOWN ALL MEN by these presents that we _______________________
_____________ of ___________________________________ having our
registered office at __________________________________________ (hereinafter
called “the Bank”) are bound onto Paradip Port Trust (hereinafter called the
purchaser) in the sum of Rs. _________ (Rupees
________________________________) only, for which payment will and truly to be
made to the said purchaser, the Bank binds itself, its successors and assigns, by
these presents. Sealed with the Common Seal of the Bank this ________________
day of _______ 20______.
THE CONDITIONS of obligation are :
(Applicable for EMD only)
1. If the Bidder withdraws its Bid during the period of bid validity specified by the
Bidder on the Bid Form, after bid opening or
2. If the Bidder submits fraudulent documents and / or wrong information in
support of it’s eligibility / qualification or
3. If the Bidder, having been notified of the acceptance of its bid by the
purchaser during the period of bid validity,
a) fails or refuses to execute the contract form, when requested , or
b) fails to sign the Agreement and/or fails to submit the required performance
security deposit and/or does not agree to carry out the work as per the work
order, in accordance with the Instructions to Tenderers (Section – II of the
Tender Document).
We undertake to pay to the purchaser the above amount, according to and
upon receipt of their first written demand, without the purchaser having to
substantiate their demand, provided that in their demand the purchaser will note that
the amount claimed by them is due to them owing to the occurrence of any one or all
of the above-stated conditions, specifying the occurred condition or conditions.
THIS GUARANTEE will remain in force up to and including Dt. _______and
any demand in respect thereof should reach the Bank not later than such date.
Ref No. (TCN No. to be inserted )

(Name of the Bank)

By ______________
Title
Authorized Representative
(Signature of witness)
Name & Address of witness:
 APPENDIX-V

BANK GUARANTEE FORMAT FOR INITIAL SECURITY DEPOSIT (ISD)

To : The Paradip Port Trust

Paradip Port – 754 142
ORISSA, INDIA.

WHEREAS ____________________________________ (Name of Supplier)

hereinafter called “the Supplier” has undertaken, in pursuance of Contract No
__________ dated __________ 20 ___ to supply (Description of Goods and
Services) hereinafter called “the Contract”.

AND WHEREAS it has been stipulated by you in the said Contract that the
Supplier shall furnish you with a Bank Guarantee by a recognized bank for the
sum specified therein as security for compliance with the Supplier’s
performance obligations during the execution in accordance with the Contract
AND WHEREAS we have agreed to give the Supplier a Guarantee :
THEREFORE WE hereby affirm that we are Guarantors and responsible to you,
on behalf of the Supplier, up to a total of ___________________________
(Amount of the Guarantee in Words and Figures) and we undertake to pay you,
upon your first written demand declaring the Supplier to be in default under the
Contract and without cavil or argument, any sum or sums within the limits of
Rs.__________ (Amount of Guarantee) as aforesaid, without your needing to
prove or to show grounds or reasons for your demand or the sum specified
therein.

This guarantee is valid until the __________________ dayof ___________ 20__

(Ref:- TCN No: _______________________ )

The above reference must be used for all correspondences on this Bank
Guarantee.

Authorised Signature of the Bank

Date: Name & Address:
 APPENDIX-VI

BANK GUARANTEE FORMAT FOR WARRANTY PERFORMANCE DEPOSIT

To
The FA & CAO,
Paradip Port Trust,
Paradip Port – 754142.

WHEREAS (Name of Supplier) _____________________________________

herein after called “the Supplier”, has undertaken to perform in pursuance of
Contract No. ___________________________ dated _____________________,
(hereinafter called the “CONTRACT”) AND WHEREAS it has been stipulated by
you in the Contract that the Supplier shall furnish you with a Bank Guarantee from
a nationalized Bank having its branch at Paradip Port for the sum specified
therein as security for compliance with the Supplier’s warranty performance
obligations in accordance with the Contract; AND WHEREAS we have agreed
to give the Supplier a Guarantee; THEREFORE WE hereby affirm that we are the
Guarantors and responsible to you, on behalf of the Supplier, up to a total of
(Amount of the Guarantee in Words and Figures) and we undertake to pay you
Rs.
_________________________________________________________________
_ upon your first written demand declaring the Supplier to be in default under the
Contract, and without cavil or argument, any sum or sums as specified by you
within the limit of (Amount of Guarantee ) as aforesaid, without your needing to
prove or to show grounds or reasons for your demand for the sum specified
therein.

This guarantee is valid until _________ day of _______________, 20___.

Ref No. (TCN No. to be inserted )

Date: By
___________________
Address: (Title)
Authorized Representative
 APPENDIX-VII

BANK GUARANTEE FOR ADVANCE PAYMENT.

To : The Paradip Port Trust

Paradip Port – 754 142.
ORISSA, INDIA.

Subject : ___________________________________ (Name of the

Contract)

Gentlemen:

In accordance with the provisions of the General Conditions of Contract Clause

16(a) and (b) (“Advance Payment”) of the above mentioned Contract,
_______________________________ (Name and address of Supplier)
(hereinafter called “the Supplier”) shall deposit with The Paradip Port Trust a
bank guarantee to guarantee his proper and faithful performance under the said
Clause of the Contract in an amount of ________________________________
(Amount of Guarantee in Words and Figures).

We, the ______________________________ (Bank) as instructed by the

Supplier, agree unconditionally and irrevocably to guarantee as primary obligator
and not as Surety merely, the payment to The Paradip Port Trust on his first
demand without whatsoever right of objection on our part and without his first
claim to the Supplier, in the amount not exceeding ________________________
(Amount of Guarantee in Words and Figures).

We further agree that no change or addition to or any modification of the

terms of the Contract to be performed thereunder or of any of the Contract
documents which may be made between The Paradip Port Trust and the
Supplier, shall in any way release us from any liability under this guarantee,
and we hereby waive notice of any such change, addition or modification.
This guarantee shall remain valid and in full effect from the date of the advance
payment under the Contract until The Paradip Port Trust receives full repayment
of the same amount from the Supplier.

(Ref:- TCN No: _______________________ )

The above reference must be used for all correspondences on this Bank
Guarantee.

Yours truly,

Signature and Seal _____________________

Name of Bank/
Date: _____________________________
 APPENDIX- VIII

CORPORATE PERFORMANCE GUARANTEE

(Name of the Firm), having their Head Office at ……………………, hereinafter

called as “the Supplier” do hereby offer guarantee to Paradip Port Trust, Paradip
herein called the purchaser as specified in the Purchase/Work Order
Nos……………….. for satisfactory performance for a period of ___years from the
date of acceptance subject to the following conditions in addition to the
clauses/conditions mentioned in the above purchase/work order and subsequent
revision.

1. The Guarantors obligation under this guarantee shall be to repair all defects with
material and labor free of charge during the guarantee period of ___ years.
“Defects” during the guarantee period shall mean as under:
a)
b)
c)
2.The guarantee shall commence on the date of acceptance of the goods and
services as specified in the contract agreement.
3. The defects shall be rectified by appropriate as deemed necessary so as to meet
the specifications and/or instructions of the Engineer – in – Charge so that the
repair work shall not show any defects as defined above within guarantee period.
4. The guarantor shall rectify the defects within four weeks from the date of receipt
of the notice from the owner giving brief details of the nature of the defects, unless
otherwise specified.
5. If the guarantor fails to perform his obligation as per this guarantee, PPT
reserves the right to rectify the defects by another agency at guarantors risk and
cost.
6.The guarantor shall have no liability under this guarantee for the following:

a) Damage caused by physical abuse, fire, explosion, accident.

7. Force Majeur: The Guarantor(s) obligations are automatically waived and void to
the extent that it becomes unreasonably difficult or impossible to carry out the
claims procedure or repair as a consequence of strikes, war, invasion, acts of
terrorists or foreign enemies, hostilities( whether war be declared or not), civil war,
rebellion, revolution, insurrection, military or power, confiscation or nationalization
or requisition or destruction of damage to property by or under the order of any
Government or Authority and to the extent that loss or damage is directly or
indirectly caused by such circumstances.

Corporate Seal: Authorised Signatory

Date:
 APPENDIX-IX

PROFORMA CERTIFICATE FOR COMMISSIONING OF GOODS.

PROFORMA OF CERTIFICATE FOR ISSUE BY THE PURCHASER AFTER

SUCCESSFUL COMMISSIONING OF GOODS.

No.__________________

Date_________________
M/s ______________________________

Subject : Certificate of Commissioning of Goods.

This is to certify that the Goods as detailed below has/have been received in good
condition along with all the standard and special accessories (subject to remarks in Para
No.2) and a set of spares in accordance with the Contract/Specifications. The same has
been installed and commissioned.
(a) Contract No. ________________ dated _____________________
(b) Description of the Goods _________________________________
Plant Nos.__________________________________________________
Quantity ______________________________________________
Bill of Lading _______________ dated ___________(for import contract)
Name of the vessel/transporter ____________________________
R/R No. _______________________ dated _________________
Name of the consignee __________________________________
Date of commissioning and proving test _____________________

Details of accessories /spares not yet supplied and recoveries to be made on

that account.

Sl. No. Description Amount to be Recovered

The commissioning tests has been done to our entire satisfaction and operators
have been trained to operate the plant.

The Supplier has fulfilled his contractual obligations satisfactorily.

OR
The Supplier has failed to fulfill his contractual obligations with regard to the following.
(a)
(b)
(c)
(d)
The amount of recovery on account of non-supply of accessories and spares is
given under Para No.2.

The amount of recovery on account of failure of the Supplier to meet his

contractual obligations is as indicated in endorsement of the letter.

Signature : _________________________
Name : _________________________
Designation with Stamp : ________________
 APPENDIX - X
LETTER OF INTENT FORMAT
No.: ___________________ Date: ____________

To

Sub: ( Name of the Work.)

Dear Sirs,
With reference to your above offer and subsequent correspondences on the
subject, we are pleased to inform you that your offer has been accepted by the
competent authority and you are hereby requested to initiate actions to commence
the work at the earliest as per the terms and conditions of the contract. The Engineer
In-charge for this work shall be Mr. ________________.
Agreed Schedule date of commencement of the work is ____________ and
Schedule date of completion of the work is ________________.
You are requested to sign the Agreement and fulfill other formalities as per the tender
conditions.
Yours faithfully,

(Signature of the Controlling Officer)

****************************
WORK ORDER FORMAT
W. O. No.: ___________________ Date: ____________
To

Sub : ( Name of the Work )

Ref : Letter of Intent dtd. ________________ .

Dear Sirs,
We are pleased to inform you that your offer for the above work has been
approved by the competent authority and you are requested to execute the work in
accordance with the terms and conditions of the contract and complete the work /
services to the full satisfaction of the Engineer Incharge (EIC) within the stipulated
time period.
Agreed date of commencement
& completion of the Work/Services: ______________________________ .
Total Contract Amount : Rs. ________________

Payment: On satisfactory completion of the work, the bills along with all the
required documents in triplicate shall be submitted to the EIC for
certification and other processing for the payment within thirty (30)
days of submission of bills in full shape.
Warranty: The warranty period for this work shall be ________ from the date of
acceptance of the work / services.
Yours faithfully,

(Signature of the Controlling Officer)

 PARADIP PORT TRUST
VOLUME - II

[ SECTION-VII ]

TECHNICAL SPECIFICATIONS

DESIGN, FABRICATION, SUPPLY, ERECTION

AND
COMMISSIONING OF RECLAIMER
OF CAPACITY 3200 TPH
 SECTION VI TECHNICAL SPECIFICATIONS

Contents

SCOPE OF WORK

GENERAL
WORK INCLUDED
WORK NOT INCLUDED
PURCHASER SUPPLY
RELATED AND OTHER CONTRACTS

SYSTEM DESCRIPTION AND PERFORMANCE REQUIREMENTS

INTRODUCTION
CONTROL PHILOSOPHY
OPERATIONS

EQUIPMENT REQUIREMENTS

GENERAL
RECLAIMERS
CONFIGURATION
PORTAL GANTRY
SUPERSTRUCTURE
SLEW ASSEMBLY
BUCKET WHEEL
RECLAIMER OPERATION

3.3 PORTAL AND TRAVEL ASSEMBLY FOR ALL MACHINES

3.3.1 LOAD DISTRIBUTION AND MOVEMENT COMPENSATION
3.3.2 LINKAGE POINTS
3.3.3 BOGIE ASSEMBLIES
3.3.4 TRAVEL DRIVES
3.3.5 BUFFERS AND END STOPS

3.4 SLEW ASSEMBLIES

3.4.1 GENERAL
3.4.2 SLEW BEARING
3.4.3 STRUCTURAL REQUIREMENTS
3.4.4 INSTALLATION
3.4.5 CALCULATIONS AND MANUALS
3.4.6 SLEW DRIVES

3.5 LUFF ASSEMBLES

3.6 BOOM CONVEYORS
3.6.1 GENERAL
3.6.2 CONVEYOR DRIVES
3.6.3 BELT TENSIONING
3.6.4 BELT WEIGHTERS
3.6.5 BELT CLEANING
3.6.6 CONVEYOR DISCHARGE AND RECEIVAL CHUTES
3.7 OPERATORS CONTROL CABIN
3.8 STORM TIE DOWN
3.9 MAINTENANCE ACCESS
3.10 FIRE PROTECTION EQUIPMENT

4.0 CODES, STANDARDS AND STATUTORY REQUIREMENTS

5.0 QUALITY ASSURANCE

5.1 GENERAL
5.2 SUBCONTRACTS
5.3 QUALITY SYSTEM DOCUMENTATION
5.3.1 GENERAL
5.3.2 QUALITY PLAN
5.3.3 ITPs
5.3.4 RECORDS
5.4 QUALITY AUDITS
5.5 INDEPENDENT INSPECTION/QUALITY ASSURANCE SERVICES
5.6 INSPECTION VISITS BY PURCHASER
5.7 PROOF ENGINEER

DRAWINGS AND DOCUMENTS

6.1 GENERAL
6.2 DRAWING PRACTICE
DRAWING TITLES, SHEETS AND NUMBERS
SUBMISSION OF DRAWINGS AND DATA
REVIEW OF DRAWINGS AND DATA
CERTIFIED DRAWINGS
FINAL DRAWINGS
REQUIREMENTS FOR CALCULATIONS

DESIGN CRITERIA

7.1 GENERAL
CLIMATIC CONDITIONS
PROHIBITED MATERAILS
DESIGN CRITERIA – STRUCTURAL
7.4.1 DESIGN STANDARDS
DESIGN LOADINGS
WIND LOADS
FLOOR AND WALKWAY LOADS
MACHINERY FLOOR LOADS
EFFECTS OF ELASITC DEFORMATION OF
SUPPORTS AS MACHINE TRAVELS
EARTHQUAKE LOADS
LOADS NOT SPECIFIED
LOAD COMBINATIONS
ALLOWABLE STRESSES
FATIGUE
WHEEL AND RAIL TRACK TOLERANCES
STABILITY AND SAFETY
CONSIDERATION FOR DETAILING
SLENDERNESS RATIOS
 DEPTH TO SPAN RATIOS
MINIMUM THICKNESS
MATERIALS
ACCESS STRUCTURES
CONNECTIONS
RESIDUAL STRESSES
DUPLICATION OF OPERATORS CABIN SUPPORT
7.5 DESIGN CRITERIA – MECHANICAL
IRON ORE PROPERTIES
NOISE
VIBRATION
7.6 DESIGN CRITERIA – ELECTRICAL
7.7 DESIGN CRITERIA – CONTROL SYSTEMS
HARDWARE
SYSTEM PERFORMANCE REQUIREMENTS
CABINET ARRANGEMENT

STRUCTURAL REQUIREMENTS

8.1 INTRODUCTION
STANDARDS
WORKSHOP DRAWINGS
STEEL
STEEL WORK FABRICATION
8.5.1 GENERAL
CUTTING AND HOLING
WELDING
WELDING CONSUMABLES
WELDING PROCEDURES
WELDING SUPERVISOR
WELDING OPERATORS
INSPECTION AND TESTING
STRESS RELIEVING
MILLING, MACHINING AND LINE BORING
8.6 FABRICATION TOLERANCES
GENERAL
PLATE PANELS
FABRICATED BOX SECTIONS
ALIGNMENT OF WELDED SPLICES
MILLED SURFACES OF BOLTED SPLICES
AND BRACKET FITTINGS
8.7 HANDRAILS
8.8 FLOOR PLATE AND GRATING
STAIRWAYS AND LADDERS
FABRICATION OF ALUMINIUM
8.10.1 MATERIAL
CUTTING
WELDING
INSPECTION

MECHANICAL REQUIREMENTS

9.1 STANDARDS
9.2 GEAR REDUCERS
 GENERAL
DESIGN FOR STANDARDIZATION
REDUCER TYPE
MOUNTINGS AND ASSEMBLY TYPE
DESIGN DUTY
DESIGN STANDARDS
THERMAL CAPACITY
SPEED REDUCER RATING
COUPLING DESIGN REQUIREMENTS
OVERHUNG LOAD
NOISE
CASINGS
LUBRICATION
BEARINGS
SEALS
HEAT CONTROL
PROTECTIVE COATINGS
TESTING
DRAWINGS

9.3 MECHANICAL COUPLINGS

9.3.1 GENERAL
9.3.2 COUPLING TYPES
9.3.3 BRAKE DRUM/DISC CONNECTION
9.3.4 SERVICE FACTOR
9.3.5 BALANCING
9.3.6 DESCRIPTION

9.4 FLUID COUPLINGS

GENERAL
COUPLING TYPE
STARTING TORQUE
STALLED TORQUE
SLIP
STARTING FREQUENCY
CAPACITY TO VARY THE OUTPUT
THERMAL OVERLOAD PROTECTION
SEALS
BALANCING
OIL TYPE AND LEVEL
DESCRIPTION

9.5 BRAKES
BRAKE ARRANGEMENT
BRAKE CONSTRUCTION
FAIL SAFE
ADJUSTMENT
DESCRIPTION

9.6 DRIVE BASES

GENERAL
DESGIN CRITERIA
DESCRIPTION
9.7 BEARINGS
GENERAL
BALL AND ROLLER BEARINGS
PLAIN BEARINGS
SPHERICAL PLAIN BEARINGS
BEARING HOUSINGS
SEALS
LUBRICATION
BLANKING PLATE
INSTALLATION

9.8 CONVEYOR IDLERS

GENERAL
CONCENTRICITY
BALANCING
MOUNTING FRAME
RETURN IDLER BRACKETS
BARREL
END BEARING HOUSING
BEARINGS
SHAFT
SEALS
PROTECTIVE COATINGS
IDLER TYPES

9.9 CONVEYOR PULLEYS

GENERAL
DUTY
RATIONALISATION OF PULLEYS
DESIGN CRITERIA
MATERIALS OF MANUFACTURE
PULLEY SHELL
END DISCS
WELDING
WELD PREPARATION
WELD PROCEDURE
HEAT TREATMENT
SHELL MACHINING
PULLEY LAGGING
SHAFT
LOCKING ASSEMBLY
BEARIANGS
ECCENTRICITY CHECT
BALANCING
INSPECTION AND TESTING

9.10 CONVEYOR BELTING

9.11 GENERAL MECHANICAL REQUIREMENTS

TOLERANCES
SURFACE FINISH
FASTENINGS
FLANGED CONNECTIONS
SHAFTING
 KEYS AND KEYWAYS
CASTINGS
PACKERS AND SHIMS
ATTACHMENTS
LUBRICATION EQUIPMENT
CHUTES, LINERS, IMPACT PLATES AND SKIRTS
SCRAPERS AND PLOUGHS
SAFETY GUARDS
SAFETY AND IDENTIFICATION SIGNS

9.12 HYDRAULIC SYSTEMS

GENERAL
HYDRAULIC PUMPS
HYDRAULIC DRIVE MOTORS
HYDRAULIC CYLINDERS
VALVES
VALVE PANELS
POWER PACKS
OIL TANKS
ACCUMULATORS
FILTERS
PRESSURE GAUGES
OIL COOLERS
PIPES, HOSES AND FITTINGS
ELECTRICAL EQUIPMENT
CONTROLS
SURFACE TREATMENT
EQUIPMENT IDENTIFICATION
INSPECTION AND TESTING
PACKING FOR TRANSPORT

ELECTRICAL REQUIREMENTS

10.1 GENERAL
SWITCHGEAR
3.3KV SWITCHGEAR
HARMONIC GENERATION
VOLTAGE DIPS AND HARMONICS
VOLTAGE LEVEL UTILISATION
ELECTRONIC EQUIPMENT POWER SUPPLY
ELECTRICAL CONTROL VOLTAGES
EQUIPMENT RATINGS
CABLE REELER SLIP RING ASSEMBLIES
TRAILING CABLES
CABLING
EARTHING
EARTH SHOES
GENERAL POWER
LIGHTING
EMERGENCY LIGHTING
COMMUNICATIONS
LOW VOLTAGE SWITCHGEAR AND CONTROL ASSEMBLIES
MOTORS
HARDWIRED INTERLOCKS
CONTROL SYSTEM REQUIREMENTS

GENERAL REQUIREMENTS
OPERATOR INTERFACE
FIELD DEVICES
SOFTWARE REQUIREMENTS
CONTROL SYSTEM SOFTWARE DOCUMENTATION
& MANAGEMENT
CONTROL SYSTEM TESTING

ERECTION AND INSTALLATION REQUIREMENTS

12.1 GENERAL
ERECTION OF STRUCTURAL STEELWORK
BOLTING
TRIAL ASSEMBLY
ERECTION TOLERANCES
EQUIPMENT INSTALLATION
COMPLETION OF INSTALLATION

SURFACE TREATMENTS AND PROTECTIVE COATINGS

GENERAL
STANDARDS
COATING SYSTEMS
ALTERNATIVE SYSTEMS
MATERIALS
SURFACE PREPARATION
ABRASIVE BLAST CLEANING
CARE OF ABRASIVE BLAST CLEANED SURFACES
APPLICATION OF COATINGS – GENERAL
APPLICATION OF PRIME COATING TO STEELWORK
TESTING OF INORGANIC ZINC SILICATE PRIMER
APPLICATION OF INTERMEDIATE COATING TO STEEL WORK
TESTING OF INTERMEDIATE COATING
APPLICATION OF FINISH COATING TO STEELWORK
APPLICATIONS OF COATINGS TO INTERNAL SURFACES OF
SEALED AND BOX SECTIONS
13.16 SURFACE PREPARATION AND APPLICATION OF COATINGS
TO MOTORS, GEAR REDUCERS, AND OTHER PROPRIETARY
EQUIPMENT
13.17 SURFACE PREPARATION AND APPLICATION OF COATINGS
TO ALUMINIUM FABRICATIONS AND EQUIPMENT
HOT DIP GALVANISHING
COLOUR SCHEME FOR PROTECTIVE COATINGS
TO STEELWORK
13.20 SCHEDULE OF PROTECTION
13.21 PROTECTIVE COATING COLOUR SCHEDULE

OPERATION AND MAINTENANCE MANUALS

14.1 GENERAL
MANUAL DETAILS
SUBMISSION OF MANUALS
ADDENDA
MANUAL CONSTRUCTION
CONTENT

TESTING COMMISSIONING AND ACCEPTANCE

15.1 GENERAL
PRE-COMMISSIONING
NO LOAD COMMISSIONING
LOAD COMMISSIONING
ACCEPTANCE
COMMISSIONING SPARES

TRAINING

SPARES

TOOLS AND MAINTENANCE EQUIPEMENT

A. CLIMATIC CONDITIONS :

1.1 LOCATION OF THE PORT

The Port of Paradip is situated on the east coast of India; in the State of
Orissa. It is located 210 nautical miles south of Kolkata Port and 250
nautical miles North of Vishakhapatnam. Latitude & Longitude of Paradip
Port is as follows :

Latitude : 200 15’ 55.44” N

Longitude : 860 40’ 34.62” E

1.2 TOPOGRAPHY

The Paradip Port serves a vast hinterland, which is rich in mineral,

industrial and agricultural resources and connected through network of
roads, railways & water ways. The Port is connected by state high way
with Cuttack (96 kms.) and the State capital Bhubaneswar (125 kms.) and
is also linked to the National High Way (NH-5) through an extension
subsequently declared as NH-5A. An express high way of 142 kms. was
constructed from Daitary Mines directly to Paradip Port in 1966, running
across NH-5, for movement of iron ores by trucks. Indian Railways serve
the Port through a direct broad gauge link to Cuttack, the commercial hub
of the State of Orissa. The Taladanda Canal, starting from the Mahanadi
river near Cuttack is extended up to Paradip, providing inland navigational
facilities for the Port. The confluence of Mahanadi River lies about 7.5
kms. North of the Port and the river is also navigable during good part of
the year.

The present Estate of Paradip Port stretches over an area south of

Atharbanki Creek measuring about 5995 acres. Out of this area, about
850 acres of land area has been earmarked for residential complex,
commercial buildings and institutional utilization. The dock area is
surrounded by a boundary wall and covers about 1500 acres. The rest of
the area has been kept reserved for development of storage facilities and
development of Port based industries. The water area of the harbour
including the stretches covered by the North and South break waters, the
approach channel, the turning circle and a two dock arm is about 248
acres. There are provisions for enlargement of the dock area for future
expansion.

1.3 OCEANOGRAPHIC DATA.

Oceanographic data, such as tidal conditions, waves, currents, littoral drift

etc. are very important factor for any Port development. Details of those
data are as follows :
1.3.1 TIDAL CONDITIONS.

The tides at Paradip are semi-diurnal in character. The tidal height with
respect to the Port chart datum is presented in table-3(a)

Table 3 (a) : Tidal Heights with respect to Chart Datum

Sl. No. Description Height w.r.t. Chart

Datum
1. Highest High water +3.50 m
2. Highest High Water (Design) +3.25 m
3. Lowest Low Water +0.40 m
4. Mean High Water Springs +2.58 m
5. Mean Low Water Springs +0.71 m
6. Mean High Water Neaps +2.02 m
7. Mean Low Water Springs +1.32 m

The Port survey Chart Datum is established at 1.54 m below Indian Mean
Sea Level.

1.3.2 WAVES.

Following table gives the average frequency distribution of wave heights

with their directions at Paradip coast :

Table 3(b) : Average Frequency Distribution of Wave Heights with their

Directions at Paradip.

Month Wave Heights Directions

March i) 0.6 m to 1.2 m 52.68 SSE 2.15
ii) 1.2 m to 1.8 m 41.94 S 53.76
iii) 1.8 m to 2.4 m 5.38 SSW 9.67
iv) 2.4 m to 3.1 m - SW 34.42
April i) 0.6 m to 1.2 m 20.00 SE 25.54
ii) 1.2 m to 1.8 m 32.22 SSE 5.57
iii) 1.8 m to 2.4 m 47.78 S 60.01
iv) 2.4 m to 3.1 m - SW 8.88
May i) 0.6 m to 1.2 m 55.90 SE 7.53
ii) 1.2 m to 1.8 m 32.26 SSE 4.31
iii) 1.8 m to 2.4 m 11.84 S 60.01
iv) 2.4 m to 3.1 m - SSW 10.76
SW 28.87
June i) 0.6 m to 1.2 m 3.34 SE 46.67
ii) 1.2 m to 1.8 m 40.00 SSE 12.21
iii) 1.8 m to 2.4 m 47.77 S 41.12
iv) 2.4 m to 3.1 m 8.89
July i) 0.6 m to 1.2 m 1.13 SE 4.52
ii) 1.2 m to 1.8 m 25.86 SSE 4.51
iii) 1.8 m to 2.4 m 44.86 S 43.70
 iv) 2.4 m to 3.1 m 19.12 SSW 11.29
v) 3.1 m to 3.7 m 4.52 SW 35.98
vi) above 3.7 m 4.51
August i) 0.6 m to 1.2 m 26.97 S 92.14
ii) 1.2 m to 1.8 m 30.34 SW 7.86
iii) 1.8 m to 2.4 m 20.22
iv) 2.4 m to 3.1 m 13.49
v) 3.1 m to 3.7 m 5.61
vi) above 3.7 m 3.37
Sept. i) 0.6 m to 1.2 m 44.78 SE 16.86
ii) 1.2 m to 1.8 m 33.74 SSE 3.62
iii) 1.8 m to 2.4 m 9.64 S 79.52
iv) 2.4 m to 3.1 m 10.84
Oct. i) 0.6 m to 1.2 m 78.88 SE 35.55
ii) 1.2 m to 1.8 m 20.00 SSE 5.55
iii) 1.8 m to 2.4 m 1.12 S 58.90

Nov i) 0.6 m to 1.2 m 63.34 E 6.67

ii) 1.2 m to 1.8 m 24.43 ESE 4.45
iii) 1.8 m to 2.4 m 5.56 SE 37.77
iv) 2.4 m to 3.1 m - SSE 3.34
v) 3.1 m to 3.7 m 1.11 S 45.54
vi) above 3.7 m 5.55 SW 2.23
Dec i) 0.6 m to 1.2 m 92.47 E 6.45
ii) 1.2 m to 1.8 m 7.53 ESE 8.60
SE 59.14
SSE 13.89
S 11.83

Jan i) 0.6 m to 1.2 m 88.87 E 15.54

ii) 1.2 m to 1.8 m 11.13 ESE 16.67
SE 41.11
SSE 10.00
S 16.68

Feb i) 0.6 m to 1.2 m 88.00 E 29.34

ii) 1.2 m to 1.8 m 12.00 ESE 13.33
SE 34.67
SSE 22.66

It is observed from the above table that for most of the time the significant
wave heights are between 1.2m to 2.4m, while on some occasions
particularly during the south-west monsoon season it may exceed 2.4m.
The period between December to February is considered to be a very
calm period.
The CWPRS, Pune made wave hindcasting studies from synoptic weather
charts, which confirmed the occurrence of a maximum significant wave
height of 18’ (5.5m) during 1971 storm. During other seasons the normal
wave height seldom exceeds 9.5’ (2.7m). The CWPRS hindcasting study
 compared well with the observed data from ships. The wave periods are
varying between 5 to 10 seconds and most of the observations are in the
range of 5 to 7 seconds.

1.3.3 CURRENTS.

From navigational point of view the study of surface currents is important.

The flood and ebb currents during spring tides are of the order of 0.6knots
(1.2m per second) and during the neap tides 0.45 knots (0.9m per
second). Maximum currents reported did not exceed 1.2 knots (2.2m per
second).

1.3.4 LITTORAL DRIFT.

There is a net established annual littoral drift of the order of 1.5 million
tones from south to north. This drift is intercepted by the south breakwater
and the navigable entrance channel. In order to maintain adequate depths
of the entrance channel and to avoid the littoral drift settling in the
entrance channel a sand trap has been built on the south side of
breakwater.

1.4 METEROLOGICAL DATA

Meterological data, such as records of wind, cyclonic storms, depressions,

rainfall, temperature, relative humidity, visibility etc. are recorded regularly
at the observatory at Paradip and at regional meterological centre at
Bhubaneswar.

1.4.1 WIND.

The wind direction and their speed can be divided into three main periods
i.e. winter months (January to February), south-west monsoon months
(March to September) and north-east monsoon months (October to
December). The monthly variations of wind as experienced are detailed
below :

Table 3(c) : Monthwise Wind Description at Paradip

Month (s) Wind Description

January & In the morning hours, the predominant approach directions of
February wind are between north and north-east and on 75% of the
time wind blows from these directions. In the evening hours,
wind approach direction changes and blow between east and
south-west direction. The wind speed during any time
normally does not exceed Beaufort scale 4 (20 to 29 kms/hr.)
March The predominant approach direction of wind in the morning
hours is between south and south-west and for 83% of the
time speed is within Beaufort Scale 3 (12 to 19 kms/hr.) and
speed from any direction does not exceed normally Beaufort
Scale 4. Whereas in the evening hours the wind mainly from
south and south-west and for 30% of the time it is in the
 Beaufort Scale 4 and sometimes reaches higher velocities.
April & The wind speed both in the morning and evening and
May reaches Beaufort Scale 6 (40 to 50 kms/hr), though most of
the time the wind speed is within Beaufort Scale 4. The
predominant direction of approach is between south and
south-west.
June & The approach direction of wind during this period in the
July morning and in the evening hours mainly varies between
south and west. The speed most of the time remains below
Beaufort Scale 5 (30 to 39 kms/hr.) but sometimes reaches
higher velocities in the evening hours.
August & The approach direction of wind during this period is between
September south and north-west. About 17% of the time, the wind speed
remain above Beaufort Scale 4. Sometimes it reaches
Beaufort Scale 6 & above.
October, During north-east monsoon period, the approach November
November direction of the wind in the morning hours remains between
& north-east and north-west. The wind speed, however, does
December not exceed the Beaufort Scale 5. In the evening hours, the
direction of the wind is mainly from south-east and north-east
and normally remains within Beaufort Scale 5.

1.4.2 STORMS & CYCLONES.

Paradip Port is in the cyclone passage region and disturbances occur

during the depressions in the Bay of Bengal. Cyclones of 1971 & 1982
and Super-cyclone of 1999 caused enormous damages to the life and
property with wind speed of 185 kmph, 167 kmph and 259 kmph
respectively.

The Indian Meteorological Department has installed several stations along

the east coast of India with cyclone warning radar facilities. Radar having
range of 300 to 400 km and advance information on occurrence of storms
and depressions are made available to the Port authorities. Such Radar
facilities exist at the Meteorological stations at Kolkata, Paradip,
Vishkhapatnam, Machillipatnam, Karaikal and at Chennai along east
coast. The frequency of occurrence of depressions and storms in Paradip
area are presented in table below :

Table 3 (d) Frequency of Occurrence of Depression/ Storms at Paradip

Month Depressions Storms Severe Total

Storms
January - - - -
February - - - -
March - - - -
April 1 2 3 6
May 8 8 17 33
June 55 16 5 81
July 94 23 8 125
 August 120 18 3 141
September 110 18 16 144
October 44 25 22 91
November 7 20 16 43
December 4 3 10 17
Total 443 133 100 681

1.4.3 RAINFALL.

The annual average rain fall at Paradip is 1426.98 mm per year, which is
distributed amongst 3 main sub-periods of winter (January & February)
48.62mm, during south-west monsoon months (March to September)
1209.04mm and during the north-east monsoon months (October to
December) 169.32 mm. The variation of average rain fall is indicated in
the table below :

Table 3(e) : Monthly Mean of Maximum & Minimum Temperature

Month Average rain Maximum rain Minimum rain

fall (in mm) fall (in mm) fall (in mm)
January 10.0 – 12.0 27.7 0.0
February 36.0 – 40.0 76.7 6.1
March 48.0 – 50.0 177.4 15.0
April 38.0 – 42.0 67.2 16.0
May 42.0 – 44.0 139.9 4.2
June 235.0 – 245.0 451.6 81.6
July 268.0 – 276.0 577.9 135.3
August 308.0 – 316.0 362.4 235.8
September 245.0 – 255.0 331.4 15.3
October 116.0 – 120.0 331.4 15.3
November 12.0 – 14.0 41.1 0.0
December 36.0 – 40.0 134.2 0.0

1.4.4 TEMPERATURE AND HUMIDITY.

The mean values of maximum and minimum temperature are given in the
following table. The relative humidity in the mornings is 90% or above
throughout the year while the minimum during the evening hours is 60%
during south-west monsoon season and 55% during the currency of north-
east monsoon and winter months.
 Table 3(f) : Monthly Mean of Maximum & Minimum Temperature at
Paradip.

Month(s) Mean of Maximum Mean of Minimum

temperature (in temperature (in
degree Centigrade) degree Centigrade)
January 29.52 13.30
February 30.44 15.54
March 31.38 19.12
April 33.94 20.96
May 35.82 22.54
June 34.52 22.44
July 35.96 22.50
August 33.20 21.26
September 34.14 24.88
October 33.94 22.00
November 32.42 17.66
December 28.68 13.62

1.4.5 VISIBILITY .

Visibility data are recorded at Paradip observatory daily at 0830 Hrs. and
at 1730 Hrs. and records are available since 1975. Normally lowest range
of visibility occurs at sunrise or at sunset and as the times of recording at
Paradip observatory are fixed lowest values are not available. Records are
maintained in coded form (WNO code 4377) as approved by World
Meteorological Organization. The approved code is given in the following
table.

On analyzing the records maintained by I.M.D. for a particular year (1985 )

87% of the readings were in scale 96, 6% in scale 95 and 7% in scale 97.
For other years, it was comparable. Only one reading over the years was
in scale 92. From these records, it may be stated that during day light
hours between 0830 hrs and 1730 hrs visibility at Paradip does not
present and problem for navigation.
Table 3(g) :
Visibility Data Specification as per World Meteorological
Organization.
Code Visibility
90 Less than 50 m.
91 50 m to 200 m
92 200m to 500m
93 500 m to 1000 m
94 1000 m to 2000 m
95 2000 m to 4000 m
96 4000 m to 10000 m
97 10000 m to 20000 m
98 20000 m to 50000 m
99 Above 50000 m
1.5 GEOTECHNICAL DATA.

Paradip Port is situated within the close proximity of Mahanadi delta.

Therefore, generally, soil comprises of alternate alluvial layers of silts and
sea sand. This is confirmed by the Sub-soil explorations carried out by
various agencies at Paradip Port. Geo-technical investigation at the
proposed site for deep draught iron ore berth is yet to be carried out. The
nearest location at which the information is available is West Quay area.
Geo-technical investigations in this area were carried out in 1997.

1.6 ENVIRONMENTAL CONDITION

Environmental conditions at Paradip are satisfactory. The main polluting
factors at the Port are dusts generated from thermal coal and iron ore. The
direction of wind, at Paradip, being predominantly from south-west to
north-east, the residential areas are not directly affected and areas along
the direction of wind is very thinly populated. By adopting suitable dust
control measures, satisfactory conditions can be created to control the
dust pollution within satisfactory limits.
B. SCOPE OF WORK

1.1 GENERAL

This Contract shall be for all necessary engineering, design,

management and co-ordination, supply of all drawings, manuals and
documents, supply of materials, provision of any temporary structures
and supply of all plant and labour for the fabrication, delivery, erection,
inspection, training of personnel, testing and commissioning of the
following:-

An electric powered, rail mounted, traveling, slewing and luffing

Reclaimer hereinafter referred to as “the machine” for the Iron Ore
Handling Plant, Paradip Port Trust.

The machine shall be complete including structures, mechanical

equipment, electrical equipment, trailing cables and cable reelers,
cabling, controls, dust and noise suppression systems, access
platforms, walkways and stairs, wash down water system and fire
fighting equipment, plus all other ancillary equipment necessary for
Reclaimer.

1.2 WORK INCLUDED

The work included under this Contract shall be described in this Scope
of Work and specification.

The Supplier shall supply all items necessary for complete and
operational machine including but not limited to:-

• Contract documentation, drawings, calculations, data,

information including testing, commissioning and acceptance,
operating and maintenance manuals in accordance with Clause
6.0(Drawing, design & Documentation), Clause 15.0 (Testing,
Commissioning and Acceptance) and the Documentation
Schedule.

• All approvals and licences required by any authority having

regulatory powers to control the design, manufacture, erection
and operation of the machine within the State of Orissa in India.

• Management co-ordination and planning for all aspects of the

work including but not limited to occupational health and safety
quality programming, cost control, design, manufacture, delivery
to site , site management , erection, testing and commissioning
and training.
• Ground mounted strikers or flags for the machine mounted
electrical devices such as travel limit switches or over-travel limit
switches.

• Ground and machine mounted buffer and end stop equipment.

• Ground and machine mounted storm tie down equipment

• Independent 3rd Party Auditor, National/International, to audit

design, manufacture, erection, installation, commissioning and
testing.

• Inspection during manufacture, fabrication, shop assembly and

packing for transport by an independent international/National
inspection agency.

• All temporary structures, rigging and equipment required for

erection.

• All equipment and labour for setting out , survey and checking of
dimensions and tolerances.

• All consumable materials required for inspection and testing.

• First fill of all lubricants, flushing oils and hydraulic fluids.

• Materials, fabrication, pre-assembly, surface treatment in

accordance with the Approved for Construction drawings and
Contract documents.

• Delivery to site and storage of equipment in accordance with the

Contract documents.

• All plant, labour , equipment and consumables necessary for the

safe and complete site erection of the machines.

• Operations and maintenance training of Paradip Port Trust

personnel.

• An IP65 rated field termination panel including cable turn over

devices and all terminations required to terminate the power,
communication and control cables at the machine termination
point located at the center of travel of the machines.

• A 3.3 kv power cable suitable for mounting on a cable reeler to

supply power from the termination panels to the mobile
machine.
• A multi-core control cable suitable for mounting on a cable reeler
with sufficient cores to cater for the on-board controls and
statutory interlocks from the termination panels to the machine.

• Termination of machine trailing cables at the central termination

panels.

• On-board power transformers required to transform a supply

voltage of 3.3 kv to 415 v

• On-board switchrooms to enable safe switching of all on-board

equipment supplies and to provide suitable graded protection for
all components within the mobile machine.

• All motors switches, encoders and detectors to enable correct

and safe operation of the mobile machine

• All on-board lighting for the mobile machine including operation

lighting to illuminate the stockpile reclaim surface.

• Installation of PLC equipment in cubicles on the machine

complete with all inputs and outputs required to monitor and
control all switches, motor currents , electrical loads, machine
positions and other inputs and outputs necessary for the correct
operation of the machine.

• Installation of a screen based operator interface, mounted in the

control desk of the machine.

• The additional programming units, if any, shall be suitable for

connection to the PLC and be completed with all operating
software, carrying case, connection leads and consumables for
one years operation.

• Design , implement, install and commission the Control System

software for the PLC and Operator Interface equipment to
provide for safe and correct operation of the machines, including
interfaces to the fixed plant control system.
• Assemble and test the complete machine control system in
conjunction with Iron Ore Handling Plant Control System,

• Functional Specification and Software Specification detailing

suppliers hardware and software interfacing and submit to the
Purchaser for approval prior to commencement of system
software development. The software shall have to be developed
by the Supplier based on an approved logic.
 • Installation, commissioning and testing of all supplied equipment
including all associated costs.

• Consumable spares for 2 years operation.

• All necessary equipment to ensure earthing of the machine.

1.3 WORK NOT INCLUDED

Work not included under the Contract are:

• Supply and installation of footings and foundations for
ground mounted end stops storm tie down equipment and
cable termination panels.

• Supply and installation of trailing cable trays and support

brackets.

• Supply and installation of stockpile earthworks including

ballasted long travel rail tracks hard standing areas and road
works.

• 3.3 kv supply to the central termination panels

1.4 PURCHASER SUPPLY

In addition to the materials and equipment specified as being supplied

by the Purchaser elsewhere in the Contract the Purchaser shall supply
the following:

• Iron ore and ships as required for commissioning in

accordance with the approved testing and commissioning
programme. No guarantee, however can be made on train
and ship scheduling

• Maintenance and operations personnel to be involved with

training and load commissioning.

• Training facilities comprising a training room, desks, chairs,

overhead projector and whiteboards for use by the Supplier’s
training personnel when conducting training courses for the
Purchaser’s personnel.

1.5 RELATED AND OTHER CONTRACTS

During the progress of this Contract, the supplier should co-

ordinate with the Port officials so that the normal loading
operation or running of conveyor is not affected. It should not
cause any stoppage or hindrance to other agencies in the site
also.
 The Supplier shall make due allowance for access by other Suppliers
for the delivery and storage of their materials and the execution of their
work, and shall properly connect and co-ordinate his work so that
normal operation of Iron Ore Handling Plant does not suffer

The Supplier shall carry out his work in such manners to minimise
inconvenience to Port operation and to the other agencies on the site.

2.0 SYSTEM DESCRIPTION

2.1 INTRODUCTION

The Reclaimer is to be installed on the rail of 3B conveyor circuit of

IOHP to reclaim the Iron ore which can be further conveyed to the
vessel.

The major components of the Iron Ore Handling Plant are as follows:-

• Twin rotary wagon tippler.

• Two yard conveyors having three rows of stack yards.

• One Reclaimer and a Reclaimer on 3A yard conveyor and

one stacker with one Reclaimer in Conveyor 3B stream. The
Stacker will be replaced by a Reclaimer shortly.

• One surge bin with nominal capacity of 300 tonnes to ensure

minimum interruption to the shiploading process due to hatch
changing or vessel trimming.

• Two shiploaders operating on a single shipping conveyor.

• A process flow diagram for the plant is shown in the
Drawings.
 I O H

JN H O U S E

2B 2A

2.2 CONTROL PHILOSOPHY

 The Reclaimer shall be manned and locally controlled from an on
board operators cabin. The machine shall be equipped with its own
PLC which will perform the control functions for the correct and safe
operation in conjunction with commands and modes initiated by the on-
board operator. In the event that the operator attempts to perform an
illegal operation, the PLC control system shall activate an audio-visual
alarm and prevent the execution of that operation .

Supply and installation of mounting cubicle, installation of PLC

equipment, wiring, supply and installation and cabling of field
equipment and programming, testing and commissioning of the PLC
shall be the responsibility of the Supplier.

The machines shall be capable of being operated in:

Interlock Mode (Operation mode).

De-interlock Mode (to be used during Maintenance manoeuvers

repositioning and emergency).

Selection of Interlock/De-interlock mode should be by means of a key

operated switch in the Operators Cabin.
Safety features shall, inter alia, include the following:
a) Lubrication failure in slew bearing should not allow the slew
drive to function.
b) Bucket Wheel drive gear box lubrication failure must stop
Reclaimer wheel Operation.
c) Important Bearings must be provided with temperature sensors
and in case of temperature exceeding a set limit there must
be an audio visual alarm and if the temperature rises further up
to a trip limit the trip function must get activated.
d) Temperature sensors must have local as well as remote
indicators fitted in the Operator’s cabin at a strategic location.
e) Screen Washer must be provided on the Operator’s window and
the operating controls for the screen washer must be provided at
a convenient point inside the cabin.

2.3 RECLAIMING.

For reclaiming operation, the motorized rotating bucket wheel with

eight buckets is used to cut into the pile and collect the ore.

The complete bucket wheel frame, including the drive, is attached to

the end of the boom. The bucket wheel is of cell-less type. The material
is discharged from the bucket wheel at the top position and are guided
by the lowered bucket wheel chute onto the boom conveyor which
carries the material towards the slew center. On reaching the end of
 the conveyor the material falls through the central transfer chute onto
the yard conveyor.

The reclaiming operation is done bench wise starting with the top layer
at one end of the pile. It is generally performed with to & fro slew
motions at a constant height along with a small advance of the
machine by long travel after each slew operation. After the desired
terrace length has been reclaimed, the machine is moved backward,
the boom luffed down by the height of one slice and the next terrace
reclaimed. The slewing speed is varied through a VVVF drive to
maintain the desired reclaiming rate using the belt weigher rate
indicator for guidance. The other pile is also reclaimed in a similar
fashion.

3.0 EQUIPMENT REQUIREMENTS

3.1 GENERAL

The major components of the machines, including the portal gantry

slew bases and equalizer beams shall be of closed box sections.

The pivoting superstructure including the main boom counterweight

boom and masts shall be linked together to be self supporting

The machines and equipment shall be designed to:-

Facilitate inspection, cleaning, adjustment, repairs and maintenance

Prevent ingress of dust, grit , water or other contaminants.

Eliminate potential corrosion due to accumulated material at steelwork

connections and penetration of moisture into ‘hollow’ sections and in
between steelwork components.

Avoid flat level surfaces beneath boom conveyors and elsewherewhich

would permit material build up.

3.2 CONFIGURATION

The Reclaimer shall be traveling, slewing and luffing type machine. The
Reclaimer shall be designed to operate on ballasted track rails of
gauge width 22 ft or 6.706 mtr.

A Reclaimer shall comprise of a main portal gantry supporting a

slewing superstructure with a pivoted conveyor boom and bucket wheel
, masts and counterweight boom.
 The Reclaimer shall be equipped with a self leveling operator’s cabin in
accordance with the requirement of Clause 3.7 of this section.

3.3 PORTAL GANTRY

The portal gantry shall provide rigid and robust structural support
to evenly distribute the loads and ensure equalized corner loading
and minimize distortion. The gantry should be a three point four
corner fully equalized support system. Out of three points one
point should be at the centre line of the yard conveyor.

The portal gantry shall also incorporate the long travel drive
assemblies. Provision should be provided in the portal gantry to
support the base of the central chute. The central chute shall be
designed to receive ore from the boom conveyor for all book
operating positions without iron ore spillage.

The discharge chute shall be designed to provide central loading

onto the yard reclaim conveyor without spillage.

3.4 SUPERSTRUCTURE

The superstructure shall consist of the conveyor boom,

pantograph, masts, counterweight boom and base frame. The
superstructure shall be completely stable and self supporting
structure with the base frame seated on the slewing assembly.

The boom structures shall be designed to avoid material build-up

on structural members particularly arising from the return belt of
the boom conveyor. The conveyor boom shall be designed as a
built up girder or as an open truss and shall include walkways on
both sides of the boom conveyor Rolled steel sections are the
member type to be used for trusses. Truss joints shall be of
welded construction, detailed so as to avoid ore build up. The
boom conveyor return belt and idlers shall be located above the
walkways and be accessible for replacement from the walkway.

The boom conveyor shall direct ore from the bucket wheel to the
central circular chute. The conveyor and its equipment shall be in
accordance with the requirements of Clause 3.10.

A belt weigher shall be installed on the boom conveyor to ensure

that the specified reclaim rate is maintained. The weigher shall
compensate for boom inclination and have an accuracy of 2
 percent or better Calibration equipment for the weigher shall also
be provided.

The bucketwheel shall transfer ore to the boom conveyor without

spillage and/or overflow

Material carry over from the buckets shall not build up on the
boom structure but be directed back onto the stockpile.

The jack pads to be provided on the portal gantry and

superstructure must be located on easily accessible region and
sufficiently strengthened to avoid buckling during hydraulic jack
application.

3.5 SLEW ASSEMBLY

Slewing shall be accomplished with a slew ring bearing and gear

drive designed as a properly mounted and rigid robust assembly.
The slewing mechanism shall be designed in accordance with the
requirements of Clause 3.8.

Safety devices shall be provided to prevent excessively large

lateral forces which may arise when slewing against stockpile
slopes or any fixed structure or surface.

The sufficient gap must be provided between superstructure and

portal gantry to accommodate standard hydraulic jacks instead of
low height jack for easy access to carryout maintenance works.

3.6 BUCKETWHEEL

The bucket wheel shall be of cell-less design with a cutting

diameter suitable for three bench reclaiming operations in the
12m high stockpiles at the specified capacities and also capable
of reclaiming from 1m down below the rail level.

The bucket wheel body shall be of welded steel construction

properly stiffened for the required duty and configured to form a
rigid support for the buckets. There shall be no pockets for
material accumulation and all hollow parts shall be completely
sealed to prevent the ingress of moisture or other contaminants.
The wheel shall be designed to withstand the maximum drive
output torque . Spoked wheels are not acceptable.
The assembled bucket wheel shall have a “run out” (axial and
radial) which should be within a permissible unit. Limits must be
specified.

The bucket wheel shall be connected to the drive shaft by a

“shrink disc” or similar coupling. The drive shaft shall be a forging
and shall be ultrasonically tested before machining to certify that
it is free from flaws.

All parts of the bucket wheel subject to wear shall be adequately

protected with replaceable liners. Access shall be provided to all
parts for ease of maintenance and removal of all components for
replacement.

The buckets shall be designed with good emptying characteristics

to handle the specified ore which may be sticky and non free
flowing. The bucket cutting clearance angles and internal corner
radii shall be designed to prevent material hang-up in the bucket

The cutting edges shall be of abrasive resistant steel along with

the hard faced bucket teeth.

The buckets shall be attached to the bucket wheel body by

means of pins or similar connections to permit convenient
removal and replacement. Those parts of the bucket attachments
subject to wear shall be suitably protected.

The bucket wheel drive shall be provided with a quick response,

reliable ultimate torque limiting protection device. This may be
accomplished with the a fluid coupling. The fluid coupling, if used
shall be of constant fill type which shall limit the transmitted
torque to 180 percent of the motor full load torque.

The bucketwheel drive assembly shall be fully assembled on a

single base frame. The drive shall be shaft mounted onto the
bucketwheel shaft and also supported by a single self aligning
torque reaction mounting designed to cater for all tensile and
compressive loads and prevent excessive movement. The drive
arrangement shall be designed to provide proper alignment under
all operating conditions.

The bucketwheel shaft and drive assembly shall be arranged to

provide as large a free cutting angle as possible.
 The bucket wheel shaft material shall comply to Indian
/International standards with (EN24) Graded material with the
following properties:-

Ultimate Tensile Strength 850 Mpa minimum

1000 Mpa maximum

Yield Stress 650 Mpa minimum

Elongation 13% minimum

Charpy V-Norch Impact Energy 50 J minimum at 10 deg C

Brinell Hardness 248 – 302 HB

Certificates for Chemical analysis Certification, Heat treatment

temperature chart and Mechanical tests for tensile and Charpy
impact properties shall be produced. Ultrasonic testing shall be to
Indian/International standard with acceptance for “No indications”
Magnetic Particle tests shall be carried out with “no visible
defects”.

Access for inspection maintenance and replacement of all

components of the bucketwheel drive shall be provided.

The bucketwheel drive shall be designed for ten equally spaced

starts per hour and two consecutive starts.

An automatic lubrication system shall be provided for all principal

points on the bucketwheel and bucketwheel drive assembly.

3.7 PORTAL AND TRAVEL ASSEMBLIES FOR RECLAIMER

3.7.1 LOAD DISTRIBUTION AND MOVEMENT COMPENSATION

The design of the linkages and equalizer beam arrangements

which transfer all forces to the bogies and subsequently to the
rails shall also compensate for variations in rail spacing
straightness and level as specified .

The elastic deformation of the portal shall not generate additional

forces acting perpendicular to the rails.
3.7.2 LINKAGE POINTS

The linkage points of the various structural and mechanical

components shall utilize spherical plain bearings where feasible.

Links shall incorporate a configuration such that in the event of a

bearing failure the maximum “drop” should be limited to 25mm.

3.7.3 BOGIE ASSEMBLY

The bogie assembly shall provide for replacement of a complete

axle assembly consisting of wheels, shaft and bearings , including
housings, at any point along the rail tracks using not more than
two manually activated hydraulic jacks and a 5 tonne mobile
crane.

The drop height of the bogie frame in case of wheel or shaft

failure shall be 25mm or less

All bogie assemblies shall be designed for equal distribution of

lateral and vertical forces and to compensate for rail level and
spacing variation

The bogie assemblies shall incorporate a configuration such that

optimum alignment at commissioning and realignment as a
consequence of minor wear can be carried out without “on site”
machining. Bogies shall incorporate alignment aids that will allow
simple measurement of alignment.

The wheels shall be cylindrical and shall be designed to comply

with the Indian/International standards .

Reclaimer wheel shafts shall incorporate one double flanged

wheel with a face profile suitable for R-52 Kg/m IU grade
stockpile rails

The wheels shall be double flanged with a face profile suitable for
the 52 kg/m rail .

The machined surfaces of the wheels shall be tested by magnetic

particle methods to Indian/International standard Wheels
exhibiting surface cracking shall be rejected.
 The drive shaft shall be extended through the bearing housing
and be suitable for a shaft mounted gear reducer.

3.7.4 TRAVEL DRIVES

Long travel drives shall be designed to achieve the specified

traverse speeds in the most adverse combination of load
condition and gradient.

The drive speeds shall be infinitely variable from 100% of the

nominal speed of 20 m/sec and capable of smooth reversal
through zero speed and smooth starting from standstill and
stopping down to standstill. The lowest steady state speed shall
be not higher than 15% of rated speed. The drives shall be
equipped with acceleration and deceleration ramp controllers
which shall be adjustable between 3 and 10 seconds and shall
start and finish in a parabola like transition.

The drive shall consist of a gear reducer motor and brake

mounted on a common base frame . The drive shall be shaft
mounted onto the driven wheel shaft and be fitted with a suitable
coupling and reaction mounting attached to the bogie frame.

The brakes shall be designed as holding brakes and not to be

used during travel reverse and applied at standstill below 5%
travel speed for a stop under controlled operating conditions.

A typical drive shall consist of combinations of individual motors

each driving a bogie mounted on two wheels via gear reducer of
suitable rating.

Long travel drive shall be located on the rails.

All motors shall share load under all operating conditions

Long travel drives shall be fully interchangeable .

3.7.5 BUFFERS AND END STOPS

All machines shall be fitted with energy absorbing buffers to

engage with ground or wharf mounted end stops and to stop the
travel motion at the ends of the rail tracks.
 The buffers shall be designed to decelerate the machine from
maximum travel speed without the application of brakes. Buffers
shall be of the hydraulic type.

The buffers shall extend fully again on reversal of the machine

after impact.

3.8 SLEW ASSEMBLIES

3.8.1 GENERAL

The slew assembly shall be designed for a life equivalent to

reclaim over a nominal period of 30 years. The Supplier shall
unconditionally guarantee the “Slew Assembly” for a period of two
years and shall provide expectancy calculations covering all
aspects of the slew assembly

The installations tolerances and under casting procedures shall

be in accordance with the manufactures recommendations.

3.8.2 SLEW RING BEARING

The slew ring bearing shall be in accordance with the design

criteria and be suitable for the machine manufacturers design and
specified operating conditions.

The slew ring bearings for the Reclaimer should be -

• Three race roller bearing such as Rothe Erde

large diameter anti-friction bearings or approved
equivalent

• For this type of bearing the diameter of the slew

assembly shall be selected to ensure continuous
“compression” of all the load carrying elements
despite the overturning moments created by
reclaiming operations and the wind forces. For
this type of Bearing uplift restraint hooks must be
provided.

If grease lubrication is employed, excess lubricant shall be

discharged into a collector ring which should be located at the
accessible side of the bearing for easy cleaning. The seals and
sealing arrangement shall be designed to prevent grease
escaping at the other side.
3.8.3 STRUCTURAL REQUIREMENT

The slew base sitting on and the portal supporting the slew
assembly shall be designed sufficiently stiff to eliminate any
undue elastic deformation that will be detrimental to the function
and life expectancy of the slew assembly. The structural design
shall include consideration of and provision for jacking of the
superstructure for slew bearing replacement. The slew base shall
be sufficiently rigid to accommodate the jacking loads without any
elastic deformations.

3.8.4 INSTALLATION

The slew assembly shall be installed in such a way that it

conforms to the slew bearing manufacturer’s specification in the
fully ballasted but otherwise stable machine.

Jacks and jacking points shall be provided to lift the rotating

superstructure for bearing replacement and for the measurement
of concentricity and flatness of the contact elements. The supplier
shall carry out , record and present these measurements to the
Purchaser for review.

3.8.5 CALCULATIONS AND MANNUALS

The bearing life and all other relevant calculations relating to the
slew assemblies shall be supplied for the machine during the
design stage. Other data such as bearing manufacture number,
serial number etc. must be submitted to the Purchaser for future
reference.

The calculations, if possible, may include the following:

Finite Element Analyses (FEA) of the structural components

“joined” by the slew bearing . The analysis shall model the forces
acting on the rolling elements and deflections of the structures
and bearing elements for the following load conditions or changes
from one load condition to another in slew positions spaced at not
more than 30 degree intervals over the operating slew range. The
“Zero” reference datum shall be the no “bearing load” installation
condition (first or changeout):-

- Working condition form no load to all operating

luff positions.
 - Change out of bearing , utilizing installed
number of jacking points and subsequent
removal of jacking points and loading or
bearing
Maximum non-operating load in actual slew load position only

Gearing calculation if applicable.

Bearing life calculation for all working loads and slew cycles
relevant to the particular application under consideration,
including any additional forces acting on the rolling elements due
to the elastic deformation of associated components as
determined from the FEA above. These calculations shall be
endorsed by the slew bearing manufacturer.

Bolt connection calculations for operating and maximum non-

operating conditions

The manufacturer’s quality control activities shall include the

testing of all roller and/or ball races of the bearing for cracks or
imperfections using magnetic particle testing in accordance with
AS 1171or equivalent Indian Standard. The test certificates shall
be submitted for approval by the Purchaser prior to the dispatch
of the bearing.

In addition to the requirements of Clause 15.0 (Testing,

Commissioning and Acceptance) the operating and maintenance
manuals shall contain:-

♦ Certified drawing of bearing

♦ Calculations
♦ Gear tolerances and proposed mating gear (Pinion)
modifications if applicable
♦ Assembly and disassembly instructions for each bearing
♦ Installation drawings
♦ Drawing(s) of bearing seating rings if applicable
♦ Illustrated description of installation procedure
♦ Number, position and size of jacks required
♦ Flatness tolerances of bearing seat prior to installation of
bearing
♦ Undercasting (grouting) procedure and materials if
applicable
 ♦ Circularity and flatness tolerance of installed (bolted down)
bearing
♦ Permissible elastic deformations (in operation)
♦ Permissible bearing wear including methods and intervals
of measurement
♦ Grade and tightening methods or torques of bearing
holding bolts including tolerances and recommended re-
torquing intervals
♦ Position of bearing “soft spots” and their required
placement relative to stationary and rotating parts of the
machine
♦ Proposed backlash and alignment tolerances for gearing if
applicable
♦ Grease types and recommended greasing intervals for the
labyrinth seals, bearing and gears as applicable

3.8.6 SLEW DRIVES

The machines shall have a minimum of three slew drives. The

drives shall be designed such that any two of the drives will be
capable of successful operation in the most adverse conditions
of tilt due to variations in rail track level.

The slew drives shall be infinitely variable from -100% to +100%

of nominal speed capable of smooth reversal through zero speed
and smooth starting from standstill and stopping down to
standstill. The slew drives shall be fitted with acceleration and
deceleration ramp controllers adjustable between 3 and 10
seconds and which start and finish with parabola like transitions.

The slew drive arrangement shall include limit switches and a

resolver to give sufficient positional accuracy to properly stop at
the required positions, such as storm tie down

Each slew drive assembly shall comprise the following

components

• Electric motor

• Safety coupling (motor to gear reducer)

This shall be a mechanical , non-slip type accurate torque limiting

coupling with a proximity switch to indicate engage conditions.
 The coupling should remain in the disengaged position until
mechanically reset.

• If the safety coupling is not of the flexible type then a

separate flexible coupling shall be installed.

• Brake and brake disc

This shall be a fail-safe magnetic disc brake with a limit switch to

detect the de-energised or brake “on” condition. The brake disc
shall be mounted at the gear reducer side of the coupling

• Gear reducer

• Bevel, planetary helical or worm reducer fitted with a lip

seal on the vertical output shaft

• Pinion and shaft assembly

The pinion shall be removable without removal of the slew gear

reducer. Involute splines instead of keyways shall be used to
connect the reducer output shaft and drive pinion

The pinion, shaft or complete drive assembly including motor

shall be mounted in such a way that backlash and the axis of the
pinion can be adjusted for even flank contact or wear at any time
during the life of the machine

The gear ring and pinions shall be fully enclosed to prevent the
ingress of dust, moisture and other contaminants.

3.9 LUFFING ASSEMBLIES

The luffing equipment shall be designed to raise, lower and hold

the boom under all operating and non-operating conditions.

The luffing motion shall be fitted with ramped acceleration and

deceleration at times of 3 second or longer.

The luffing control shall automatically reverse the luffing motion

for a pre-determined time upon sensing contact of the bucket
wheel, boom or counterweight with the stockpile or any other
obstructions.
 The luffing control for the Reclaimer shall be capable of following
both the longitudinal and transverse slope of the stockpile base
during automatic and semi-automatic operation.

All joints that swivel or rotate during luffing shall be fitted with
maintenance free spherical plain bearings.

The hydraulic cylinder shall be tested at 200% of the design

pressure.

The cylinder stroke shall be cushioned at both ends for a length

equal to a minimum of three times the normal stopping distance.

Pilot operated check valves and direct operating safety pressure

relief valves shall be mounted on each cylinder port. The valves
shall be of the leak free design.

Pressure transducer(s) shall be installed for overload detection

The hydraulic controls shall provide for even deceleration in the

event of power loss or emergency stop during luffing or broken
hydraulic lines.

The cylinder shall be installed to operate in positions with suitable

inclination to the horizontal and shall utilize trunnion mounting or
suitable clevice mounts with spherical bearings.

The cylinder shall not be subjected to other than axial external

forces and shall adjust itself to all directions.

The cylinder shall be located in an area free of spillage and if

possible above the boom conveyor.

Adequate maintenance access shall be provided to each end of

the cylinder and provision shall be made to remove the cylinder
for repair / replacement. The procedures for hydraulic cylinder
renewal shall be given with details like tool placement, support
arrangement, measurements before and after renewal etc.

3.10 BOOM CONVEYORS

3.10.1 GENERAL

The boom conveyors shall be designed in accordance with the

requirements of IS 11592
 The boom conveyors on each machine shall be provided with
walkways on both sides.

The return idlers of the boom conveyors shall be located above

walkways level and be accessible for replacement from the
walkways.

A minimum clearance of 150 mm on both sides of the boom

conveyor belt shall be provided to allow belt wander without
damage to belt or structures.

The boom conveyors shall be fitted with protection devices which

shall include but not be limited to:

Belt drift switches

Underspeed detector

Blocked chute switch

Take-up travel limit switch

3.10.2 CONVEYOR DRIVES

The conveyor drives shall be designed for torque arm mounting

and shall comprise an electric motor, flexible coupling with brake
disc, a bevel-helical gear reducer and fail-safe disc brake
mounted on a common drive base of boxed design with
appropriate torque arm connections.

The boom conveyor shall have sufficient power to pull out under a
bogged feed chute at maximum inclination angle.

The motor shall be fitted with a delayed fill fluid coupling which
shall limit the transmitted start-up torque to 200% of the nominal
demand torque of the fully loaded belt in the most adverse boom
position.

Forced oil lubrication or air cooling of the reducer shall be an

integral part of the reducer. No separate electrically driven pump
or fan shall be employed. Water cooling is not acceptable

3.10.3 BELT TENSIONING

 The allowance for take-up travel shall be 45% higher than
recommended by the belting manufacturer.

The belt shall be tensioned by means of hydraulic cylinders. The

hydraulic cylinder shall be readily accessible for inspection and
adjustment.

Exposed piston rod shall be protected by “Denso” tape or

approved equivalent.

The hydraulic pump, cylinder and the pressure gauge shall be

permanently fixed in the working position.

The guage shall indicate the force in kN (kilo Newton) and shall
be marked for the correct tension

3.10.4 BELT WEIGHERS

A digital electronic scale of proven industrial design shall be

supplied and installed on the boom conveyor of the Reclaimer.
The belt weigher shall be of the multiple-idler type with
temperature compensated strain gauge load cells. The belt
weigher shall provide the following as a minimum.

Feed rate in tph to be displayed in the operator’s cabin on a

dedicated digital display to be incorporated into the operators
control desk.

Totaliser to be displaced in the operator’s cabin on a dedicated

digital display to be incorporated into the operators control desk.

Both signals shall be interfaced with the PLC system The feed
rate signal shall also be used to ensure even stacking rate or to
control the reclaiming rate to ensure even feed on to the reclaim
yard conveyor.

The belt weigher shall be capable of indicating feed rates from

1000 tph to 4000 tph and shall be capable of withstanding a
minimum overload of 25% of the maximum scale reading

The belt weigher shall compensate for boom inclination and shall
be accurate to within 2% for the range of feed rates.

3.10.5 BELT CLEANING

 Belt cleaning devices shall be installed on the carry side of the
belt at the discharge pulleys of the boom conveyors.

The belt cleaners shall be in accordance with clause 9.11.12

These belt cleaning devices shall limit the ore carry over to less
than 5 kg/hour

A self adjusting Vee-plough scrapper including a fixed hood shall

be installed on the return belt in front of all pulleys where material
could enter between the belt and pulley. The suspension linkage
shall be designed to minimize lifting forces due to friction between
the belt and the cleaning blade to maintain stable, non-vibrating
operation . End stops shall be provided to restrict the plough
movements to safe wear limits.

The belt cleaners shall be easily accessible for inspection,

adjustment and wearing parts replacement.

3.10.6 CONVEYOR DISCHARGE AND RECEIVAL CHUTES

The chutes shall be designed in accordance with Clause 9.11.11

The receival chutes of the Reclaimer shall be designed to achieve

central loading of ore onto the boom conveyors in all positions of
slew and luff

The boom conveyor of the Reclaimers shall discharge into the

centre of the receiving circular chute.

In both the cases this may be achieved by use of a wear resistant

impact or deflection plate.

3.11 OPERATOR’S CONTROL CABIN

The control cabins shall be of agronomic, modern design with

ample glassed area for optimum visibility of the working area.

The cabins shall be manufactured from metal framing clad with

sheeting and be appropriately stiffened, heat and noise insulated
and dust sealed. They shall also be fitted with a cable access
floor and a sun protection roof.
 The windows shall be of approved type tinted safety glass. The
front windows shall be equipped with a heavy duty window wiper
and washer system.

Safe access to the control cabin shall be provided over the full
range of luffing angles.

The access door shall be hinged type double door with hydraulic
closures, self closing and fitted with an approved type of security
lock.

A suitably sized (minimum 1.5 Tonne capacity) industrial air

conditioner unit and wall fan shall be fitted.

Access ways around the control cabins shall be at least 600 mm

wide

Equipment installed inside the operators cabin shall include but

not be limited to the following

Swivelling height and back adjustable operators chair

incorporating joysticks switches and push buttons
Light fittings with dimmers
A minimum of four 240 Volt General Purpose Outlets(GPO)
Fold down jump seat on the back wall to allow for an instructor
Operators console and monitoring interface as specified

3.12 STORM TIE DOWN

Each machine shall be provided with ground mounted equipment

which shall be used to secure the machine during cyclone
conditions. The equipment shall comprise.

A “tie down fork” to secure the boom near the boom head Ground
or wharf mounted frames which can be attached by pins in the
machine travel bogies to secure the machine against movement
in the long travel direction

The tie-down form shall also provide for access during boom
anchorage and access while undertaking boom maintenance
such as replacing the luffing cylinder.

The tie down procedure shall not require the use of cranes
external lifting equipment, specialized tools or devices and shall
be capable of being implemented by one person without
assistance from others.
3.13 MAINTENANCE ACCESS

Safe and direct access shall be provided to all drives, auxiliaries

electrical equipment including limit switches and junction boxes,
lubricating points and all other areas of the structure where
switches , indicators or pivots of any type are installed. Ready
access shall also be available between parts of the machine
which move relative to one another.

All walkways and stairways shall be 750mm clear width unless

otherwise specified.

Platforms, walkways , stairs, ladders and handrails shall comply

with the requirements of Indian/International standard.

All structural steel surfaces intended for access shall be treated

with a proprietary approved non-slip surface. All other surfaces
intended for pedestrian access shall consist of hot dip galvanized
welded flat bar grating unless otherwise specified. Angular
pattern floor plate shall not be used except in front of electrical
cubicles or over structural members where spillage can be
trapped by grating

Stairways shall be of uniform slope and stair treads shall be hot

dip galvanized grating with floor plate nosings.

Hand railings shall preferably be of proprietary tubular design with

all joints seal welded.

3.14 FIRE PROTECTION EQUIPEMENT

The Supplier shall provide the machine with fire protection

equipment including but not limited to the following:

Smoke and thermal type fire detectors shall be installed in the

switch room and shall be connected to the PLC for alarming. A
Xenon flash lamp or approved equivalent and siren warning
system shall be installed above the operator’s cabin.

A fire water pipe work system which shall be installed on the

machine and include hydrants hoses and hose reels located to
provide coverage of all operating areas. The system shall also
include a 50m hose reel connection that can be accessed at
ground level to manually couple to the nearest 65 NB hydrant
 connection. The hydrant connection shall be compatible with
Indian Standards. The pipe work system shall be galvanized and
painted in accordance with this Specification.

Portable 5.5 kg dry chemical fire extinguishers shall be provided

in the operator’s cabin at the entrance in the electrical
switchroom and adjacent to all major electrical drives and oil
filled equipment on the machine.

4.0 CODES, STANDARDS AND STATUTORY REQUIREMENTS

The system of units known as the System International(S.I) shall

be adopted and used in accordance with ISO 1000.

The work shall be carried out in accordance with the

requirements of the latest revision of the applicable ISO, India
and International Codes.

Other similar, equivalent and recognized standards may be used

if specifically approved by the Purchaser. The Supplier shall
demonstrate the equivalence of any other Standards or Codes
proposed to be used.

It shall be the Supplier’s responsibility to ensure that all statutory

requirements necessary for the safe operation of the mobile
machine will be adhered to and incorporated into the design.

Where conflict exists between this specification and other

requirements the most stringent requirement shall be satisfied.

5.0 QUALITY ASSURANCE

5.1 GENERAL

The Supplier quality system shall comply with ISO 9001 or

equivalent.

The Supplier shall maintain effective control of the quality of the

Works, provide test facilities and conduct all tests and
examinations necessary to demonstrate conformance of the
Works to the requirements of the Contract.

The Supplier shall be responsible for the provision of objective

evidence that the Supplier’s controls and inspections are effective
in maintaining the quality requirements of the Contract for this
 purpose objective evidence means any statement of fact, either
quantitative or qualitative observations relating to the quality of
the Works based on measurement or tests which can be verified.

5.2 SUB-CONTRACTS

The quality assurance requirements of the Contract shall also

apply to all sub contracts.

5.3 QUALITY SYSTEM DOCUMENTATION

5.3.1 GENERAL

The following documents shall be provided to permit audit and

surveillance of the Suppliers quality system during the execution
of the Contract.

a) Quality Plan

b) Inspection and Test Plans (hereinafter referred to as ITPs)

c) Records

5.3.2 QUALITY PLAN

The Supplier shall submit its Quality Plan to the Purchaser within
28 days of Award of the Contract. The Quality Plan shall
demonstrate the Supplier’s commitment to quality and shall
include the following minimum elements:

A policy statement identifying the specific quality system

implemented for the Contract.

The Supplier’s proposed management for the Contract showing

specific management responsibilities including the management
and responsibility for quality.
An outline of procedures for reviewing updating and controlling
the Quality Plan and referenced documents.

A description of the steps in the Scope of Work and Specification

and the means that the Supplier shall adopt to ensure the steps
are controlled. Methods of control of a step include: a document,
procedure, schedule , qualified person or process etc.

Reference to technical or quality features peculiar to the Contract.

 Method of control of sub-contract work.

Details of special processes and control procedures.

Details of design verification activities to be performed to control

the design.

Details of records to be maintained.

5.3.3 INSPECTION AND TEST PLANS (ITPs)

The Supplier shall submit ITPs to the Purchaser at least 28 days

prior to the programmed date for the commencement of work
covered by each plan.

As a minimum ITPs shall contain the following:

Identifications of tests/inspections against specific requirements

of the Contract.

Hold points and witness points where specified in the Contract.

The Identification of records to be maintained

Details of test equipment to be used.

The Purchaser shall review the ITPs insert hold points and
witness points as required and return them to the Supplier within
14 days of receiving the plans.

For the purposes of this Clause, the following definitions apply

Hold Points: Means a position in the production and inspection

cycle beyond which work shall not proceed without mandatory
verification and acceptance by the Purchaser or his
representative.

Witness Points: Means a position in the production and inspection

cycle where the option of attendance for the purposes of
verification and acceptance may be exercised by the Purchaser
or his representative.

The Supplier shall give the Purchaser and his authorized

representative a minimum of 7 working days of a forthcoming
 hold or witness point. Proceeding past a hold point without the
written approval of the Purchaser shall constitute a non-
conformance.

5.3.4 RECORDS

The Supplier shall establish and maintain a system of records

which shall provide objective evidence that the requirements of
the Contract have been satisfied. The Supplier shall provide such
records to the Purchaser as required.

Records shall be maintained by the Supplier until expiry of the

Defects Liability Period (Warranty Period) at which time all
records shall be submitted to the Purchaser.

5.4 QUALITY AUDITS

At any time and from time to time during the Contract, after giving
the Supplier a minimum of 5 working days notice the Purchaser
may arrange an audit of the Supplier’s Quality System. The
Supplier shall provide the necessary access to documentation
and processes and such other assistance as may be required in
order to assess the Supplier’s Quality System.

5.5 INDEPENDENT INSPECTION / QUALITY ASSURANCE SERVICES

The Supplier shall employ an independent international

inspection agency experience in the inspection of machines of
this type to perform the inspection and quality assurance
surveillance on behalf of the Purchaser. The scope of work for the
independent inspection agency will be determined by the
Purchaser after award.

5.6 INSPECTION VISITS BY PURCHASER

The Supplier shall make his manufacturing facilities and those of

its sub Suppliers available for an inspection visit by the Purchaser
during the course of the Contract.

5.7 PROOF ENGINEER - ( DELETED )

The Supplier shall engage an independent Proof Engineer to

review for compliance with the design criteria, regulations, codes
and standards specified in the Contract.
All costs associated with the engagement of the Proof Engineer
shall be borne by the Supplier

The selection of the Proof Engineer shall be subject to approval

by the Purchaser.

The Supplier shall co-operate readily and fully with the Proof
Engineer to expedite completion of the Proof Engineer’s
functions. Copies of correspondence including the attachments
for calculation etc. between the Supplier and the Proof Engineer
shall be forwarded to the Purchaser for information.

After award of the Contract the following actions shall take place.

The Supplier shall submit the following information to the Proof

Engineer for his preliminary review.

Tender submission and correspondence.

The range and individual values of any changes in the load

assumptions that may be proposed.

The Supplier’s preliminary stability analyses.

The Supplier’s general arrangement drawings.

Any changes to the manufacturing methods proposed by the

Supplier.

Where necessary the Proof Engineer shall request for revision of

the foregoing in order to comply with the requirements of the
Contract and this shall be implemented by the Supplier .

Progressively during the validity of the contract the Proof

Engineer shall

Review arrangement and detail drawings of structures and other

main load carrying members that could effect the strength and
stability of the machines (e.g travel gear, main frames ,
equalizers) Such drawings should show joint details

Review calculations and computer analyses for structural and

other main load carrying parts.
Specifically review calculations for the structural rigidity in relation
to the slewing bearing for each machine type.

The Supplier shall not commence manufacture of any part of the

machine until completion of the review and approval in writing on
the part concerned by the Proof Engineer.

Erection shall be in accordance with the Contract and shall not

commence until the Proof Engineer has written that he is satisfied
that the selected drawings and calculations comply with the
design criteria regulations, codes and standards that are
specified in the Contract Structures and other parts reviewed by
the Proof Engineer should have passed the inspections that are
included in the Contract.

On completion of erection, the Proof Engineer shall review the

results of weighing of the machines and confirm agreement with
any necessary strength and stability adjustments including
ballasting proposed by the Supplier.

The Proof Engineer shall define the following on the completed

machine.

Items that are to be corrected before the machine goes into

service.

Items that are to be corrected within one year of being put into
service.

The Proof Engineer’s final approval shall be provided within one

year of putting the machine into service during which the following
actions shall be taken.

Review with the Purchaser and Supplier any modifications that

need to be made to drawings so that the Proof Engineer may
give final approval.

Obtain confirmation from the Purchaser and the Supplier that the
review above has been completed.

The Proof Engineer shall compile an opinion report in accordance

with the documentation Schedule. The report shall be in the
English language, and for each machine, include the load
assumptions for the machine, as built, detailing the checks
carried out by the Proof Engineer and carrying a statement to the
 effect that the Proof Engineer has no objection a structural
grounds to the machine being allowed to operate.

6.0 DRAWING AND DESIGN DOCUMENTATION

6.1 GENERAL

The requirements for drawings prepared by the Supplier shall be rigidly

controlled as set out hereunder to maintain a workable drawing register
and to ensure that a complete and consistent set of up to date
drawings exists during and at the completion of the project. Any points
requiring clarification shall be directed to the purchaser.

The Supplier shall be responsible for arranging for the courier delivery
of all drawings calculations and documents to and return from the
Purchaser. All costs for this courier service shall be paid for by the
Supplier.

6.2 DRAWING PRACTICE

Drawings prepared by the Supplier shall include sufficient detail

to allow checking against the specified requirements. The
specifications of the material used is to be mentioned in the
drawings. Most of the times the detailed dimensional drawings
with materials specification of the purchased items like gear
boxes, wheel, pulley etc. are not provided. Special care must be
taken to supply the drawings of the purchased items to the full
satisfaction of the Purchaser. It shall be the responsibility of the
Supplier to obtain necessary drawings and documents in
accordance with the tender requirements from it’s sub-suppliers
on whom the Supplier has placed purchase orders for
procurement of components / equipment to be installed on the
Reclaimer. The Supplier is advised to clarify the same before
placing purchase orders for bought out items like Gear Boxe,
Motor, Coupling, Bearing etc.

6.3 DRAWING TITLES, SHEETS AND NUNBERS

All drawings shall be prepared on A3, B1 or A1 size format.

In general, drawing sheets of A3 size shall be used for electrical circuit

and wiring diagrams, drawing sheets of B1 and A1 size shall be used
for manually drafted drawings, drawing sheets of A1 size shall be used
for layout and arrangement drawings and for most CAD produced
drawings (except electrical).

The Supplier shall use on all Supplier prepared drawings and in all
official communications a numbering system.
 The title block of every drawing and material list shall contain a title
which clearly defines the purpose of the document and its application
to the facility.

The drawing title shall be of the following format.

Title Block Heading RECLAIMER FOR PARADIP PORT

Line 1 MACHINE DESCRIPTION
Line 2 COMPONENT OF MACHINE DETAILS
Line 3 TYPE OF DRAWING (e.g. arrangement,
detail,
section etc.)

6.4 SUBMISSION OF DRAWINGS AND DATA

Before any part of the work is commenced, the Supplier shall submit all
drawings and data for approval in accordance with the requirements of
the documentation and approved programme.

Drawings prepared by the Supplier shall include sufficient detail to

allow the final assembly and installation to be checked against the
specified requirements. The drawings shall be accompanied by all the
required design data, calculations and technical information and a letter
of transmittal which shall list the titles, drawing No. and revisions of all
drawings submitted.

All fabrication drawings for steelwork shall have weld details in

accordance with the requirement of relevant Indian Standards”.

Welding symbols on workshop drawings shall include a reference to

the relevant welding procedure sheet for the type of weld shown. The
Supplier shall submit detailed welding procedures concurrent with
workshop drawings.

The first issue or original issue of each drawing or set of calculations

shall be designated Revision A.

The Supplier shall not submit drawings or calculations that have not
been checked first by himself and endorsed as such. The Supplier shall
mark the drawings and / or calculations as “ Good for Construction “.

6.5 REVIEW OF DRAWINGS AND DATA

All drawings submitted will be reviewed by the Purchaser and either

commence or a marked-up copy of each drawing will be returned to the
Supplier.
 Such review however, shall not relieve the Supplier of his responsibility
for design and dimensional accuracy or other contractual obligations
under the contract.

All drawings shall be submitted in time for review by the Purchaser

before commencing manufacture. Any design, manufacture or
installation undertaken before a review shall be at the Supplier’s risk.

6.6 CERTIFIED DRAWINGS

Upon receipt of the Purchaser review, the Supplier shall mark the
original “APPROVED FOR CONSTRUCTION”, mark-up the revision
and identify the revision to “0” on the drawing.
These originals shall thereafter be referred to as “Certified Drawings”.

Only Certified Drawings shall be used for manufacture/construction.

The Supplier shall supply to the Purchaser. Copies of all certified

drawings no later than 5 (Five) working days after receiving approval to
the use of drawings.

Subsequently each time a certified drawing is revised the revision no.

shall be incremented (i.e. 1,2,3 etc.). The revision and reason shall be
identified on the drawing.

6.7 FINAL DRAWINGS

Prior to Practical Completion of the Contract, the Supplier shall mark

the certified drawings “AS BUILT” increment the revision number and
identify the revision on the drawing. The Supplier shall supply the
Purchaser with one (1) set of current original drawings and a set of
microfilm reproductions of the drawings. The drawings and microfilm
shall show sufficient detail to enable operation, maintenance,
inspection and repairs to be carried out on the equipment.

All drawings upon receipt will become the property of the Purchaser.

In the event that the Supplier fails to prepare and submit the relevant
drawings or should the information thereon be in the opinion of the
Purchaser, inadequate for its purpose, the Purchaser may, without
prejudice to any other rights he may have under the contract deduct
from payments due to the Supplier the cost of having the said drawings
prepared by others and may charge an overhead up to 20%.

If required by the Documentation Schedule and where drawings are

prepared on a computer based CAD system, the Supplier shall provide
an electronic file copy on CD of each drawing and files shall be either
AutoCAD release 12 or higher in dwg. format or dxt format for
AutoCAD.
 6.8 REQUIREMENTS FOR CALCULATIONS
Calculations shall be neat and legible in English using ISO units with a
summary of assumptions and conclusions and an explanation of all
symbols and computer printouts.

All calculations shall be prefaced with the following information :

A table of contents sectionalizing the calculations and covering

individual main items for easy reference.
A complete list of all associated drawings.
A list of texts and references used.
Computer printouts supplied shall include a summary sheet of the
results details of any software system used and any other necessary
explanations.

Where computer based analysis or design is utilized, evidence of

“bench marking” of the results of standard problems shall be
referenced as part of the design calculation.

All calculations shall be prepared by Engineers with qualifications and

experience suitable for the work performed.

7.0 DESIGN CRITERIA

7.1. GENERAL

The machines shall be designed in accordance with the requirements

of the contract documents with special emphasis placed on safety,
efficiency and reliability.

The machines shall be designed to operate on a continuous basis, 24

hours per day on an average of 345 days per year and have a design
life of 30 years.

All materials and equipment supplied shall be suitable for sustained

operation in a marine industrial environment and shall take into account
especially the effects of corrosion due to salt spray and an atmosphere
containing fine iron ore dust and seasonal torrential rain.

7.2 CLIMATIC CONDITIONS

The plant and equipment shall be designed for the prevailing

weather conditions for the Paradip Port Region.

7.3 PROHIBITED MATERIALS

Use of the following chemicals or materials is prohibited :-

 Poly Chlorinated Biphenyl (PCB)
Asbestos
Radioactive Materials
Known Carcinogenic Substances

7.4 DESIGN CRITERIA – STRUCTURAL

7.4.1 DESIGN STANDARDS

The structural design of the machines shall conform to the latest

applicable standards and code. It shall be the supplier’s responsibility
to ensure that all statutory requirements necessary for the safe
operation of the mobile machine will be adhered to and incorporated
into the design.

7.4.2 DESIGN LOADINGS

The design loads for the respective machines shall be classified into
Main Loads Additional Loads and Special Loads according to ISO
5049/1 Load terminology.

The Main Loads shall comprise the following :

Dead Loads
Useful Loads
Incrustation or Material Build-up
Normal digging and lateral resistance
Forces of the Conveying Elements for useful Loads
Permanent Dynamic Effects
Loads due to inclination of the Reclaimer Boom
Loads on Floors, Walkways, Platforms, Stairs and
Railings
Effect of ground settlements and elastic deformation of
supports as the machine passes.
Normal digging and lateral resistance.

The Additional Loads shall comprise the following :

Wind Loads Normal Operation
Resistance to friction and travel
Horizontal and lateral forces during travel (including Rail
track misalignment)
Temperature loads
Abnormal digging and lateral resistance
Non-permanent dynamic effects
Wind loads for restricted travel
Effect of rolling movement of the machine.

The Special Loads shall comprise the following :

 Clogging of chutes
Resting of boom end or bucket wheel
Blocking of traveling devices
Lateral collision of boom or wheel with Stockpiles
Cyclone wind loads
Buffer effects
Earthquake loads
Failure of safety devices

7.4.3 WIND LOADS

Wind pressures and loads shall be calculated in accordance with the

relevant standards using the following values:

Normal Operating wind velocity : 22 m/sec at all levels

Restricted travel wind velocity : 33 m/sec at all levels
(permitting travel to the storm tie down position
Cyclone Wind velocity : 69 m/sec.

7.4.4 FLOOR AND WALKWAY LOADS

All floors, walkways access platforms and stairways shall be designed

for a uniform live load of 5 kPa for local flooring and steel member
design.

7.4.5 MACHINERY FLOOR LOADS

All machinery floor shall be designed for following loads :

Machinery dead load plus a uniform live load of 5 kPa for local flooring
and steel member design.
Any beam shall be designed for a concentrated load of 10 tonnes
placed at mid span.

7.4.6 EFFECTS OF ELASTIC DEFORMATION OF SUPPORTS AS

MACHINE TRAVELS

The machine shall be designed for the effect of elastic deformation of

supports under operating weights equivalent to a maximum
deformation of 15 mm while traveling.

7.4.7 EARTHQUAKE LOAD

Earthquake effects shall be calculated in accordance with Indian

Standard IS 1893. Notwithstanding the requirements of this standard,
the machines shall be designed for a minimum horizontal & vertical
ground acceleration of 0.05g (0.49 m/sec/sec).
7.4.8 LOADS NOT SPECIFIED

All loads not specified above shall be in accordance with ISO 5049/1.
Consideration shall be given to construction loading as part of the
design process.

7.4.9 LOAD COMBINATIONS

The loads shall be combined in a manner to produce the

maximum stress on a particular structural member. The load
combinations shall be in accordance with ISO 5049/1.

7.4.10 ALLOWABLE STRESSES

The allowable stresses for structural steel shall be calculated as

follows (refer ISO 5049/1 Table 4)

For Load Combination I Stress Factor 1.5

For Load Combination II Stress Factor 1.33
For Load Combination III Stress Factor 1.2

Structural codes often incorporate a variable factor of safety (ranging

from 1.5 to 1.67) hence formulae for calculating structural capacities
may need to be modified accordingly.

7.4.11 FATIGUE

Fatigue design shall ensure a 30-year life based on calculated

loading spectra for handling.

7.4.12 WHEEL AND RAIL TRACK TOLERANCES

Vertical wheel loads along runway - 140 KN. Wheel loads may be
increased by 10% for restricted travel in wind velocities up to 30 m/
sec.
Transverse wheel loads along runway - 20 KN.
Vertical wheel loads at cyclone tie down - 180 KN.
Transverse wheel loads at cyclone tie down - 25 KN.

The number of wheels and the wheel diameter shall be based on

the final loading as determined from the required local conditions.
The number of wheels shall not produce moments or stresses on
rails or ballasted track greater than produced from the loads
shown above. The existing track can take a wheel load of 20T
(maximum ).
 The spacing of the wheels shall not be less than 1.5 times the wheel
diameter.

Normal inclination due to ground settlement should be considered for

the Reclaimer’s designs.

7.4.13 STABILITY AND SAFETY

The machines shall be stable in all operating, restricted travel and

storm tie down conditions.

The superstructure consisting of boom conveyor, counterweight boom

masts, pantograph or connecting structural elements shall comprise a
completely stable self supporting structure seated on the gantry.

The Reclaimer shall be designed with the following minimum stability

factors against overturning.

Load Combination (ISO 5049/1) Stability Factor

I 1.5
II 1.3
III 1.2

The machine design shall ensure stability for all conditions including
when the boom rests on the ground, stockpiles or vessel through faulty
operation or by failure of the luffing motion or any other circumstances.

Drifting safety shall be designed in accordance with ISO 5049/1.

7.4.14 CONSIDERATIONS FOR DETAILING

Structural design and detailing shall be such as to produce a structure

of modern appearance without any pockets that will hold dust or water.
The design shall minimize welded or other connections that can
produce stress concentrations.

For individual member designs, rolled shapes or heavy duty tubular

sections will be preferred and a lattice type fabrication will not be
acceptable. Any build-up sections of angles or channels shall be
spaced to enable easy inspection and maintenance of all surfaces.
Sections shall not be connected to form battened or starred struts Back
to back angle sections shall not be permitted.
Irrespective of load carrying requirements all welds shall be continuous
and form fully sealed joints. The ends of tubular or other hollow
sections shall be completely sealed.
 The structures shall be designed so as to easily facilitate maintenance
and painting. All non-hermetically sealed sections shall be accessible
for inspection.

Cope holes shall be minimized. Any detail deemed to require cope

holes for assembly shall be shown on the shop drawings for approval
prior to fabrication. In general cope holes where permitted, shall be left
open and

The cope hole shall be at least 50 mm diameter.

For fillet welded details the fillet weld shall be returned
through the cope hole to meet the filet weld on the other
side
of the plate.
For complete penetration weld details care must be taken
to
ensure acceptable weld profiles inside the cope hole.
The cope hole shall be dressed to the same finish as for
plate edges.

Stresses in heavily loaded gussets such as luffing attachment points on

tubular members shall be calculated by Finite Analysis Methods.

7.4.15 SLENDERNESS RATIOS

The slenderness ratio for axially loaded members shall not

exceed the following :-
Tension members 250
Main Compression members (columns, frames,
Principal diagonals and struts for trusses) 100
Secondary compression members
(diagonals and braces) 200
Built-up compression members : The ratio for members consisting of
individual shapes or bars connected together with intermittent plates or
bars shall be calculated for the members at the minimum cross section
and the unconnected free length of the individual component. The ratio
in this case shall not exceed 50 for the individual member. The ratio for
the member as a whole shall be as stated previously.

7.4.16 DEPTH TO SPAN RATIOS

Unless otherwise proved by detailed calculation and specifically

approved, the depth to span ratios for bending members shall be
limited to the following values :-
Conveyor decks and walkways 1:25
Floor beams 1:20
Floor beams for drives
less than 300 KW 1:15
 greater than 300 KW 1:12
Trusses
vertical 1:15
Horizontal 1:30
Enclosure girts 1:50
Roof Purlins 1:30

7.4.17 MINIMUM THICKNESS

The minimum thickness of all steels shall be as follows :-

Webs of rolled shapes 6 mm
Welded built-up sections 8 mm
Gusset plates 10mm
Pattern floor plate (measured through
Plate body without pattern) 8 mm
Other closure plates 3 mm
Hollow Sections 4 mm

7.4.18 MATERIALS

Steels with the yield strength in the range 250-350 Mpa shall be used
for structural components.

Structural steel shall comply with the brittle fracture requirements of AS

4100 or relevant Indian Standards for a basic design temperature of 10
degrees C.

7.4.19 ACCESS STRUCTURES

The design and manner of support for all floorings, platforms, walkways
and stairs shall be such that deflection, sway or vibration is restricted to
no more than span/360 for simply supported spans, or span/180 for
cantilever spans. These deflections shall apply to the design loading
conditions.

7.4.20 CONNECTIONS

All connections shall withstand forces of a minimum of 50% of the

member capacity or 1.1 times the applied load, whichever is greater.

Shop connections shall be welded, unless otherwise approved.

Major field connections shall be either

Field welded
Bolted, with mating bearing surfaces milled or machined
with adequate tolerances to ensure contact is maintained,
 joints shall be designed as pre-tensioned by means of high
strength bolts or alloy steel pre-stressing bars.

Field welded connections shall not be used where there is any

likelihood of distortion induced by welding causing misalignment of
bearings and machined surfaces.

Secondary field connections shall be designed as bolted. Secondary

connections are defined as connections for conveyor deck platforms,
walkways, stairs purlins and girts.

Bolted connections shall incorporate a minimum of two bolts for angles

and four bolts for structures, tees, universal columns, beams and
channels over 150 mm deep.

Where pinned connections are employed in main joints internal

lubrication patterns and lubrication points shall be provided. Where
bushings are used in pinned connections, bushings shall have internal
lubrication patterns and shall be provided with the necessary wall
thickness to prevent elastic and thermal distortion under load. Thin
walled bushings are not acceptable.

As a minimum standard, structural bushings shall be manganese

bronze, press fitted into suitable housings for pin connections.

Special spherical bearings for heavy duty application and ease of

alignment may be employed for boom connections or other similar
applications. Provision shall be made for the ready lubrication of all
such bearings.

“Purpose designed low friction and lubricated for life” type bearings
shall be employed for pantograph mechanisms or any bearings difficult
to access. In such cases bearings shall have a design factor of at least
twice the normal safe working load, the design shall employ normal
factors of safety based on this increased design working load.
Notwithstanding that the bearings are lubricated for life, lubrication
points shall be provided.

7.4.21 RESIDUAL STRESSES

The effect of residual stresses in steel weldments shall be taken into

account in the design. In particular, consideration shall be given to
stress relieving or other heat treatment of heavy weldments in order to
improve fatigue and fracture performance.

7.4.22 DUPLICATION OF OPERATORS CABIN SUPPORT

Where an operator’s cabin is on a boom and the cabin or boom is

supported by a strap or stay system, two totally independent strap or
 stay systems shall be provided, each one capable of supporting the
cabin and boom. Such double strap or stay systems shall be designed
so that the load can be equalized between straps or stays. For the
situation where strap or stay fails, the required safety factor for the
remaining independent system shall be met during the course of failure
of the other strap or stay, taking into account any dynamic loading that
may result from failure of the one strap or stay and consequent rotation
and bottoming of any equalizing arrangement on the remaining system.
Strap or stay anchorages and areas of the structures to which they are
attached, as well as connecting pins shall satisfy the same minimum
safety factor requirements. The machine shall be designed so that in
the event of failure of a double strap or stay system, the machine will
remain stable and the main structural members will not be
overstressed by virtue of the remaining independent support carrying
the full load.

7.5 DESIGN CRITERIA – MECHANICAL

7.5.1 IRON ORE PROPERTIES

The Reclaimer shall be designed to handle the range of iron ore lumpy,
calibrated, fines which will be received from the mining through rail /
road.

Some physical material characteristics of the Iron Ore are :

Bulk Density 1800 - 2200 kg./m3

Size -200mm, calibrated, fines

7.5.2 NOISE

Noise levels emanating from the machines shall be limited in

accordance with all relevant standards and regulations.

The noise emitted by an individual item of equipment shall not exceed

85 dB(A) when measured at a distance of 1 metre from the item of
equipment in accordance with relevant standards or approved
equivalent standard.

Noise levels at any location on the machine shall not exceed 85 dB(A)
for all operating conditions. Noise levels within electrical switchrooms
and operator cabins shall not exceed 60 dB(A).

7.5.3 VIBRATION

Vibration levels of the machines and their equipment shall be

limited in accordance with BS 6472 (Pt. I & II) or any relevant
standards. The multiplying factor given below shall be used in
 conjunction with BS 6472, Pt.II to define the acceptable magnitude of
vibration levels for various locations on the structures and equipment.

Location Multiplying factor

Control Cabin 10
MCC Rooms 30
Equipment Maintenance Areas 40
General Access 40

7.6 DESIGN CRITERIA - ELECTRICAL

The environment in which the mobile machines will be operating will be

extreme in terms of temperature, humidity, corrosion and dust.

Ambient temperature for the design and manufacture of the cubiciles

and equipment shall be taken as 450 C.

Particular attention shall be given to the mounting of the switchboards

and control equipment to ensure that it is not subjected to vibration and
other environmental influences.

Physical access to all equipment shall be possible without requiring the

removal of other equipment and shall be in accordance with the local
Indian regulations for access clearance.

The switchboard and control equipment housings which shall be

located in the on-board switch room shall be manufactured to IP54. All
electrical equipment external to the switch room shall have an
enclosure rating on IP 65.

Normal voltage levels as follows shall be utilized for all on-board

electrical equipment.

Fixed speed motors (< 200 kW) 415V,+/-10% , 3 Phase,

50Hz , I 10%
Variable speed AC motors 415V,+/-10%,3Phase
VVVF
Fractional kW motors not suitable 230V,+/-10%,1 Phase,
50Hz
for 3 Phase operation
Motor starter Contactor 230V,+/-10%,1 Phase,
50Hz

Motor Starter, Control and safety circuit, 48VDC,negative earthed

Control voltage including programmable,48V DC, negative earthed

Logic controller inputs and outputs
 Welding/splicing outlets 415V,+/-10%,3 Phase,
4 wire, 50Hz,100A
General Purpose Outlets (GPO) 240V,,+/-10%Phase,
50Hz
Lighting circuits 240V,+/-10%,1Phase,
50Hz

7.7 DESIGN CRITERIA – CONTROL SYSTEMS

7.7.1 HARDWARE

The PLC equipment (controller, I/O cards, communication

equipment and associated mounting hardware) except for remote
I/O shall be within a cubicle inside the on-board switch room.

All PLC equipment cubicles shall be sized to ensure that the internal air
temperature does not exceed 550 C with the internal equipment
operating at design conditions.

The PLC’s shall be of rugged modular construction designed for

reliable and fail safe operation in a location where electro-magnetic
noise caused by high voltage switching devices and high humidity are
prevalent.

The PLC equipment, shall use high capacity I/O racks, with at least two
spare module slot per I/O rack and one power supply per rack.

The Supplier shall supply a complete hardware specification for their

system. This shall contain a complete list of all hardware to be
supplied. Each field device shall be cross-referenced to its PLC I/O/
point.

Appropriate rated power supplies and circuit breakers shall be provided

for powering the PLC equipment and all PLC I/O circuits with individual
fuse protection in connectors with LED indication. Each I/O card shall
have a separate circuit breaker to protect it.

For the design of the control system all digital I/O shall be 48V DC,
negatively earthed and all analog I/O shall be 4-20 mA signals.

The Supplier shall specify the amount of I/O to be provided with each
PLC. The specified requirement shall be sufficient to allow all field
device signals associated with a machine to be individually interfaced
to the PLC. A spare I/O capacity of 25% shall remain at the completion
of commissioning.
7.7.2 SYSTEM PERFORMANCE REQUIREMENTS

The PLC application software and interfacing shall be designed to

include as many “fail safe” features as possible to ensure the safety of
men and equipment during normal and abnormal circumstances.

7.7.3 CABINET ARRANGEMENT

Control cubicles and other enclosures housing electrical control

equipment shall be designed to group devices according to voltage,
control function and I/O module and shall be suitable for operation in a
corrosive atmosphere as could be reasonably expected at a seaport.
Layouts of all electrical equipment within the control cubicles shall be
approved by the Purchaser.

All analog input/output wiring shall be screened twisted pair flexible

multistrand copper conductor. The individual screens on each twisted
pair shall be carried through to the PLC card, but be terminated to
earth at the terminal strip end only.

Cable entry to control cubicles shall be from below floor level through
gland plates rising to terminal blocks and termination points within the
cubicles. Cables shall be installed in a neat and organized manner.

All control and power wiring within electrical equipment enclosures

shall be installed on the horizontal and vertical in a neat and organized
manner. Wiring on the diagonal will not be acceptable.

Control and power wiring to electrical equipment installed on movable

panels and doors shall be neatly loomed and secured with insulated
clips of fixings to facilitate future wiring additions. Control and power
wiring on fixed panels within electrical equipment enclosures shall be
installed in covered PVC ducting (maximum 50% occupancy). All PVC
ducting shall be slotted type and designed for maximum through
ventilation. Separation between ducts and terminal strips shall be a
minimum of 45 mm.

A minimum of 40% spare terminal blocks shall remain for future use
after commissioning.

Relays, terminal strips and markings and all other control devices, must
be completely accessible for maintenance and not be obstructed by
cabling or ducting.

All labeling shall be in accordance with nomenclature used on the

endorsed electrical drawings. Labeling shall be secured with screws
and be of sufficient height (3 mm minimum) to be easily read.
8.0 STRUCTURAL REQUIREMENTS

8.1 INTRODUCTION

This clause covers structural requirements for the supply and

fabrication of all structural steelwork and aluminum. This clause applies
to the supply, storage, connections and associated fastenings and all
miscellaneous attachments including handrails, floor plate and floor
grating.

8.2 STANDARDS

All relevant standards applied for all materials and workmanship shall
be specified by the Supplier as per Indian & International standard.

8.3 WORKSHOP DRAWINGS

All workshop drawings for steelwork shall have welds and non
destructive testing detailed in accordance with the requirement of
clause 6. Welding symbols on Workshop Drawings shall include a
reference to the relevant welding procedure sheet for the type of weld
shown.

Detailed welding procedures, certificates and samples shall be

submitted concurrently with workshop Drawings.

8.4 STEEL

All materials shall be new, free from loose rust, pitting, flaws, cracks
and any other defects and shall have a smooth uniform finish. All steel
plates, flats and rolled sections in the work shall be in accordance with
relevant Indian Standards. The actual grade adopted shall be noted on
the Workshop Drawings.

Mill Certificate, heat numbers etc. shall be supplied for all steel used in
the works, cross reference to the item numbers to be cut from the
materials, prior to the commencement of cutting or fabricating.

All steel plate greater than 30 mm in thickness shall be ultrasonically

tested by the steel supplier in accordance with AS1710 quality steel
classification calss A or any relevant standards. The manufacturer shall
supply records of test results in accordance with relevant standards.
These results shall be submitted with the relevant mill sheets.
8.5 STEEL WORK FABRICATION

8.5.1 GENERAL

Fabrication of all steelwork shall conform to the requirement of AS

4100 or equivalent Indian Standards and all other relevant standards.
A detailed fabrication programme shall also be provided. The
programme shall be based upon the tender programme.

All measurements shall be made by a steel tape related to a standard

tape which has been certified correct. The tape and steel to be
measured shall be at the same temperature and precautions shall be
taken to tension the tape in accordance with the methods taken to
calibrate the tape.

Where individual members of fabricated assemblies are required to be

cambered, the amount will be specified on the Drawings and the
means of achieving the correct camber shall be agreed prior to
fabrication of the member or assemblies concerned.

Additional splices to members (other than those shown on the

Drawings) shall generally not be allowed.

The minimum length of a splice joint should not be less than 6 times
the depth of the section or 1000 mm.

Welded splices in compound members shall be staggered and the

component plates and sections spliced before compounding.

Critical field splices and joints shall be mated in the shop on completion
of fabrication to ensure satisfactory fit when installed.

All members shall be fabricated true to shape and size, without

distortion complete with all necessary temporary brackets, straps,
gussets, cleats, fixings and the like necessary for erection and
assembly of the steelwork.

Suitable jigs and supports shall be used to accurately fabricate

steelwork to the dimensions shown on the Drawings. Welding
sequences shall be planned and adjusted where necessary to control
distortion and achieve dimensional accuracy.

Methods for correcting distortion or damage shall be submitted in

writing for review before any remedial work is commenced.

Welding procedures and orientation of cutting of steel plates relative to

the direction of rolling shall be designed to minimize the risk of lamellar
tearing.
 Temporary erection cleats and the like will be permitted, subject to
approval, but on completion they shall be removed and the structure
made good. The final appearance, soundness of the structure and
quality of the paint coatings shall be as if no such erection cleats, etc.
have been attached.

Notwithstanding the above, all major assemblies of machinery that can

be de-mounted for maintenance or replacement, shall be fitted with
permanent lifting eyes, jacking points, etc.

Unless noted otherwise on the Drawings, hollow section members shall

be provided with 6 mm plates welded all around at the open ends to
exclude the entrance of moisture.

Cope holes shall be minimized. Any detail deemed to require cope

holes for assembly shall be shown on the shop drawings for approval
prior to fabrication. In general cope holes shall be left open subject to
approval and :-

• The cope hole shall be at least 50 mm diameter.

• In fillet welded details the fillet weld shall be returned through
the cope hole to meet the fillet weld on the other side of the
plate.
• In full penetration weld details care must be taken to ensure
acceptable weld profiles inside the cope hole.
• The cope hole shall be dressed to the same surface finish as for
plate edges.

The fabrication programme shall be arranged to ensure close co-

operation between the surface treatment and protective coating Sub-
Supplier and the fabricator. In particular, sufficient time must be
allowed for protective coatings to cure before transportation.

On completion, all fabricated steelwork shall be handled and stored so

as to prevent damage or corrosion.

8.5.2 CUTTING AND HOLING

All structural steel components shall be neatly and accurately machine

flame cut sheared or sawn in accordance with AS4100 or relevant
Indian Standards. Flame cutting by free-hand will not be permitted
without prior approval.

Structural steel hollow sections shall be profiled to fit the shape of the
members to which they are to be welded.

Where slotted holes are shown or specified they shall be accurately

shapped with sides smooth, straight, parallel and circular at the ends.
 Holes for base plates or bearing plates shall be drilled.
Holes shall be cleaned cut without torn or ragged edges and free from
burrs.
Flame cutting of holes shall not be permitted.

8.5.3 WELDING

All welding shall be in accordance with AS/NZS 1554.1 or relevant

Indian standards.

The nominal tensile strength of weld metal (Fuw) shall be designated

on the Workshop Drawings

For the preparation of welding :

All material(s) shall be properly prepared in a workmanlike manner by

machining, grinding, profiling, gas cutting or grouping and the finished
surface shall be of an even contour and free from oxide, scale or slag.
Surfaces to be incorporated in a weld shall not have a surface
roughness greater than Class 3 as defined in WTIA Technical Note 5.

The preparation and set up of all butt welds shall be subject to

inspection as part of the QA plan prior to the commencement of
welding. Run-on/run-off tabs shall be required for butt welds. Run-on
and run-off tabs shall be removed and the surface ground flush.

In assembly, all parts shall be accurately positioned and held in the

required alignment with special attention directed to abutting plates of
unequal thickness. Due allowance should be made for the warpage
and shrinkage of welded parts, and where necessary, the work shall be
held in frames or jigs to ensure that the completed work will be
dimensionally acceptable.

Oil, paint, rust or any other foreign matter shall be removed by the use
of wire brush or other suitable means such as flame cleaning or grit
blasting.

Welding shall not proceed on wet surfaces, and such surfaces shall be
dried before welding is commenced. Unless the welding operator and
the work are properly protected welding shall not be carried out when
rain is falling or under strong wind conditions.

Preheating of welded joints shall be carried out in conformity with

AS/NZS 1554.1 or relevant standards requirement.
 All welds shall be continuous around the perimeter of the parts
being joined to provide a sealed joint. All tubular and boxed
members shall be hermetically closed by seal welding for complete
corrosion protection.

8.5.4 WELDING CONSUMABLES

All welding consumables to be used in the works shall be

restricted to those which conform to the relevant Indian Standards
and this Specification and shall be of such quality to ensure
sound welds.

8.5.5 WELDING PROCEDURES

Welding procedures shall be in accordance with AS/NZS 1554 or

equivalent Indian Standards. Where possible, pre-qualified
welding preparations shall be used.

Special care shall be exercised to ensure that slag inclusions are not
present between weld beads. Each weld bead must be free from slag
and brushed bright with a wire brush before succeeding runs are
applied. All welds shall have good fusion with the parent metal.

The reverse side of complete penetration butt welds shall be gouged

back to sound metal by gas or arc gouging, machining, or grinding.
When necessary to machine grind in lieu of gas or arc gouging. “Dye
penetrant” testing shall be carried out to ensure all defects are
removed.

Increases in design throat thickness and exemption from back gouging

for welds made with fully automatic welding processes shall only be
allowable if the extent of NDT on the joint considered is increased to
100% UST or 100% RT.

All backing strips to welds to be left in place after welding shall be

made continuous by butt welding. Backing strips, where not in fully
sealed spaces, shall be continuously seal welded in position after
completion of the main welds.

Special care shall be taken with the application of weld sequence

procedures, in order to minimize distortion and residual stresses.
Procedures should allow maximum freedom of movement of the parts
being welded so as to reduce distortion. Preheating and/or post heating
may be necessary under certain conditions.

Where welding is carried out during night hours, or in such positions

that natural light is impaired the adjacent area shall be adequately
 illuminated to allow close inspection of each weld pass for cleanliness
before proceeding with the next pass.

Tack welds shall be made with the same type of electrode that is used
for depositing the root pass, unless the tack weld is to be removed prior
to welding. Welding procedures for tack welds shall be required.

8.5.6 WELDING SUPERVISOR

All welding shall be carried out under the supervision of an

experienced person who has had suitable training and practical
experience in the execution of both machine and hand welding in
accordance with relevant standards.

8.5.7 WELDING OPERATORS

Welders shall pass a proficiency test, prior to the commencement

of production welding or at any stage during the progress of the
work.

Should an operator consistently deposit welds which are below

the required standard any defective weldment shall be removed
and if necessary the operator replaced with another who will
provide the required standard.

8.5.8 INSPECTION AND TESTING

Inspection of fabricated steelwork shall be undertaken in

accordance with the quality assurance programme.

Any inspection of items shall not prevent the ultimate rejection of

any work or material in which defects have been found at any
time prior to the completion of the contract .

Non-destructive testing shall be carried out as appropriate to

ensure the sufficiency of all welding procedures and finished
welds.

• Surface examination (including visual, dye

penetration or magnetic particle testing)
• Ultrasonic Examination
• Radiographic Examination

Testing shall be in accordance with relevant standards as

appropriate and shall be carried out by an approved independent
organisation.
Minimum levels of inspection of the weld categories shall be as
specified :-

Item Location & Type of Welds Method of NDT Level of

NDT
Boom & Tower Butt Welded Splices in Visual 100%1100%
above Slewing Plates and Members
Bearing Radiography or Ultrasonic 100%

Visual 100%
Other Welds
Ultrasonic 30%

Base below slewing Plate Butt Welded Splices Visual 100% 100%
Bearing
Ultrasonic 30%

Other Welds Visual 60%

Ultrasonic 10%

General Fatigue Sensitive Welds Visual 100%

Radiography or Ultrasonic 100%

General Fillet Welds Visual 60%

(NDT - Non Destructive Test)

Note that the specified levels of inspection are in addition to

100% visual scanning. Acceptable levels of imperfections shall be
in accordance with AS / NZS 1554 or any relevant standards.

Hot rolled sections and plate having welded connections on the

rolled face, which imposes a tension component normal to the
face, shall be inspected by ultrasonic techniques and no
unacceptable lamination or part of such lamination will be
permitted within an area extending 3 plate thicknesses beyond
the weld boundaries. Acceptance standards for laminations or
lamellar tearing defects in weldments shall be as for lack or
fusion, incomplete penetration, slag or other inclusions.

All faulty welds shall be removed, replaced and retested to the

specification requirements.
 In any group of steel work tested, if 10% or more of those tested
of each of weld types prove defective, all welds of the defective
type in that group which have already been completed shall be
100% tested and if any of these welds prove defective, they shall
be removed and replaced and retested.

8.5.9 STRESS RELEIVING

Weldments subject to high level of residual stress shall be stress

relieved as required by the design.

Stress relieving shall be carried out under controlled furnace

conditions. A certificate shall be provided stating temperatures,
time and other conditions of the heat treatment.

Stress relieving shall typically be carried out as follows :-

• Stand the weldment on end in a furnace with

temperatures not exceeding 3000C when loaded.
• Heat the furnace to 6500C at a rate not exceeding
2200C per hour.
• Hold at 6500C for one (1) hour for each 25 mm of
member thickness.
• Cool in a closed furnace at a rate of 1.50 C + 10%
per minute.

8.5.10 MILLING, MACHINING AND LINE BORING

All milling, machining and line boring operations shall be carried

out after fabrication and stress relieving.

Abutting ends of bolted splices shall be end milled to obtain plane

square ends to the tolerance permitted in Section 8.6. Milling
shall only be performed after all welding has been completed on
adjacent items to be joined.

Bearing surfaces on base plates or bracket fittings for sheaves,

rams, bogies and chutes pivots shall be milled and mating
surfaces on flanges shall be machined to achieve the fitment
tolerance specified in Section 8.6.

Pivot points for boom, bogies, equalizer beams etc. shall be line
bored in one operation to ensure correct fit up and alignment.
8.6 FABRICATION TOLERANCE

All steelwork shall be supplied and fabricated to tolerance such

that it is possible to achieve the specified erection
tolerance.

8.6.1 GENERAL

Structural members consisting primarily of a single rolled section shall,

after fabrication, unless otherwise specified, conform to the appropriate
tolerance allowed by AS 3679 and as prescribed in clause 14.4 of AS
4100 or any relevant standards.

Built-up structural members shall conform to the tolerance allowed for

universal beams except for specific requirements as set out in this
Specification.

Completed members shall be free from twist, bends and open joints.

The above tolerance, whilst applying to individual members or units

shall not be allowed to or be interpreted in any way to permit a
cumulative error over the whole or part of any structure.

The tolerance below shall not result in a cumulative error over the
whole or any part of the structure.

8.6.2 PLATE PANELS

For the purposes of this Specification a plate panel is defined as

an area of plate bounded by stiffeners (whether located on
one face or not) or by other stiff parts of a section.

A stiffened panel is defined as an area of stiffened plate bounded by

diaphragms webs and flanges each capable of preventing out of plane
distortion of the panel edges.

Tolerance for plate panels and stiffened plate panels shall be in

accordance with BS 5400.

During inspection plate panels shall be supported on surface

representing their intended fabricated shape or at their boundaries in
manner similar to that in the completed structure. There shall be no
other restraint or external load on any part of a panel during the
inspection.
8.6.3 FABRICATED BOX SECTION

The following tolerance shall apply to fabricated box sections.

Lateral Bow (1) if gradual 10 mm over length

(2) if localized 5 mm over affected length
Lateral Kink 6 mm over length of girder
Hog or Sag (1) 6 mm over length of girder
(2) if localized 3 mm over affected area
Depth of Section + 3 mm
Width Section + 3 mm
Twist (1) + 3 mm over flange width from horizontal
(2) + 3 mm over depth of web from vertical

Box sections shall be supported at their ends on level supports. Long

boxes capable of significant deflection under self weight may also be
supported at an intermediate position beneath an internal diaphragm
in-such a way as to eliminate deflection without inducing twist.

8.6.4 ALIGNMENT OF WELDED SPLICES

Abutting plates at welded splices or butt joints are to align within

the tolerances set out in relevant standards.

8.6.5 MILLED SURFACES OF BOLTED SPLICES AND BRACKET

FITTINGS

Over at least 60% of the total area that is common to both items
to be joined, the clearance between the surfaces shall not exceed
0.25 mm. Over the remainder of the total area that is common to
both items to be joined the clearance between the surfaces shall
not exceed 0.5 mm.

The maximum deviation of plane of splice from specified plane shall

be plus 10 minutes, minus 30 minutes. The maximum misalignment
shall be 2 mm.

8.7 HANDRAILS

Handrails shall be installed in the locations as shown on the drawings.

Handrail systems shall preferably be a proprietary tubular type. All
stanchions, handrails, knee rails, kick-plates and other components of
the handrail system including fasteners shall be hot-dip galvanized in
accordance with Clause 13.
 Handrails shall be installed in accordance with the Manufacturer’s
recommendations and so as to minimize the requirement for on-site
welding. Kick-plates shall be bolted and not welded to stanchions
Welds used to splice handrails and knee rails shall be ground smooth
to bright metal and coated with two liberal coats of an approved cold-
galvanised paint.

8.8. FLOOR PLATE AND GRATING

Floor plate shall be fabricated and installed in panels as shown

on the drawings. The floor plate shall have a non-slip surface
provided by a raised angular pattern rolled onto the top surface of
the plate. The pattern shall consist of regular bi-directional raised
ridges approximately 20 mm by 5 mm by 1.5 mm high at
approximately 22.5 mm centers. The thickness of plate
nominated of the drawings shall be exclusive of the pattern
thickness.

Floor plate shall be continuously welded to floor beams so as to

provide a flat uniform surface. The top surface at butting edges of
adjacent plat shall not misalign by more than 2 mm. Continuous seal
welding of floor plate shall be carried out and intermittent welding shall
not be accepted.
For the purposes of protective coating, floor plate shall be deemed to
be structural steelwork.
Floor grating shall be welded flat bar type with 32 mm x 5 mm serrated
load bars. Gratings shall be provided with banding bars to all cut edges
of grating panels and at notches and penetrations. Banding bars shall
be of the same section as the load bars and fully welded to each load
bar. Grating panels shall be hot-dip galvanized in accordance with
Clause 13 after fabrication has been completed. Grating shall be
secured in place at each corner and at not greater than 600 mm
centers using approved bolted clip type fasteners consisting of a
double saddle, 8 mm round head screw and clamping bracket. Grating
shall not be welded in place.

8.9 STAIR-WAYS AND LADDERS

Stair treads shall be welded flat bar type grating with serrated
grating panels, bolted end plates and floor plate nosing and shall
match the profile of the floor grating.

For the purposes of protective coating, stair stringers and other

steelwork and ladders complete with safety cages shall be deemed to
be structural steelwork.
8.10 FABRICATION OF ALUMINIUM
8.10.1 MATERIAL
Aluminium alloys shall be in accordance with AS1664, AS1734 & AS
1866 or any relevant standards.

The following materials shall be used in the works.

External Sheeting 5083 alloy H321 temper
External Sheeting 5086 alloy H32 or H34
temper
Floor Plate 5251 alloy H34 temper
Extrusions 6061 alloy T6 temper

Fabrication shall be in accordance with AS1664 & AS1665 or any

relevant standards.

8.10.2 CUTTING
Material may be cut by shearing mechanical sawing or plasma arc
methods. On no account shall oxygen cutting be used. Cut edges shall
be smooth and free of notches, excessive burrs or ragged edges.
8.10.3 WELDING

Welding shall be by Metal Inert Gas (M.I.G.) or Tungsten Inert Gas

(T.I.G) methods in accordance with relevant standards.
All welders employed on the works shall be suitably qualified and
experienced and evidence of qualification shall be submitted.

8.10.4 INSPECTION
Permissible levels of imperfection shall be in accordance with relevant
standards.

Weld defects during inspection shall be repaired in accordance with the

relevant standards.

9.0 MECHANICAL REQUIREMENTS.

9.1 STANDARDS.

All materials and workmanship shall comply with the requirements of

Clause 4.0. Relevant Indian/International standard codes must be
mentioned by the supplier of machine as specified below:-

Methods for Ultrasonic Testing of Ferritic Steel Forgings

Methods for Magnetic Particle Testing of Ferromagnetic Products and

Components.
SAA Unfired Pressure Vessels Code.

Hot Dipped Galvanized Coating on Threaded Fasteners.

Acoustics – Determination of Sound Power Levels of Noise Sources.

Acoustics – Hearing Conservation.

Conveyor Belting – Textile Reinforced.

Conveyor Belting of Elastomeric and Steel Cord Construction.

Methods of testing conveyor and Elevator Belting.

Bourdon Tube Pressure and Vaccum Gauges.

Design of Rotating Steel Shafts.

SAA Crane Code.

Carbon Steels and Carbon Manganese Steels – Hot Rolled Bars

and Semi Finished Products.

Wrought Alloy Steels, Standard and Hardenability (H) Series.

Circular and Non-circular Carbon Steel Tubes for Mechanical and

General Engineering Purposes.

Short Pitch Transmission Precision Roller Chains and Chain Wheels.

Code of Practice for Preparation and Pretreatment of Metal Surfaces

Prior to Protective Coating.

Limits and Fits for Engineering (Metric Units)

Wire Rope Slings.

Method of Test Elastomers.

Tanks for Flammable and Combustible Liquids.

Conveyors – Design, Construction, installation and Operation – Safety

Requirements.

Iron Castings – Grey Cast Iron.

Iron Castings – Spheroidal or Nodular Graphite Cast Iron.

 Solid Bearing Housings Dimensions and Tolerances.

Steel Castings.

Surface Roughness Comparison Specimens.

Surface Texture.

Gears – Spur and helical – Guide to Specification and Rating.

Gears – Spur and Helical – Guide to Specification and Rating.

Vibration and Shock – Balance Quality of Rotating Rigid Bodies.

Metric Keys and Keyways.

Standard for Spur, Helical, Herringbone and Bevel enclosed Drives.

Fundamental Rating Factors and calculation Methods for Involute Spur

and Helical Gear Teeth.

Rating for Pitting Resistance and Bearing Strength of Generated

Straight
Bevel, Zerol Bevel and Spiral Bevel Gear Teeth.

Fabric Belt Testing.

Specification for Pulleys for Belt Conveyors.

Specification for idlers and idler sets for belt Conveyors.

Glossary for Conveyors Terms and Definitions.

Code of Practice for Selection and Design of Belt Conveyors.

9.2 GEAR REDUCERS.

9.2.1 GENERAL.
The list of vendors is placed at Annexure – 1 to this Section – VI. The
Purchaser recommends that the vendor list be followed by the Supplier
for procurement of important equipment / component which shall be
installed on the machine. However, if the Supplier intends to deviate
from the vendor list at Annexure – 1, the Supplier shall have to obtain
the approval of the Purchaser for procurement of important equipment
from other manufacturers not mentioned in the vendor list. The vendor
list at Annexure – 1 is applicable to all bought-out items. All equipment
supplied shall be of approved manufacture unless otherwise specified.
The equipment shall be the Supplier’s normal design suitable for the
 duty specified. Replacement gears, bearings and seals shall be readily
available in India.

9.2.2 DESIGN FOR STANDARDISATION.

Reducers selection shall be standardized in such a way that it will be

available from open market and from reputed gearbox manufacturer.

Reducers shall be capable of being driven in either direction at the

rated capacity without reduction of the specified design life. Reducers
of the same rating and reduction ratio, but used for left hand or right
hand drive output, shall be interchangeable for either application.

9.2.3 REDUCER TYPE.

Speed reducers shall be the split type helical, bevel helical or planetary
gear type.

9.2.4 MOUNTING AND ASSEMBLY TYPE.

Drive assemblies shall comprise motor, high speed coupling, disc /

drum type brake, speed reducer incorporating a geared output
coupling, guards, sub-base and torque arm.

9.2.5 DESIGN DUTY

All components of speed reducers shall be designed for continuous

duty at maximum demand power with capacity to stop and start under
fully loaded conditions. The speed reducer shall also be designed to
allow back driving through the reducer to the motor.

9.2.6 DESIGN STANDARDS.

Speed reducers shall be designed in accordance with current

International/Indian Standards.

Bearings shall be selected in accordance with Indian/International

Standard.

9.2.7 THERMAL CAPACITY.

The thermal rating for reducer operation shall be based on the

lubricating oil bulk (or sump) temperature not exceeding 800 C for 450
C ambient shade air temperature.
9.2.8 SPEED REDUCER RATING.

Speed reducer rating shall be based on Indian/International Standards

and design should be such that it will operate in adverse conditions
without failure.

In addition to the requirements stated in paragraph 2.1 of AGMA 6010

– E88, all gearing shall be capable of safely withstanding not less than
the full peak torque of the drive motor applied twice in direct
succession.

The reducer shall be capable of not less than 10 starts per hour under
full load.

When the braking torque is applied to the high speed shaft and the
braking torque exceeds the starting torque, then the braking torque
shall be considered in the selection of the speed reducer.

9.2.9 COUPLING DESIGN REQUIREMENTS.

The flexible couplings shall be designed to transmit 3 X motor full load

torque or 1.5 X maximum brake torque (whichever is greater)
multiplied by the actual gear reduction ratio as a minimum.

9.2.10 OVERHUNG LOAD.

Overhung loads generated by flywheels and/or brakes and/or fluid

couplings shall not exceed the speed reducer manufacturer’s
recommendation. If excessive overhung load can be induced, these
items shall be mounted between pedestal bearings with flexible
coupling used between both the motor shaft and the reducer input
shaft.

9.2.11 NOISE.

Noise level of the speed reducer, running at the design conditions at

site, shall be within the permissible micropascals limits as per the
Indian/International standards.

9.2.12 CASINGS.

Unless otherwise specified, reducer casings shall be manufactured

from fabricated steel.
 When the reducer casings are specified or offered as all welded steel
construction, the welding shall be oil-tight and the housing stress
relieved after welding, and prior to any machining.

Reducer casings shall be provided with easily removable inspection

covers to allow the reducer internals to be viewed without disturbing
the drive.

Reducer casings shall be provided with lifting lugs.

Provision shall be made in the casing design for horizontal alignment of

the reducer in longitudinal and transverse direction, as well as vertical
adjustment.

Mounting areas for attachment of vibration monitoring transducers shall

be provided adjacent to all bearings. The vibration transducers may be
either fixed or temporary magnet mounted type.

A drilled and tapped connection shall be provided for installation of a

temperature transducer in oil well which shall be covered with oil. The
hole shall be plugged.

9.2.13 LUBRICATION.

Adequate means of lubrication for all gears and bearings shall be

maintained at all operating positions of the reducers. Splash lubrication
using mineral oil is preferred. Where pumped lubrication is
unavoidable, the pump suction shall remain submerged in the lubricant
for all operating positions of the reducer. A pressure gauge and an
adjustable oil flow switch shall be fitted to the delivery line from the
pump.

Reducers shall be provided with an integral filler/breather/

level/temperature and drain plug. The drain plug will comprise a 75 mm
square hollow section steel tube body within which is assembled.

A UCC filler/breather cap or equivalent.

A UCC sight glass or equivalent along with oil dipstic arrangement.
A 32mm BSP drain plug.

The assembly will be supported by and located adjacent to the reducer.

Connection to the speed reducer shall be by means of :

A breather hose from the top of the tube body to the top of the reducer.
A connection pipe and union from the bottom of the tube body to the
bottom of the reducer.

The reducer identification plate shall specify the required oil type and
quantity.
 Magnetic inserts shall be fitted to the drain plugs.

Oil sampling points shall be fitted in a suitable location to allow

sampling when operating.

9.2.14 BEARINGS.

Bearings shall be of standard type and size readily available in India.

Bearing selection and life shall be suitable for sustain operation in most
adverse condition.

9.2.15 SEALS

All reducer shaft seals shall be of the “labyrinth and double lip
neoprene” type with provision to purge with grease. TACONITE type
seals or modified TACONITE type with non contact lip seals are
preferred or approved equivalents. All the seal details must be
submitted along with the drawings for acceptance and approval.

9.2.16 HEAT CONTROL.

It is preferred that reducers be rated with sufficient thermal

capacity so as high speed shaft fan cooling will not be required.

If fan cooling is used, then the fan impeller shall be of the split type to
facilitate replacement without removal of the couplings and/or
disturbing the alignment of any component in the drive.

9.2.17 PROTECTIVE COATINGS.

Unmachined external surfaces of the speed reducer shall be painted in

accordance with Clause 13.0.

Machined surfaces shall be suitably protected from rusting during

transport and storage with an easily removable coating.

Threads on casing locating dowels shall be covered with a thread anti-

sieze solution (Kopr-Kote or equivalent) prior to installing the nut.

9.2.18 TESTING.

SHOP TEST

The speed reducer shall be test run in the factory prior to delivery.
 Notification of factory testing is required in accordance with clause 5.0.

A report on the test shall be submitted in accordance with the

Documentation Schedule.

The speed reducer shall be subjected to no-load test when installed in

the drive assembly comprising all drive components :

Motor
High speed coupling
Fluid coupling, if applicable
Brake, if applicable.
Reducer

The test will include a full frequency vibration-analysis using magnetic

mounted accelerometers.

Test duration shall be not less that four(4) hours. The test report
shall provide the following minimum information:

Test duration
Ambient conditions
Final temperature of the casing
Final oil temperature
Noise level recorded
Background noise level
Backlash
Vibration signature
Any pertinent observations.

9.2.19 DRAWINGS.

In addition to other specified requirements certified dimensional

drawings of the reducer shall be submitted. The drawings shall show
the following information :

Total mass (without oil)

Oil type, viscosity grade quantity
Mechanical power rating
Thermal power rating
Reduction ratio
Fully dimensioned outline drawing including mounting dimensions and
loads and shaft dimensions with tolerances.
Limits of permissible angular and parallel misalignment between shaft
pairs.
Expected life in hours for the weakest item of assembly.
Maximum eccentric load on the input shaft within the unit rating.
 Internal details of the reducer (cross-sectional dimensional drawings).
Material list – The list shall show all the items of the equipment.
Commercially available items such as bearings and seals shall have
SKF or other common part numbers.

9.3 MECHANICAL COUPLINGS.

9.3.1 GENERAL

Mechanical couplings are used for connection of speed reducers to

driving motors and driven equipment. The high speed flexible couplings
are required to compensate for radial and angular misalignment
between motor and speed reducers, as well as to dampen torque
fluctuations and possible torsional vibration. Low speed flexible
couplings often are required to compensate for angular and radial
misalignment.

Rigid high speed couplings (with flange) are required to couple electric
motors to fluid couplings.

9.3.2 COUPLING TYPES.

For general application, couplings fitted to the high speed shafts

of speed reducers shall be of Flender “N-Eupex Type A” type or
approved equivalent with flexible coupling blocks replaceable without
disturbing the reducer or driver alignment. The coupling shall not be
manufactured from grey cast iron.

Couplings fitted to the low speed shafts of foot mounted drive unit shall
be of double engagement David Brown “Gearflex” type, or approved
equivalent.

9.3.3 BRAKE DISC CONNECTION.

Where a brake drum or a brake disc is to be fitted to the high

speed coupling assembly, it shall be fitted to the reducer side of the
coupling.

9.3.4 SERVICE FACTOR.

Couplings shall be selected to allow for the expected shock load

and misalignment. The minimum service factor shall be

3 X full load motor torque corrected for speed

1 X stalled motor torque corrected for speed

The coupling torque rating shall exceed the required braking torque of
the driven equipment.
9.3.5 BALANCING.

Couplings operating above 500 rpm speed shall be dynamically

balanced. Low speed couplings shall be statically balanced. The
balancing shall be in accordance with Indian/International standards.
The balance quality grade shall be selected to suit the particular
application.

9.3.6 DESCRIPTION.

SEALS

Where couplings are fitted with seals these shall be suitable for
operation in highly abrasive dust laden atmosphere. The seals shall be
suitable for high pressure water washdown.

LUBRICATION.

“Gearflex” type couplings shall be provided with grease nipples to

allow grease to be pumped into the internals of the couplings. Each
coupling shall have two removable hydraulic type grease nipples set at
1800. The grease can be pumped in on one side while the other grease
nipple may be removed to allow grease to exit the coupling thus
ensuring that the coupling is full of new grease.

SHAFT ATTACHMENT.

Coupling bore shall be machined, concentric with the coupling body.

Couplings shall be attached to their shafts using a light interference fit
equal to H7 p6 as defined in Indian/International standards and a
rectangular parallel key in accordance with Indian/International
standards.

High Speed Coupling – Drive Half

The drive half of the high speed coupling shall be bored and keyed to
size and to the tolerance specified above.

High Speed Coupling – Driven Half

The driven half of the high speed coupling shall be bored and keyed to
size and to the tolerances specified to suit the speed reducer
manufacturer’s recommendations. When specified, it shall incorporate
brake discs.

Low Speed Coupling – Drive Half

The driving half of the low speed coupling shall be machined as
specified to suit dimensions of the output shaft of the speed reducer.
 Low Speed Coupling – Driven Half
The driven half of the low speed coupling shall be supplied by the
coupling manufacturer with an unbored hub. It shall be finish bored by
the manufacturer of the driven equipment.

PROTECTIVE COATING.

All machined surfaces of the couplings shall be coated with an easily

removable protective material to prevent rust and damage during
shipment and storage.

External surfaces of the couplings shall be painted in accordance with

Indian/International Standards.

TESTING

The coupling shall be tested during the no-load test of the drive
assembly. Load testing of the coupling shall be carried out during the
commissioning of the drive assembly.

9.4 FLUID COUPLINGS.

9.4.1 GENERAL

A fluid coupling shall be used to transmit torque from a standard

squirrel cage electric motor started DOL to a speed reducer.

Under normal operating conditions and with the requisite number of

starts per hour, the oil temperature shall not exceed 90 0 C under all
ambient temperatures. External oil cooling shall not be provided.

9.4.2 COUPLING TYPE

The fluid coupling shall be capable of bi-directional rotation. Couplings

with delay fill chamber may be used where close control of acceleration
is required. Couplings shall be capable of being back-driven (i.e.
through the gearbox) for extended periods.

9.4.3 STARTING TORQUE

The coupling and its associated motor drive system shall give a smooth
and progressive build-up of torque during acceleration.

The maximum torque transmitted during the acceleration period shall

not exceed 150% of the driven equipment full load running torque.
 During acceleration of the motor the torque-speed curve of the coupling
shall at no stage intersect the torque speed curve of the motor before
peak motor torque has developed at worst case with low supply
voltage. A graphical chart showing TVsN curve of F.C. with respect
to TVsN curve of selected motor rating must be produced along
with supply coupling.

9.4.4 STALLED TORQUE

In the event of the conveyor stalling, the maximum torque transmitted

to the drive pulley shall not exceed two hundred per cent (200%) of the
motor full load torque.

9.4.5 SLIP
When running at full load conditions with the specified oil level, the
coupling slip shall not exceed 3%.

9.4.6 STARTING FREQUENCY

Fluid couplings shall be selected so that they will be capable of starting
the fully loaded conveyor twice in direct succession plus as many
evenly spaced starts per hour as would be applicable to the anticipated
duty, but not less than a total of 10 starts/hour without the fluid
temperature exceeding the manufacturer’s recommended maximum
temperature. For the above selection condition, it shall be assumed
that the coupling has been running at full load and has attained its
operating temperature. Ambient temperature of 450C shall be used for
this calculation.

9.4.7 CAPACITY TO VARY THE OUTPUT.

The coupling shall have the capability of limiting the output torque
between 250% and 150% of the design full load torque by varying only
the oil filling in accordance with the manufacturer’s recommendations.
Such oil filling torque setting shall be reliable predetermined and
consistent.

The couplings shall exhibit inherent output torque limitation of the same
order during both acceleration and running conditions for any given oil
filling within the above range.

9.4.8 THERMAL OVRLOAD PROTECTION

Each coupling shall be fitted with two temperature dependent

protective devices.

• Thermal control element shall trip a base-mounted limit

switch which will be wired to stop the drive. A spring-
loaded pin retained by a fusible disc, to be released at a
set temperature, may be used for the tripping device.
 Operation of this device shall not cause loss of oil from
the coupling.
• Fusible plug designed to melt at a temperature 200C
above the setting of the thermal control element.

9.4.9 SEALS

External bearing seals shall be suitable for operating in a highly

abrasive dust laden atmosphere and shall withstand high pressure
water wash.

9.4.10 BALANCING.

The coupling shall be dynamically balanced by the manufacturer.

9.4.11 OIL TYPE AND LEVEL.

The fluid coupling shall be filled to the required level with oil in
accordance with the manufacturer’s specification for the duty. A
permanent label stating the oil type and level shall be fixed to the fluid
coupling casing.

9.4.12 DESCRIPTION OF EQUIPMENT.

COUPLING ARRANGEMENT – GENERAL

The input shaft of the fluid coupling shall incorporate a flexible

coupling.

The coupling assembly shall be designed to allow removal of the fluid

coupling without displacement of either the motor or the gearbox.

PROTECTIVE COATING.

All exposed machined surfaces of the coupling shall be protected with

an easily removable coating to prevent corrosion or damage during
shipment and storage.

External surfaces of the coupling shall be painted in accordance with

clause 13.0.

TESTING.

The fluid coupling shall be tested during the no-load test run of the
drive assembly and during the commissioning of the drive unit.
9.5 BRAKES.

9.5.1 BRAKE ARRANGEMENT.

Braking arrangement for various systems is already defined in
Appendix – 1 Section – V , Schedule of Requirements in Volume – 1.

9.5.2 BRAKE CONSTRUCTION.

The brake shall be of heavy duty construction fabricated from

corrosion-resistant components.

9.5.3 FAIL SAFE.

The brake shall be fail safe on loss of power.

9.5.4 ADJUSTMENT.

The brake shall have adjustment to allow progressive application of

braking torque.

9.5.5 DESCRIPTION OF EQUIPMENT.

GENERAL

Braking equipment shall be designed to operate in a highly abrasive

dust laden atmosphere.

Application of brake shall be progressive such as to achieve gradual

stopping without jerking.

Electromagnetic or electrohydraulic release mechanisms must be

used. Brakes shall be self-compensating for wear.

Brake callipers shall be selected to accommodate the float in the disc /

drum supporting shaft without detriment to the brake, shaft bearing or
related gear.

Provision shall be made to enable the brakes to be released manually.

BRAKE DISC / BRAKE DRUM:

The brake disc / drum shall be replaceable and self-ventilating. The

diameter and thickness of the disk/drum shall be adequate to absorb
mechanical and thermal loads.

The disc material shall be compatible with the brake pads. It shall be
selected for long wear life and thermal stability.
STRESS RELIEVING

The brake discs shall be stress relieved before machining.

MACHINING.

Brake discs shall be machined to 3.2 micrometre Centre Line Average

(CLA) all over before final machining and balancing. The machining
shall be performed on the braking surfaces, bore, boss faces and any
mounting surfaces.

The braking surface of the discs shall be machined to 1.6 micrometer

CLA. The discs braking surfaces shall be parallel to within 0.05mm.

BALANCING AND ECCENTRICITY.

The permissible residual imbalance of brake discs shall be within the

permissible as per Indian/International standards.

Balancing may be achieved by drilling.

The axial and radial run out of discs and drums shall not exceed values
stated below.

Run out Tolerance – mm. Total Indicator Reading

Axial Radial
Brake Workshop Mounted Workshop Mounted
Disc 0.2 0.3 0.1 0.3

MOUNTING.

Where specified, brake discs shall be mounted on, or integral with, a

high speed coupling. Otherwise, the brake discs shall be attached to
the speed reducer input shaft using a light interference fit equal to H7
p6 as per Indian standards.

If brake disc dia exceeds 400 mm, the brake assembly shall be
mounted between pedestral bearings using a flexible coupling between
both the motor shaft and the speed reducer input shaft. The pedestral
bearings shall be grease lubricated and selected such as to allow for
continuous operation under no-load conditions with occasional brake
torque being applied. Preferred bearings are spherical roller type.

When a disc brake less than 400 mm diameter with a single calliper is
used, the speed reducer input shaft and bearing shall be checked for
the maximum possible radial force produced by the brake calliper. If
the speed reducer cannot accommodate this force, the brake shall be
mounted in the same fashion as for large diameter disc brakes, i.e.
between pedestal bearings.
 ELECTRICAL EQUIPMENT.

Electrical equipment shall be sealed to IP65. Electromagnetic or

electro-hydraulic thruster release brakes shall be designed to operate
on a solidly earthed 415V 50 Hz power supply. Power packs for
hydraulic brakes shall operate on the same supply.

BRAKE LINING AND/OR BRAKE PADS.

Brake lining and brake pad material shall be selected for long life. The
material shall not contain asbestos.

LIMIT SWITCHES.

The brake shall be fitted with a limit switch to indicate “brake off”
position.

PROTECTIVE COATINGS.

All braking surfaces and machined bores shall be protected prior to

transport and extended warehouse storage with an easily removable
coating.

Unmachined surfaces shall be painted in accordance with Clause 13.0.

TESTING.

The operation of the brake shall be tested during workshop no-load test
of the drive assembly. The operation of the brake shall be tested on
site during no-load and lod commissioning to ensure compliance with
the Specification.

DRIVE BASES.

GENERAL.

The drive base shall be designed to provide support and mountings for
the following drive unit equipment.
Electric motor
Couplings - as applicable.
Brake - as applicable.
Limit switches - as applicable.
Guard
Speed reducer

For shaft mounted drive units the base shall be fitted with a flexible
bush for connection to the torque arm.
DESIGN CRITERIA.

The drive base shall be designed for the motor, gearbox and torque
arm reactions. The reactions shall be calculated for the torque
generated during starting, operation and braking of the drive system.
The reactions generated by the stalled motor shall be included in the
calculations. The design of the drive base shall also be checked for 3 X
full load motor torque and reactions due to the belt tensions at the drive
pulley. Design loads shall include the lifting load generated when a fully
assembled drive unit is lifted by a sling attached to the lifting lugs
provided.

The drive base shall be rigid so that the maximum deflection does not
exceed 50% of the recommended coupling alignment tolerances at the
worst combination of static and dynamic loads.

For shaft-mounted drives, the drive and position of the torque arm shall
be arranged to minimise load on the gearbox output shaft due to
reaction torque and overhanging mass of the drive. As identical drives
may be used in different applications, the torque arm reaction may be
in tension or compression.

The rigidly foot-mounted drives shall be designed to transmit drive

loads to the supports.

DESCRIPTION.

GENERAL

The drive base shall be fabricated from rolled steel plates and sections.
Welding shall be in accordance with Indian/International standards.
Weld category shall be selected to suit the loading condition and level
of stress in accordance with International/Indian standards. The base
shall be fully welded with continuous fillet welds to preclude corrosion.
It shall be stress relieved before mounting surfaces are machined.

CONSTRUCTION.

Construction of the base shall be such that dead pockets which may
collect water or spilled material are not formed, and all equipment is
accessible. Holding down bolts shall be used for mounting of
equipment. There shall be access provided for assembly and
dismounting purposes to the bolt head and nuts. There shall be no
sharp corners or protrusions.

Horizontal adjusting screws (2 at each corner, with lock nuts) shall be

provided for aligning the equipment in longitudinal and transverse
direction. Means shall be provided for jacking the gearbox during
assembly.

RIGID FOOT-MOUNTED DRIVE BASE.

The rigid foot-mounted drive base shall be designed to suit the actual
installation on steel supports.

Bases mounted on structural steelwork shall be bolted using high

strength bolts. Provision shall be made for a 6 mm packing space
beneath the drive base.

SHAFT-MOUNTED DRIVE BASE.

The shaft-mounted drive base shall be fitted with a flexible bush for
torque arm connection. The flexible bush shall be designed to
accommodate drive movement and shock loads.

TORQUE ARM AND BASE MOUNTING BRACKET.

The torque arm shall provide a flexible connection between the drive
base and support structure and shall be designed to transmit all loads
generated by the drive. The torque arms shall be fitted with clevises
and pins for connection with the flexible bushes.

The base mounting brackets shall include a flexible bush and shall be
designed for connection of the torque arm to structural supports as
specified.

LIFTING LUGS.

Lifting lugs shall be provided. The lugs shall be designed for lifting of
the fully assembled drive unit including motor and speed reducer and
shall be located such that the lifting slings do not contact installed
equipment.

MACHINE PADS.

The drive base shall be provided with mounting pads at all holding
down bolt locations for motor reducer plummer blocks and brakes.
Pads shall protrude a minimum of 40 mm outside the feet of the motors
and reducer for leveling and alignment of equipment.

The mounting surfaces shall be accurately machined for uniform

seating of equipment.
Machined pads shall be flat and parallel with a maximum vertical linear
tolerance of + 0.25 mm. The maximum angular misalignment of pads in
the same or parallel place shall be 10 minutes of arc.

ASSEMBLY.

Mechanical equipment shall be assembled and aligned on the base

strictly in accordance with the drive component manufacturer’s
recommendations.

SURFACE PROTECTION.

The drive base shall be inspected during fabrication to check quality of

welding.

On completion of fabrication the drive shall be inspected for the

following :

Dimensional accuracy.
Machining flatness and parallelism.
Weld size
Paint quality.

DRAWINGS.

In addition to other specified requirements a fully dimensioned drawing

of each drive base shall be supplied.

The drawing shall show

Overall dimensions.
Installation dimensions.
Machining.
List of major components.
Full details of the flexible bush.
Size and location of lifting lugs.
Size of drip tray.
Paint finish.
Total mass of the frame.
Description of stress relieving.
Details of the torque arm and base bracket where applicable.

DESIGN CALCULATIONS.

A set of design calculations for each drive base shall be provided.

The calculations shall show.
Working stress and maximum deflection for the normal operating
conditions.
Maximum stress for the overload conditions.
Design of welds.
9.7 BEARINGS.

9.7.1 GENERAL.

Bearing types and sizes commonly available in India are preferred

SKF, FAG bearings shall be supplied.

9.7.2 BALL AND ROLLER BEARINGS.

Ball and roller bearings shall be of the self-aligning ball or

spherical roller types. Self aligning spherical roller bearings shall be
used for belt conveyor pulleys. All bearings shall be mounted on
adaptor sleeves.

All bearings shall be selected in accordance with A2729 or any

equivalent Indian/International standards for L10 life as listed below
under full load conditions using reliability material and lubrication
factors a1, a2 and a3 equal to unity

Slew Bearing - refer to clause 3.6

Slew Drives and Pinions - 100,000 hrs.
Bucket Wheel & Drive - 100,000 hrs
Conveyor Pulleys - 50,000 hrs
Long Travel Assembly - 50,000 hrs
Long Travel Speed Reducer - 25,000 hrs
Conveyor Idlers - 50,000 hrs
Conveyor Speed Reducer - 50,000 hrs
All other - 50,000 hrs

9.7.3 PLAIN BEARINGS.

Plain bearings shall only be used where other alternatives are not
possible.

Plain bearings in swivel or pivoting application which, generally, cannot

be greased due to high contact pressure shall utilise bearing materials
with self-lubricating characteristics.

At structural steel/steel linkage points the projected bearing pressures

shall be less than

100 MPa for ‘Static’ links.

70 MPa for ‘Minor Oscillation’ links.
9.7.4 SPHERICAL PLAIN BEARINGS.

For applications with no or rare reversals of load direction the

‘Maintenance Free = PTFE/Steel’ type shall be selected. In other
applications, the Steel/Steel type shall be selected and provision for
lubrication provided.

9.7.5 BEARING HOUSINGS.

Bearing housings shall be selected from the following metric types.

Shaft Diameter Housing Type

SKF, FAG

Up to 140 mm SNA 500 – 2 bolts

SAFM 500 – 4 bolts
150 mm to 300 mm SD 3100 – 4 bolts
320 mm to 450 mm CSD 3100 – 4 bolts

If no suitable housing is available in the above list written approval shall

be obtained to use alternate housings.

Bearing housing dimensions shall be in accordance with Indian/

International standard.

Housings for special purpose machines such as long travel drives of

Reclaimers may be to the special purpose machine manufacturer’s
standard.

For general application, housings shall be manufactured from high

grade cast iron in accordance with Indian/International standard.
Where specified spheroidal graphite cast iron to Indian/International
standard or cast steel to Indian/International standard housings shall
be used.

The base of the housings and the ends of the mounting foot shall be
machined parallel to the bore. The top part of the mounting foot shall
be spot-faced to allow for a standard plain washer to be used under the
head of the mounting bolts.Lifting lugs shall be provided on housings of
150 mm diameter and greater.Elongated holes shall be provided for
mounting bolts with the following minimum adjustment.

For shafts up to and including 140 mm diameter +3 mm.

For shafts above 150 mm diameter +5 mm

Tapped holes and standard grease nipples shall be provided for

bearing regreasing and for purging of labyrinth seals.
 A flat machined surface shall be prepared on a vertical side of the
housing normal to radial direction from the axis of the bearing. The spot
faced surface shall be approximately 30 mm in diameter machined to
1.6 m. This surface shall be used for fitting of a vibration transducer.
For bucket wheel pillow block, the pillow block should be split
type with split spherical roller bearing.

9.7.6 SEALS.

Bearings shall be provided with seals which shall effectively exclude all
dirt, foreign matter, water due to rain or high pressure water hosing and
prevent loss of bearing lubricant. Bearings less than 25 mm ID may be
‘sealed for life’.

Replaceable wear sleeves or plates shall be provided for contact type

seals.

Spherical plain bearings with a bore diameter of 100 mm and larger

and other spherical joints shall be provided with a taconite type seal.

Housings shall be fitted with grease purged labyrinth seals combined

with wiping lip, seals (Taconite or equivalent).

9.7.7 LUBRICATION.

Bearings shall be packed on assembly with grease in accordance with

the bearing manufacturer’s recommendation.

9.7.8 BLANKING PLATE.

Shaft without external attachments may terminate within the housing.

In this case, a steel blanking plate shall be fitted to seal the open end
of the housing.

9.7.9 INSTALLATION.

GENERAL.
Bearings shall be installed strictly in accordance with the bearing
manufacturer’s recommendations.

MOUNTING.

Bearings shall be mounted on specially designed and fabricated

frames and not directly on structural members. The frame shall have
stiffeners adjacent to mounting bolts to prevent local deformation. The
frames shall be fitted with machined mounting pads and blocks with
adjusting bolts. Shear blocks shall be welded at both ends of the
bearing housings after alignment.
Drive pulley bearing housings shall be installed with a minimum of 6
mm removable shims.

Installation shall be in accordance with bearing manufacturer’s

recommendations.

ARRANGEMENT OF BEARINGS.

Each pair of bearings on one shaft shall have one fixed and one
floating bearing. The floating clearance shall be approximately equal on
either side of the bearings with housing installed on correct centres.
The fixed bearing housing shall be clearly marked ‘FIXED’ by metal
stamping.

The fixed bearings shall be installed on the drive side of the shafts.

SETTING UP.

Housings shall be set square to the shaft.

The radial gap measured between the labyrinth seals at two

diametrically opposed points shall not vary by more than 0.5 mm.

Setting of diametrical clearance for bearings with adaptor sleeve to be

checked before running of bearings.

PROTECTIVE COATING.

Machined surfaces shall be protected for storage and transport with an

easily removable coating.

Unmachined, external surfaces of the housing shall be painted in

accordance with Clause 13.0.

INSPECTION.

Bearings shall be inspected in the workshop and on-site.

An inspection report shall be provided which shall state :

Radial clearance – before and after fitting.
Bearing center.
Type of grease used.
9.8 CONVEYOR IDLERS.

9.8.1 GENERAL.

Idlers shall be selected to comply with the duty requirements for the
conveyors nominated in addition the design load shall include 25%
allowance for overload and shock conditions.

Idlers shall be supplied in accordance with the requirements of IS

8589.

Multiple roll idler sets shall be comprised of equal length rolls. All rolls
for each idler set shall be equally rated and be interchangeable.

Standard deep groove ball anti-friction bearings, which are greased for
life and sealed against the ingress of dust and water shall be used.
Bearings shall be grease-packed using a grease specially selected for
the duty and the temperature conditions. Sodium based greases are
not acceptable.

All idlers shall be of heavy duty construction, free from vibration under
all conditions of load and belt speed.

Idler rolls shall be mounted so that they are firmly and positively
located in the bracket but can be removed without use of tools.

All surfaces which could come into contact with the belt as a result of
belt mistracking or dislodged rolls shall be made as smooth as
possible.

Load calculation shall be based on the following data :

Maximum specified belt carrying capacity.

Maximum specified material density and lump size.
Maximum nominated idler spacing.
Belt speed.
Idler troughing angle.
Specified belt mass.
Idler offset in a set of three idlers; deviation of a middle idler
from the line joining the two outer idlers - + 12mm.
Drop height at conveyor transfers.

Idler rolls shall be designed and manufactured such that the failure rate
over a two (2) year period shall not exceed 1% at the nominated design
duty.
9.8.2 CONCENTRICITY.

Idler rolls run-out shall not exceed 0.5 mm TIR (Total Indicator
Reading) for steel rolls and 1.0mm TIR for rubber disc rolls.

The run-out for the weighing idlers shall be in accordance with the
weigher manufacturers recommendations. If not specified, it shall not
exceed 0.13 mm total indicator reading.

9.8.3 BALANCING.

Total imbalance of idler rolls shall not exceed 0.028 Nm torque.

Weigh idler rolls imbalance shall not exceed 0.004 Nm torque or as
specified by the Weigher Manufacturer. Idler rolls manufactured to
these tolerances, but still generating undue vibrations shall not be
acceptable.

9.8.4 MOUNTING FRAME.

The troughing rollers and Vee return rolls each shall be supported by a
one piece fabricated steel frame. The main cross-member shall be an
inverted steel angle or steel tube of suitable size. Frame deflection
under full load condition shall be limited to 1/300 of the frame hold-
down bolt centres. Due allowance shall be made for torsional load
induced by siezed rolls. The frame shall be fabricated so that there are
no dead pockets where water can be retained. All hollow section
members shall be fully sealed.

The frame shall be designed to prevent accumulation of spillage

between the frame and rolls. The rolls support brackets shall be
designed not to damage the belt in the event of a roller being
dislodged.

Diagonal braces shall be fitted between the cross-member and outer

brackets where required.

The return roller support brackets on tubular cross members shall be

set below the top of the tube. This arrangement is designed to protect
the belt in the event that a roll is dislodged. In this case, the belt runs
on top of the tube rather than on support brackets.

Unless otherwise specified, two mounting holes shall be provided on

each frame for 16 mm diameter bolts. These holes shall be slotted to
allow 16 mm lateral adjustment.
 Longitudinal axis of all rolls shall be parallel within 0” 15’ and rolls
shafts shall be in alignment within +1 mm.

All idler mounting brackets shall be machined to fit closely to the idler
shaft ends such that no audible rattle can be detected during operation.

9.8.5 RETURN IDLER BRACKETS.

The brackets shall be fabricated from rolled steel angle or tube. There
shall be two slotted holes in each bracket for 16 mm diameter bolts.
The slots shall provide 16 mm lateral adjustment.

9.8.6 BARREL.

Idler rolls shall be fabricated from new E.R.W. tubing to

Indian/International standards. The rolls barrels shall be free from
surface defects and internal weld fins.

Roll ends shall have a minimum corner radius of 3 mm over 90.

The thickness of barrels for carry and Vee return rolls shall be not less
than 3.2 mm.

The minimum thickness of barrels for flat rolls returns shall be 6 mm.

All idlers shall have a length tolerance of +1.5 mm and a diameter

tolerance of +1mm.

9.8.7 END BEARING HOUSING.

End bearing housings shall be of pressed steel, fully welded to roll

shells and shall be designed to withstand stress reversal. All welds
shall be full penetration, smooth and free of imperfections.

9.8.8 BEARINGS.

All rollers shall be fitted with standard deep groove ball anti-friction
bearings.

9.8.9 SHAFT.

All shafts shall be stationary and manufactured from CS 1020 bright

drawn bar or equivalent. Shafts shall be machined. The shaft
tolerances shall be in accordance with the bearing manufacturer’s
recommendations.

Shaft design shall be in accordance with Indian/International

Standards.
 Shaft deflection at the bearing shall not exceed 8 minutes under the
specified load.

9.8.10 SEALS.

Idler bearing housings shall be equipped with efficient sealing

arrangements to protect the bearings from entry of rain water, high
pressure water wash down dust and foreign matter and minimise the
escape of lubricant into the interior of the rollers or out through the
bearing seals.

The seals shall be designed for minimal rolling resistance.

Metallic multi-labyrinth seal assembly shall be installed on the outside

of the bearing. There shall be an external neoprene seal on the outside
of the multi-labyrinth seal. An additional seal shall be installed to
prevent escape of grease to inside of the roller. Seal details must be
provided.

9.8.11 PROTECTIVE COATINGS.

Steel frames shall be hot dip galvanized and then painted in

accordance with Clause 13.0.

Idler roll ends shall be painted with the manufacturer’s standard paint
system.

9.8.12 IDLER TYPES.

GENERAL.

Idler roll diameter shall be selected to suit the nominated duty and to
provide minimum rolling resistance. Same diameter rolls shall be used
on all idlers for the given belt width. The idler outside diameter shall be
not less than 152.4 mm.

TROUGHING IDLERS – FRAME MOUNTED.

Troughing idlers shall incorporate three equal roll idlers.

Troughing idlers shall be spaced to give the nominated bearing life

when operating at design speed and full load. If necessary a closer
pitch shall be used to limit the belt sag between idlers to 2% of the idler
pitch or to suit the specific requirements of convex curves. Irrespective
of the above, the maximum idler pitch for all boom conveyors shall be
1000 mm.
Extra care shall be taken regarding the length of the transition from flat
pulleys to troughing section to ensure that no distortion of the belt
occurs due to increased tensions at the belt edges.

Similar care shall be taken in the positioning of idlers on convex curves

in order to ensure that no distortion of the belt occurs due to increased
belt edge tension. Idler spacing on convex curves shall be selected to
ensure bearing loading is not increased to a level which will reduce the
life below 50,000 hrs.

RETURN IDLERS

Return idlers shall be of the single roll flat type for boom conveyors
using fabric belts.

Return idlers shall be spaced at a maximum of 2.0 metre centres,

except on a convex curve where the spacing shall be determined on
bearing life considerations. Return idlers should be located adjacent to
stringer supports, and not at mid-span where stringer vibration may
initiate belt flap.

IMPACT IDLERS

Retractable impact idlers shall be installed at all loading and transfer

points. Their design shall allow removal and replacement of the rolls
from the side.

Impact idlers shall be fitted with rubber discs 450 wing angle idlers
shall be used. The rubber discs shall be abrasion resistant vulcanized
rubber. Idlers shall be fitted with retaining plates.

The maximum spacing of impact idlers shall be 300 mm.

TRANSITION IDLERS.

Transition idlers shall comprise rigid mounted, three (3) roll idler sets
having idlers interchangeable with those of the standard troughing idler
sets and with wing idlers adjustable in the range from 50 – 250 . The
wing idlers supporting member shall be provided with slotted holes to
facilitate field adjustment to suit the belt profile.

WEIGH QUALITY IDLERS.

Weigh quality idler sets shall consist of suitably balanced and

machined three (3) roll idler sets mounted on a purpose-built base to
suit the belt weigher as specified.

The idlers shall conform to the requirements of the belt weigher

manufacturer.
 TRAINING IDLERS.

The training idlers, rolls and frames shall be interchangeable with

standard idlers. Training idlers shall be pivot-mounted of positive action
type.

The frame shall be designed to prevent material build-up on the frame

or lumps or product becoming wedged between the moving and
stationary parts of the frame.

Side rolls shall be 75 mm dia X 150 mm long and fitted with ball
bearings. Bearing housing and sealing arrangement shall be of the
same standard as used for the main idlers.

The pivoted frame shall be supported on a heavy duty sealed bearing.

SUSPENDED IDLERS BRACKET.

Each suspended idler set shall be supplied complete with two mounting
brackets. The brackets shall be designed for bolting to stringers and
shall provide 16 mm lateral adjustment to idlers.

TESTING AND INSPECTION.

Random testing shall be an integral part of the quality control, including

a written report on the results. Additional testing by destructive,
ultrasonic and/or x-ray methods may be required.

9.9 BOOM CONVEYOR PULLEY.

9.9.1 GENERAL.
Pulleys shall generally be in accordance with IS 8531.

All pulleys shall be constructed of a cylindrical steel shell welded to

steel or cast steel end discs. The pulley shall be mounted on shafts
with suitable locking assemblies.

Drive pulleys shall support shaft mounted drive assemblies. It will be

acceptable to mount hollow shaft drives less than 75kW directly on the
drive pulleys. The drives greater than 75kW shall be mounted on the
pulley shaft with flanged coupling with shrink disc.

Commonly available pulleys of standard manufacture are preferred.

Pulleys shall not include intermediate discs or stud shafts.

9.9.2 DUTY.

Pulleys shall be designed for continuous operation in conditions

specified.

9.9.3 RATIONALISATION OF PULLEYS:

Pulley dimensions shall be rationalized so that for any given belt width
there is not more than three different pulleys, including a drive pulley.
Shaft and bearings shall be selected for the worst loaded pulleys in a
group of pulleys of the same diameter i.e. there shall be the same
bearings at identical bearing centres within one pulley size.

9.9.4 DESIGN CRITERIA.

All pulleys shall be designed for the following conditions with due
regard for the angle of wrap of belt on the pulley.

Fatigue Basis

The pulleys and shaft shall be designed for an infinite fatigue life based
on the endurance limit of the material used, when subjected to the
running tensions at design capacity. Shafts shall be designed as per
Indian/International Standards.

Strength Basis

Pulleys and shafts shall be designed to safely withstand the maximum

force that can be imposed during acceleration, braking or stalled motor
conditions.

The design shall include loads imposed by shaft mounted drives,

couplings or brakes.

Deflection Basis

Pulley shaft and shell assembly shall be designed as an integral unit.

The maximum slope resulting from deflection shall not exceed 0.0015
radians at the locking element. This slope shall be calculated when the
pulley is subjected to the maximum forces imposed during
acceleration, braking and motor stalled conditions.

9.9.5 MATERIALS AND MANUFACTURE

The pulley shell and end discs shall be fabricated from structural steel
plates in accordance with Indian/International Standards. All steel
 plates shall be ultrasonically tested for cracks, porosity and
delamination prior to use. Ultrasonic testing shall be carried out in
accordance with Indian/International Standards. All test results shall be
submitted.

9.9.6 PULLEY SHELL.

Shell plates shall be pre-set to template prior to rolling, allowing

sufficient “over set” or “under set” to ensure a true, circular profile. The
shells shall be straight with both ends sqaure. “Barreling” shall not
exceed 3 mm or 0.15% of shell length or diameter, whichever is the
lesser. The nominal shell length shall be have a tolerance of +0 mm to
–6 mm.

Maximum stress shall not exceed 55 Mpa.

9.9.7 END DISCS

End discs shall be symmetrically located about the pulley centreline

within +1 mm.

Thickness of the end disc shall be at least equal to the width of the
locking assembly. Maximum stress shall not exceed 50 Mpa.

9.9.8 WELDING.

All welding shall be in accordance to Indian/International Standards.

Welding may be carried out by automatic submerged arc. Semi-

automatic or manual welding. If manual, low hydrogen electrodes shall
be used.

9.9.9 WELD PREPARATION.

Weld preparation shall be by machine, oxy-profiling or machining. The

finished preparation shall be free of deep serrations or toolmarks. End
disc surfaces shall be free of annular grooves or toolmarks. Machined
preparations shall be free of sulphur bearing cutting oils.

The outer edges of the end discs shall be tapered to the weld size to
avoid stress raisers.

9.9.10 WELD PROCEDURE.

The shell seam weld shall be a full strength butt weld. The shell to end
disc weld shall be a full penetration compound weld type, consisting of
a single bevel butt or single butt weld plus an internal fillet. Backing
rings or locating lugs shall not be used.
 Both welds are subject to reversing dynamic loads. The welding
procedure must therefore, be precise and correct for this application. It
is intended that the pulley will have a practically infinite life.

Full details of the weld preparation and welding procedures shall be

submitted for approval prior to commencement of the work.

Approval of the procedure shall not relieve any responsibility for the
performance of the pulley in accordance with the specification.

Where locking assembly back plates are required, they shall be set up
true and concentric, then continuously welded to the end disc with a 6
mm fillet weld.

Welds shall be subjected to 100% ultrasonic inspection.

9.9.11 HEAT TREATMENT.

The pulley end discs and shell assembly shall be stress relieved after
welding and before machining.

The stress relief treatment shall conform to the recommendations

of Indian/International Standards and shall include the
requirements for dimensional stability.

Stress relieving shall be carried out under controlled furnace

conditions. A certificate shall be provided stating temperatures, time
and other conditions of the heat treatment.

9.9.12 SHELL MACHINING.

Pulleys shall be machined on the cylindrical belt face, shell edges and
locking element boss faces and journals. Deep scores and tool marks
shall not be permitted.

The stress relieved pulley shell shall be machined so that the pulley
face is concentric with the shaft within 0.75 mm total movement on the
dial indicator.

Shell thickness variation shall not exceed –0 mm + 2.5 mm. The

thickness of the finished pulley shell shall be certified by ultrasonic
testing.

9.9.13 PULLEY LAGGING.

Lagging must be of grooved rubber lagging shall be factory fitted to all

drive pulleys. All other pulleys in contact with the carrying side of the
belt also be rubber lagged.
 Rubber lagging shall be factory vulcanised to the pulleys, have a
minimum thickness of 12mm, and be grade m general purpose natural
rubber with a minimum tensile strength of 24 MPa and a minimum
elongation at break of 450%. The durometer ‘Shore A’ hardness of the
rubber shall be 60 + 5.

Lagging shall be applied in full conformance with the manufacturer’s

instructions.

The lagging shall be capable of developing the required co-efficient of

friction, and transmitting the required driving forces under all conditions
of operation.

Prior to application of lagging, the cylindrical surface of shell shall be

abrasive blast clean. Care should be exercised to protect hubs during
abrasive cleaning. The surface shall then be cleaned with an approved
solvent.

Drive pulleys shall have diamond grooves of “u” shape geometry 8 mm

wide X 6 mm deep on 40 mm normal pitch. Lagging shall be bonded
directly to the pulley face using the hot vulcanizing process.

9.9.14 SHAFT.

Drive shafts shall be machined from grade Indian/International

Standards steel in accordance with Indian/International Standards. All
other pulley shafts shall be machined from grade K 1045 steel in
accordance with Indian/International Standards.

Certificates shall be supplied for all steel used on pulley shafts. All
shafts shall be ultrasonically tested and test certificates submitted.

Pulley shafts shall be designed and machined such that stress

concentration is avoided. Stress concentration induced by locking
element shall be considered in shaft design. If possible, changes in
shaft diameter

shall be made using large radii so that stress raising factor K at the
shaft step is kept below 1.5.

The minimal requirements for machining are stated below.

Concentricity as measured at any
point between bearing centres 0.5 mm TIR*
Surface finish on bearings and seals 1.6 m CLA**
Surface finish on locking element 1.6 m CLA
Surface finish on coupling attachment 1.6 m CLA
Surface finish step radii 1.6 m CLA**
Surface finish elsewhere 3.2 m CLA**
 * TIR – total indicator reading
** CLA – centreline average value

The shaft at each non drive pulley shall be drilled and tapped M20 X 40
mm deep at both ends. The tapping shall be concentric and square to
the shaft axis. Shaft extensions for speed response devices may be
screwed onto this tapped hole.

9.9.15 LOCKING ASSEMBLY.

Approved locking assembly system shall be used to connect the shaft

and pulley drum. The locking assembly shall be installed in accordance
with the locking assembly manufacturer’s recommendations. The
torque used to tighten locking screws shall be recorded on the pulley
name plate.

The torque capacity at shaft locking units used on drive shafts shall be
3 times motor full load torque for the drive side and 1.5 times motor full
load torque for non-drive side.

Locking elements shall be sized such that the transmitted rotating

bending moment does not exceed 35% of the rated torque
transmission capacity or the maximum bending moment guaranteed by
the locking device manufacturer.

9.9.16 BEARINGS.

Pulleys shall be assembled complete with bearings and bearing

housings. The bearings shall be fitted within +1.5 mm of dimensioned
centres and the drive side bearing shall be within +1.0 mm of the
distance from the shaft end. The pulley shall be fitted equidistant from
the bearing. Pulley bearing housings shall be of spheroidal graphite
cast iron to Indian/International Standards.

9.9.17 ECCENTRICITY CHECK.

The final pulley assembly shall be checked for eccentricity. The face of
the pulley shall be concentric with the shaft to within 0.8 mm of the
periphery.

9.9.18 BALANCING

The pulley and shaft assembly shall be balanced to run at belt speeds
up to 6 metres per second without noticeable vibration. The assembly
shall be statistically balanced so that when rotated and stopped at
random, the torque required to commence rotation shall not exceed 2.7
N m.
 Balancing masses shall be equally distributed to each end of the pulley
and their total mass shall not exceed 1% of the pulley mass. The
balancing masses shall be attached so that:

They do not project outside of pulley rim;

They do not form corrosion pockets;
Attachment does not induce stress concentration;

9.9.19 INSPECTION & TESTING

Pulleys shall be subjected to inspection and testing as described in his

specification:

Shell material and finished Ultrasonic tests

thickness
Welding Ultrasonic tests and weld size
Shaft material Ultrasonic test
Machining Dial indicator reading
Balancing Static balance
Lagging Rubber adhesion test
Dimensional check
Visual inspection
Stress relieving certificate

A detailed inspection and testing report shall be submitted.

9.10 CONVEYOR BELTING.

The required length of 5 ply, 1200 mm width N-N belt (20 mm

thickness) shall be supplied by purchaser which are to be used in
boom conveyor belting purposes.

9.11 GENERAL REQUIREMENTS.

SI metric units shall be used on all drawings and calculations.

All machine components shall be designed to operated in a dust-laden

atmosphere. All machine components shall be suitable for high-
pressure wash down.
&
No material containing asbestos shall be incorporated into the works.

9.11.1 TOLERANCES.

Equipment shall be manufactured to the tolerances shown on the

drawings.

On non toleranced dimensions for fabrication, tolerances stated in

Indian/International Standard shall apply.
9.11.2 SURFACE FINISH.

All machine surface finish designations shall be clearly noted on all

workshop drawings in accordance with Indian/International Standards
Part

The Centre Line Average (CLA) method in accordance with AS 2536

shall be used. Surface roughness shall be expressed in microns.

Machining to a specific CLA value shall be verified against a roughness

comparator in accordance with Indian/International Standards.

Where the finish of machined surfaces is not specified, it shall be rough

machined to CLA value of 3.2.

9.11.3 FASTENINGS.

All threaded fasteners shall have metric threads and shall comply with
Indian/International Standards. For normal static applications, bolts
shall be provided with nuts and lockwashers, however, where bolted
connections are subject to abnormal vibrations, locking nuts shall be
used. All bolts, screws, etc., which are assembled up to blind holes
shall be treated with a thread locking compound prior to assembly.

Seating for bolt heads and nuts on unmachined surfaces of machine

part shall be spot faced.

Tapered washers shall be used with tapered sections.

Clearances for fitted bolts are to be in accordance with the relevant

Indian/International Standards.

Special bolts and screws shall be marked to identify the tensile

properties of the material from which they are manufactured.

All bolts and nuts shall be hot-dipped galvanized in accordance to

Indian/International Standards.

Two full threads shall protude through a nut when the nut has been
tightened to recommended torque. In the case of the use of locknuts
sufficient thread shall be available to allow two full threads to protude
after both nuts are torqued up.

9.11.4 FLANGED CONNECTIONS.

All rubber to rubber, rubber to epoxy and rubber to metal mating

flanges shall be coated with Colloidal Graphite at final assembly.
9.11.5 SHAFTING.

Shafts shall be designed in accordance with Indian/International

Standards.

Forged shafts shall prior to machining, be ultrasonically tested in

accordance with Indian/International Standards. The ultrasonic
testwork shall be performed by an authorized testing laboratory as
approved by the Purchaser.

In addition, magnetic particle test shall be carried out in accordance

with relevant standards after final machining. There shall be no visible
defects. Test certificates to be submitted.

9.11.6 KEYS AND KEYWAYS.

All keys and keyways shall be in accordance with Indian/International

Standards.

The grade of key material shall be clearly shown on all drawings.

9.11.7 CASTINGS.

Castings shall be free from blow holes, gas pockets and sand
inclusions. They shall be certified for metallurgical verification. Castings
shall be fitted, cleaned and finished as specified on the drawings.

All castings shall be clearly identified by raised lettering as follows.

Equipment no.

Part no.

Drawing no.

Material

Patterns and core boxes shall be made from first quality and well
seasoned pattern making timber, constructed to permit repetitive use.
All jointing shall be by screwing and not nailing.

All patterns shall be clearly marked with metal stamps showing mark
and drawing number.

9.11.8 PACKERS AND SHIMS.

All packers used in the levelling of equipment or its component parts

shall be made up to the required thickness with a flat surface free of
 indents or burrs. Uncoated new materials only shall be used for
packing.

All shims shall be cut from first class shimming material, free from
indents and burrs and shall give the same bearing area as if no shims
were used. Edges shall not protude from mating surfaces and any
holes shall be de-burred. Not more than 3 shims shall be used at any
one support point and any shim 3mm thick or more shall be of gauge or
machined plate.

9.11.9 ATTACHMENTS.

Lifting lugs, alignment pads and all similar temporary attachments shall
be of the same material as the parent metal.

9.11.10 LUBRICATION EQUIPMENT.

LUBRICANT SPECIFICATION.

All oils and lubricants shall be selected from materials manufactured

and readily available in India.

LUBRICANT NIPPLES AND LINES.

All grease nipples shall be 10 mm button head “Tecalemat” Standard

Hydraulic type or approved equivalent.

All fittings and pressure lines to metering valves shall be stainless

steel. For applications requiring flexibility, double braided rubber hose
shall be used.

All lubricant pressure lines and distribution lines shall be suitably

routed to avoid potential pinch points. All lines shall be supported at
hose connections near bends and at intervals not exceeding 40 times
tube OD. All lubricant lines shall be suitably sized for pressure drop.

AUTOMATIC DISTRIBUTION SYSTEMS.

A centralized automatic lubrication system shall be provided for all

points requiring lubrication at regular intervals. The lubrication chart
should show the duration of intervals for various systems.

Automatic lubrication systems shall be of approved manufacturers. The

outlets per measuring valve block assembly should be limited to 8.

Lubrication systems may be combined as applicable.

Pumps and grease reservoirs shall be located at easy access points
with provision for the replacement of grease to the reservoir from
ground level.

Reservoirs shall contain a quantity of grease to sustain operation for a

minimum period of 200 hours and shall be fitted with a grease level
switch for low level interlock and alarm.

Automatic distribution systems shall consist of an electric operated

pump and metering devices, individual hoses shall be used to distribute
lubricant from the central location.

All lubricating oil pumps, filters, coolers and other such equipment
shall be fitted with well sloped drip trays. All lubricant drain points shall
be located a minimum of 250 mm above floor level.

CENTRALIZED MANUAL LUBRICATION SYSTEMS.

Lubrication points which are not serviced by an automatic distribution

system shall be equipped for centralized manual lubrication.

All lubricant points shall be easily accessible from walkways and

platforms. Small bore steel tubing shall be used if required to bring the
lubrication point to an accessible location. High pressure braided hose
shall be used where necessary to accommodate movement. Where
there are two or more lubrication points on an item of equipment, then
individual hoses shall be used to distribute the lubricant from a central
location. Where there are ten (10) or more individual lubrication points
at one location, a lever operated centralized lubrication system shall be
used. Where there are less than ten (10) lubrication nipples at one
location, individual nipples shall be used, mounted on a central
manifold block.

Each manual grease point and line shall be identified with permanent
markings or labels.

LUBRICATION SYSTEM DRAWINGS.

The lubrication system drawing shall be presented as a lubrication flow

diagram and piping arrangement drawing and shall specify the quantity
and type of lubricant and the lubrication interval required for each point.
For automatic distribution systems, the drawing shall also indicate the
frequency and period of electric motor operation, list of all components.

TESTING OF SYSTEMS.

All lines shall be filled with lubricant and hydrostatically tested at 2 X

operating working pressure without leakage.
9.11.11 CHUTES, LINERS, IMPACT PLATES AND SKIRTS.

CONSTRUCTION.

Chutes shall be fabricated from structural steel plate as per

Indian/International Standards. The minimum plate thickness shall be 8
mm with adequate stiffening.

The minimum valley angle should suit to iron ore. The troughability of
boom conveyor & yard conveyor is 450.

Particular care shall be exercised to design the chute and supports

such that access to belt scrapers is not obstructed and the inspection
of scrapers is possible even during the normal conveyor operation.

Chutes shall be such that the material is directed in the direction of the
outgoing belt with centre of mass of the flow on the centre line of the
outgoing belt. The direction and the speed of material as it lands on the
outgoing belt should match as closely as possible the outgoing belt
direction and speed. Where this cannot be achieved, the angle
between the velocity of material at impact and the outgoing belt should
not exceed 450. The design shall be such that sideways forces are not
imparted on the outgoing belt.

All transfer heights shall be kept to a minimum and the chutes shall be
designed to minimize blockages during handling iron ore fines
especially in rainy season.

The impact face of the chute shall be at least 1000 mm from the face
of the pulley.

Chutes and hoods shall prevent ingress of dust during operation.

Rubber stripped curtain shall be fitted to the inlet of the hood above the
incoming belt.

Head chutes internal width shall be at least 100 mm wider than the
pulley face width.

Head chutes shall have provisions for at least one “chute full probe”.
The probe location shall be carefully selected to be outside of the
normal ore flow and to be actuated only by blockages. The probe shall
be located as low as practical and access shall be provided for
inspection.

Head chutes shall have provision for dust suppression sprays. Head
chutes and circular chutes shall be provided with water pipe lines for on
line sprinkling system to prevent blocking of chutes by iron ore
especially during rainy season.
WEAR RESISTANT LININGS.

All areas in chutes subject to direct impact by the iron ore stream shall
be fitted with rubber liners of appropriate thickness. All other surfaces
of chutes subject to wear by ore flow shall be lined with 16 mm thick
wear, abrasion resistant non-stick liners.

The side skirts shall commence at not less than 150 mm after the first
troughing idler in the direction of belt travel after the tail pulley.

CHUTE ACCESS.

Access doors shall be provided at the pulley discharge level and just
above the skirting. The doors shall be hinged and fitted with a rubber
seal and a locking handle. Minimum size of the access opening shall
be 600 mm high and 400 mm wide.

Access doors shall be also provided for removal of components

installed inside of the chute such as scrapers, liners and other electrical
and mechanical devices.

Inspection openings shall be provided on both sides of the chute for

checking and adjustment of belt scrapers. These openings shall be
arranged to allow for direct view of the blade tips. The openings shall
be covered with rubber flaps attached to the chute with 2 studs.

The openings shall be accessible during normal operation.

SKIRTS.

Skirts shall be provided on all transfer points.

Skirt width at the feed point shall not exceed two thirds of the belt
width. The skirt plates shall be extended at least 3 m from the feed
point in direction of belt travel and if possible, by 0.5 m behind the feed
point to avoid spillage. The gap between the skirt and the belt shall be
tapered opening in the direction of belt travel.

Skirts shall be lined with durable and replaceable liners.

The side skirts shall commence at not less than 150 mm after the first
troughing idler in the direction of belt travel after the tail pulley & the
skirts shall be sealed against the belt by rubber strips clamped to the
bottom edge of the skirt plate. The forward or exit end shall be fitted
with rubber strips cut to conform to load profile on the belt.

Skirt plates shall be fabricated from steel plate adequately stiffened

and supported.
 A suitable adjustable and full length supported clamp type rubber or
synthetic sealing strip of approved make shall be inserted between the
skirt and the belt to prevent spillage. Conveyor belting shall not be
used for this purpose.

Skirts shall be mounted independently of the upper chute.

Skirt clamps shall preferably be a proprietary quick release type.

SHEDDER PLATES.

Shedder plates shall be installed between the carry and return belt
sides of the belt at the following locations.

Conveyor transfers.
Above horizontal take up’s
Above drive pulleys, if pulleys are installed below the carry belt.
Any other location where material can drop onto the return belt.

The shedder plates shall be formed such that when installed they shall
form an angle of 450.

9.11.12 SCRAPERS AND PLOUGHS.

HEAD CHUTE SCRAPERS.

Belt cleaners are required at boom conveyor head pulleys / tail pulleys
shall be furnished with cleaners as conditions dictate.

All cleaners shall be adjustable and be suitable for the easy

replacement of wearing parts.

The head pulley belt cleaners shall be selected from either the
approved make with primary and secondary cleaners located strictly in
accordance with the manufacturer’s recommendations. Scrapings shall
be directed into the conveyor head chute.

RETURN BELT PLOUGH.

Return belt ploughs shall be installed on the top of the return belt in
front of each pulley which receives belting on the bottom of the pulley.
The belting shall be flat in the area of plough installation. There shall be
at least 150 mm clearance in plan view between stringers and belt at
the plough location to allow for exit of the scraped material from the
belt. Ploughs shall be located in areas where fines can be cleaned from
under the belt.

The permissible chain sag shall be clearly marked on the case.

 The chain cases shall be fitted with an oil drain, oil filter point and an oil
level dip-stick.

9.11.13 SAFETY GUARDS.

Guards shall be designed to prevent injury to persons and shall be

provided at every dangerous part of equipment normally accessible to
personnel. They shall be designed to form part of the equipment and
shall not in themselves create hazards.

Guards shall be provided to prevent accidental contact by persons or

parts of clothing being caught in equipment. All guards shall comply
fully with the requirements of the relevant statutory authority or where
no such statutory regulations exist, in accordance with AS 1755.

All sheet metal guards shall be aluminium. All guards shall be painted
safety yellow.

Lifting handles or lugs shall be provided where required for the safe re
removal or opening of guards.

The tops of coupling guards and brake guards shall be readily

removable by hand by one person without the use of tools.

It shall be possible to inspect brakes for adjustment, lining wear, etc.

without prior removal of brake guards being necessary.

Nameplates, warning signs or other data affixed to drive components

shall not be obliterated or covered by parts of the guards.

Where removal of the guard is infrequent for inspection or maintenance

purposes, it shall be fixed in position so that it cannot readily be
removed without the use of tools.

Fixed guards shall be provided where the equipment can be serviced

without the removal of the guards. Removable guards or removable
inserts to fixed guards shall be installed where normal maintenance,
“V” belt tension, inspection or cleaning is carried out. These shall be
installed in a manner acceptable to the relevant Statutory Authorities
and shall be clearly labelled “DANGER – ISOLATE DRIVE BEFORE
REMOVING GUARD”.

Design and Construction of guards, personnel reach dimensions and

acceptable distances between guards and danger points shall be as
defined by relevant standards or statutory requirements.

Where required for inspection or maintenance purposes, hinged

inspection doors may be provided in the guard, hinged in such a way
 that there will not be a tendency for the door to be left in the open
position.

Guards shall provide for tachometer access to rotating shafts.

Guards with any dimensions in excess of 1800 mm shall be easily

assembled in component parts that do not exceed 60 kg mass. All
component parts of the guard shall interlock together to form a rigid
and safe assembly.

Guards on conveyors shall be designed, constructed and installed in

accordance with AS 1755. Conveyors – Design, Construction,
Installation and Operation – Safety Requirements.

Solid sheet metal guards shall be provided for all fluid couplings which
are provided with fusible plugs. A catch tray having a capacity of at
least 125% of the maximum fluid capacity of the coupling shall be
provided on the opposite side to the fusible plug.

Other sheet metal guards shall be provided with at least one mesh
panel at the upper part of the guard to allow ventilation and inspection
of the guarded components. Location of this panel shall not allow water
drip or splash to enter the guard. Vee belt guards shall have solid
edges and mesh sides to ensure Vee belt ventilation.

9.11.14 SAFETY AND IDENTIFICATION SIGNS.

Safety and identification signs shall be placed on all equipment,

conveyors and work areas. All signs shall be painted on 2.5 mm
minimum thickness brass or stainless steel sheet.

Identification signs shall be black lettering (minimum of 50 mm high) on

a white background. Each item of equipment shall be clearly identified
with a minimum of two signs.

All equipment and work areas shall have signs for :

Hearing protection.
Warning that equipment may start without notice.
High voltage.
Eye protection.
Other safety signs as required.
9.12 HYDRAULIC SYSTEMS.

9.12.1 GENERAL.

Hydraulic systems shall be designed to operate in a highly abrasive

dust-laden atmosphere. All equipment shall be suitable for high-
pressure wash down.

The equipment shall be of standard design selected to meet the

specified operating conditions with special emphasis on safety,
efficiency, reliability and maintainability. Components (eg. Pumps,
valves, pipe fittings, instrumentation, bearings and the like) shall be
manufactured or readily available in India.

Hydraulic components shall be arranged so that maintenance and

servicing can be done safely and conveniently.

In order to ensure long life of equipment, it would be preferred to keep

the working pressure below 300 bar .

The design of hydraulic systems shall provide for smooth movement of

hydraulic activators (pumps, motors, cylinders), free from sudden stop
and start effects and be capable of either continuous or stop/start
operation. The circuit shall be designed to prevent uncontrolled
movement of hydraulic actuators at any time.

Maximum use of hydraulic manifolds with subplate-mounted valves

shall be made to minimize the use of hydraulic pipe/hose runs.
Hydraulic manifolds and connections between the individual items of
equipment within a unit shall be shop assembled.

Air bleeds shall be provided at all points where the system shall need
to be bled.

Hydraulic circuits shall be designed and manufactured to minimize

surge pressures. Components shall be designed to withstand such
surge pressures.

Hydraulic circuits containing accumulators shall be designed for safe

operation and maintenance. The design shall make provision for
isolation of the accumulators and release of stored energy.

Careful attention shall be given to circuit design to the possibility of

pressure intensification across hydraulic cylinders. Where this is
considered a possibility, means shall be provided to prevent this from
occurring, during operation or maintenance.
 Equipment shall be air cooled unless otherwise approved. Fluid
temperature shall not exceed 600C at the pump inlet or 700C elsewhere
in the circuit.

The system capacity shall be sufficient to maintain hydraulic oil

temperature within the hydraulic oil manufacturer’s recommended
range at continuous full load while operating at maximum ambient
temperature.

9.12.2 HYDRAULIC PUMPS.

All variable displacement pumps shall be of the axial piston type

and fixed displacement pumps shall be of the gear type. All pump
bearings shall be of the anti-friction type and pump speeds shall
not exceed 1500 rpm.

Pressure relief valves shall be incorporated in the body of the pump or

shall be manifold mounted on the pump. Relief valves shall be
capable of passing the full pump capacity at a pressure not
exceeding 15% of the set working pressure.

Each pump assembly comprising a foot mounted electric motor, flexible

coupling and pump on a common base frame shall be mounted on
vibration dampeners.

9.12.3 HYDRAULIC DRIVE MOTORS.

Hydraulic Drive Motors shall be either of the axial piston or rotary vane
type. They shall be balanced and have a high efficiency over the full
specified speed range.

9.12.4 HYDRAULIC CYLINDERS.

Hydraulic cylinders shall be fitted with progressive cushions at both

ends, preferably with stepped spear cushions.

Hydraulic cylinders shall be of heavy duty repairable construction.

Piston rods shall be hard chromed to 60 mic, induction hardened

medium carbon steel or stainless steel.

The piston and gland shall be fitted with non-metallic bearings.

The cylinder shall be fitted with high efficiency, low friction seals and a
heavy duty non-split wiper seal.

Cylinders shall show no stick-slip effect.

 The cylinder shall be provided with flexible covers to protect the rod
from dust and water when extended.

Cylinder mountings shall utilize spherical plain bearings which shall be

protected by Taconite type seals where the pin diameter is greater than
100 mm.

The minimum pressure rating shall be 25% above the specified

working pressure of the system. The rating shall be based on a
factor of safety of 4.1 on the Ultimate Tensile Strength (UTS) of
the material at the weakest section. Material stress calculations
shall be supplied when requested.

Cylinders shall be proof tested to 1.5 times the rated maximum

pressure. No external leakage shall be permitted during the test. After
completion of testing, cylinders shall be filled with standard mineral
base hydraulic oil except where butyl or ethylene propylene seals are
used, in which case tests shall be with phosphate-ester oil.

No stress from the fixing points or from the pipes must be allowed to
cause distortion or misalignment of the cylinder or its components.
Cylinders and actuators shall generally be connected to associated
pipework by flexible hoses.

Cylinders low pressure sides shall be individually connected to the

tank.

Cylinders and actuators shall be accessible for servicing, cushion

adjustment, bleeding and fitting connections.

Cylinder mountings shall be designed and manufactured to ensure that

the unit cannot vibrate or work loose during operation. Items, such as
clevis ends screwed on to cylinder rods, shall have provision for
positive locking.

9.12.5 VALVES.

Valves in any part of the hydraulic system shall be suitable for heavy
duty service and shall have a minimum working rated pressure.

Relief valves shall be incorporated into the body of pumps. Relief and
control valves shall be manifold mounted with a minimum number of
external pipe connections. Air bleed points shall be readily accessible.

Valves which might be damaged by exposure to dirt, dust or

environment shall be adequately protected.

Pressure relief valves shall be adjustable to suit system working

pressure. Relief valves shall be sized to pass full pump capacity at
 115% of set working pressure. Relief valves shall be of the direct acting
type.

Safety valves shall be provided in the hydraulic circuits which include

accumulators. These valves shall be tested in the manufacturer’s
factory. The valves shall be set at the factory and their compatibility
with the hydraulic fluid to be used, checked. The valve setting shall be
then sealed so that they cannot be set to higher pressures. These
valves are normally fitted to the hydraulic accumulators. They shall be
self operating. The pressure setting of the valve shall not exceed 110%
of the operational pressure of the accumulator. The accumulator safety
valves should not be designed to operate during the normal operation
of the hydraulic system. The pressure should therefore be set
sufficiently far above the permissible excess pressure of the hydraulic
system. The valves shall be designed with an allowance for full pump
flow.

All valve spools shall be pressure balanced. It shall not be possible to

inadvertently cause spool movement by pressurization of the tank line.

Manually adjusted relief, unloading or pressure control valves shall

have pressure gauges in order to facilitate the required setting
adjustment and checking.

Ball type valves shall be used for shut off applications.

Control valves shall be internally drained. Internal leakage drain

connections shall be separately piped to the reservoir or to a common
manifold provided for that sole function.

Unloading valves shall have an inherent relief characteristic to ensure

protection in the event of the pilot line failing to provide a pressure
signal.

Solenoid operated directional valves shall have indicator lights on the

valve terminal box.

Pilot operated directional control valves shall allow for manual

operation of the pilot spool.

Directional control spool valves shall be mounted horizontally and on

the top or on the side of panels or manifolds. Spool valves shall not be
mounted upside down or vertically.

9.12.6 VALVE PANELS.

Layout of valves and other components on valve panels shall be

generous to ensure good access to all control and pipe connections.
 Valve panels shall not be attached to the reservoir to prevent
congestion in this area and render maintenance difficult.

It shall be possible to remove individual pipe runs from valve panels

without disturbing others. All pipe work nuts shall be accessible with
standard spanners.

Valve panels shall be of rigid design. They shall have a suitable trough
on both sides to retain small leaks and spillage from the subplate
mounted valves. The trough shall be fitted with a plugged drain.

Piping between the pumps and valve panel, interconnecting piping

between the valves and the piping from the valves to the supply
manifold, shall be in steel tubing and steel fittings.

9.12.7 POWER PACKS.

The power pack shall be designed for continuous 24 hour per day
operation.

Each hydraulic power unit shall be designed as a self contained pack

complete on a fabricated steel frame with 300 mm support legs and
provided with conveniently located connections for external services
such as electric power and compressed air (if required).

Power packs shall be fully enclosed with removable hinged doors on at

least two sides of the power pack, ventilation, including easily
replaceable and washable air filters shall be provided. Forced
ventilation should be avoided. Fluorescent lighting shall be provided
inside the power pack and any electrical enclosures.

Equipment shall be laid out in a logical manner with due regard to

access for maintenance and equipment removal.

The power pack shall include the following.

♦ Hydraulic oil tank.

♦ Pumps and motors mounted on a common baseplate and arranged for
easy access for maintenance.
♦ Control valves mounted on manifold or valve panel.
♦ Interconnecting stainless steel tubes and stainless steel tubes and
stainless steel fittings.
♦ Fans and heat exchangers, if required.
♦ Accumulators, if required.
♦ 150 mm deep drip tray. This sump shall incorporate a sloping bottom
plate. The sump shall be fitted with a drain valve and hose adaptor.
♦ Lifting lugs.
♦ Sun roof.
♦ Control panel on which local start and stop controls shall be mounted,
together with indicating alarm instruments.
♦ Instruction panel showing the hydraulic circuit and operating
instructions. The hydraulic circuit diagram shall include operational
pressure settings for pressure switches, relief valves and circuit flow
rates. The panel shall have a smooth, durable, heat and oil-resistant
plastic surface. The panel shall be screwed or riveted in position.
♦ Interconnecting wiring, flexible, oil resistant and properly labelled.
♦ Return filters.

Prior to assembly all components shall be checked for soundness of

welds, joints, etc. After assembly the complete power unit shall be
flushed with an approved cleansing solvent to remove all foreign
materials and other debris from manufacturing.

The unit shall then be tested for pressure tightness of all hydraulic
circuits and components. Details of the procedures to be adopted in
cleaning and testing of the equipment shall be as per Quality Control
Plan.

9.12.8 OIL TANKS.

The oil tank shall be of robust construction to AS 1692. The tank

bottom shall be sloped to the drain side. The tank top shall be designed
to drain freely and to avoid accumulation of oil or extraneous spillage.
The tank shall be an integral part of the power pack, and shall be
positioned so the pump suction is flooded at all times. The pump
suction shall incorporate an isolating ball valve and limit switch.

Bolted and gasketed access panels shall be provided in the top of the
tank for inspection and cleaning. Internal surfaces shall be blast and
leak tested prior to surface treatment.

Equipment supplied with the tank shall include, but not be limited to,
the following items :

Internal baffles.
Low oil level float switch.
Oil temperature gauge.
High oil temperature switch.
Magnetic drain plug or suspended magnet.
Oil level sight gauge showing maximum and minimum levels.
Drain fitted with ball valve and hose adaptor minimum 25mm
diameter.
Fill point with quick connect coupling and filter.
Oil sampling test points.
 Oil tanks shall have a minimum capacity of at least three times the flow
rate per minute of the pump, plus any demand from cylinders or
accumulators.

Tanks shall be completely sealed and fitted with air filter (10
micrometer)/breathers (35kPa)

Magnetic plugs supplied shall be readily accessible and positioned to

prevent collected particles re-entering the tank on removal of the plugs.
The required service, the frequency and method of removal of the
plugs shall be clearly indicated adjacent to the magnetic plugs.

9.12.9 ACCUMULATORS.

Nitrogen charged diaphragm type accumulators shall be used.

All materials used in the accumulator manufacture shall be compatible
with the hydraulic oil specified. Pressure rating of the accumulator shall
not be less than 200 bar. Accumulators shall be supported so as not to
impose any load on connecting pipework.

The design and manufacture of accumulators shall be in accordance

with Indian/International Standards, and approval certificates shall be
submitted.

Pressure relief facilities shall be provided.

Accumulators shall be stamped with their serial number, pressure

rating and test record details.

All necessary regulators, gauges, valves, fittings and flexible pipes to

enable the testing and recharging of accumulators from standard
nitrogen bottles shall be provided.

Accumulators shall be sized to have a volume of 50% in excess of the

theoretical design working volume.

9,12.10 FILTERS.

A full flow filtration system shall be provided for the hydraulic oil. Filter
elements shall be of the renewable catridge type and shall be provided
with easy access for cleaning and catridge replacement. Filter
elements shall be a minimum of 10 microns.

Filters shall be fitted with visual indication in case of blocked condition.

Removable drip trays and isolation valves shall be provided where

necessary to prevent oil loss during filter replacement.
 A high pressure filter shall be provided on the main pump discharge
line.

A low pressure filter shall be provided on all return lines to the tank and
shall be mounted external to the tank to enable ready access.

Filter ratings shall be at least twice the system flow, taking into
consideration the resistance to flow caused by cold oil and
contamination.

All filter systems shall be designed and located to minimize the entry of
foreign material into the hydraulic system during service or inspection.

If an oil cooler is required, the return line filter shall be placed before
the cooler.

Duplex filters shall be provided on systems which require uninterrupted

operation.

Filters shall be provided for all fill points to ensure that contaminated oil
cannot be added to the system.

9.12.11 PRESSURE GAUGES.

Gauges shall conform in all details to Indian/International Standards.
Pressure gauges shall indicate system pressure in the main pressure
lines and the boost pressure lines, where a boost pump is installed.

Gauge cases shall be of corrosion resistant materials and of moisture

and fume proof construction. The dials shall have white faces with
black figures and pointers. Gauges shall have provision to reset the
pointers.

Gauges shall be 150 mm diameter, oil filled type and shall be

calibrated in bar and psr as appropriate. The operating pressure range
shall be clearly marked on or adjacent to the gauge.

Gauges shall be protected against severe pulsation by coil type

snubbers, except for vaccum or compound gauges.

Gauges shall be mounted vertically and they shall be fitted with a push
to read gauge valve. Manual isolation ball type valves shall be fitted on
the pressure side of the push to read gauge valve.

Gauges shall be clearly visible from the valve panel.

Tapping points shall be provided in drain and return lines for temporary
connection of pressure gauges during commissioning.
9.12.12 OIL COOLERS.

Air blast oil coolers shall be provided to keep the oil temperature within
the limit specified for an ambient temperature of 450C.

Oil coolers shall be installed on the return pipework and a bypass valve
and isolating valves shall be fitted.

The cooler shall be mounted outside the hydraulic power unit, and shall
include sun, dust and safety covers. An easily accessible and
cleanable insect screen shall be installed at the suction side of the
cooler.

Oil coolers with fans shall be supplied complete with motor,

thermostats, switches and power supply junction box.

9.12.13 PIPES, HOSES AND FITTINGS.

HYDRAULIC PIPING.

The term piping shall include all pipe and tubing.

Cross-sectional area of all piping shall be sufficient to prevent

cavitation, undue temperature rise and to minimize turbulence.

Pump suction pressure shall not exceed – 10 bar. Fluid velocity in

suction lines shall not exceed 1.25 m/s. Fluid velocity in pressure lines
shall normally not exceed 5 m/s. Calculations for pressure losses shall
be based on an ambient against hydraulic shock.

The strength of the piping shall be adequate to withstand the maximum

rate of surge pressure rise and the maximum surge peak pressure at
the frequency developed by the cycling of the equipment operation.
Only stainless steel seamless tubing shall be used.

Pipe connections shall be designed sized and located to ensure correct

operation of actuators remotely piloted controls and similar fluid
operated devices. Mountings and clamps shall be rigid to eliminate
vibration and chattering where this may be detrimental to operation.

Piping runs shall be as direct as possible with a minimum number of

bends. They shall, however, be neat and functional both from a design
aspect and maintenance requirement. Allowance shall be made for
expansion and contraction of lines as required.

The piping shall be designed for a pressure equal to the pressure relief
valve setting multiplied by a safety factor of 2.
All tubes shall be clamped to supporting steel at spacings not
exceeding 50 times OD for straight lines and at each side of a bend.

Air vents for bleeding shall be provided in suitable readily accessible

locations. The bleeding sequence shall be recommended in the start-
up instructions.

Piping should be bent in preference to elbows, the minimum radius of

the bend being 2.5 to 3 times the outside diameter of the tube for
carbon steel and 3.5 times the outside diameter for stainless steel.
There shall be no reduction in cross section of the piping at the bend.

Piping runs shall be placed such that they do not collect spillage or
interfere with adjustment repairs or replacement of controls or units. All
connections shall be readily accessible for maintenance.

Each piping run shall be integral and continuous between components.

Couplings shall only be used where necessary for long pipe run
lengths. Piping runs shall be removable without dismantling equipment
components.

All pipe fittings, oil passages, cored holes or drill holes shall be free of
burrs or foreign matter which might cause damage to any hydraulic
unit, or contaminate the hydraulic oil. Piping shall not be cut by oxy-
acetylene torch or similar method.

After fabrication, all pipe work and fittings shall be mechanically

cleaned and then pickled in accordance with Indian/International
Standards. The pickling process shall include degreasing, desclaing,
neutralizing and finally drying with an appropriate anti-rust solution.
Immediately before charging the system, all pipes, tubes and fittings
shall be thoroughly flushed with a suitable decontaminating solution.

FLEXIBLE HOSES.

Flexible hoses shall be provided between piping runs, hydraulic

motors, cylinders, etc. The hoses shall be designed for working
pressure not to exceed 25% of the burst pressure.

Flexible hose, tubing or pipe shall be to the following general

requirements.

• Fittings shall be either swaged or re-useable.

• The material of the hose bore shall be compatible with the
hydraulic oil specified.
• All hoses shall be assembled and mounted in accordance with
the hose manufacturer’s recommendations i.e. bend radii shall
always be greater than the manufacturer’s nominated minimum,
 there shall be no chafing, twisting and hoses shall only flex in
one plane.
• Vertical terminations are preferred. Horizontal connections are
acceptable only if flexible lines are adequately supported.
• All fittings shall be of steel suitably protected against corrosion
and shall have a factor of safety of 4:1 based on yield strength
calculations. JIC fitting shall be preferred.
• Hose lengths for similar installations shall be the same wherever
possible, to keep spares requirements to a minimum. Hose
lengths from tip to tip of fittings shall be selected from the
following range 300mm, 500mm, 600mm, 900mm, 1000mm,
1250mm, 2000mm, 2500mm, 3000mm, 5000mm. The pipes
shall be terminated to ensure correct hose installation for these
hose increments.
• Each hose shall have at least one straight female (swivel) hose
end. No hose shall have two elbows or other such ends.
• No adverse restriction on flow or high pressure drop conditions
shall be tolerated from hoses or hose fittings.
• Hoses shall have armour protection such as wire braid, when
exposed to possible damage.
• Preferred hoses for all installations are SAE 100R2. Duffield
D900 or Stratoflex 4252 shall be used for phosphate-ester
systems. High pressure systems shall utilize SAE 100 R10 or
SAE 100 R11 and the preferred hose is Duffield D400 or D1200.

PIPE CLAMPS.

Piping shall be adequately supported to minimize vibration or

movement.

PIPE FITTINGS.

Fittings with tapered threads will not be accepted.

9.12.14 ELECTRICAL EQUIPMENT.

All electrical equipment shall comply with the requirements of

Clause 10.0.

The manufacturer shall install all electrical wiring between the various
items of equipment which are mounted on the power pack unit and in
the control cabinet. Power and control electrics shall terminate in an
electrical cabinet on the power pack. The cabinet shall be sealed to IP
65 standard.

The electrical system shall have provision for local control of the power
pack for maintenance purposes and remote control for normal
operation. There shall be three terminals for each solenoid (one spare
for looping if required).
 All items of electrical equipment shall be selected from the list of the
preferred equipment.

9.12.15 CONTROLS.

GENERAL.

Over-pressure protection shall be provided on the discharge side of all

pumps.

Adjustments on pressure control units shall be accessible during all

operational conditions.

All pressure and volume controls shall be constructed so that they are
not adjustable outside their normal safe working ranges. All pressure
controls shall be marked to indicate minimum and maximum operating
pressures. Adjustable valves shall be arranged so that the adjustment
can be locked or sealed.

Controls shall be located and protected to protect inadvertent

operation.

Controls shall be protected from damage by moving equipment or

falling objects.

Controls shall not be placed in high heat areas, detrimental or corrosive

atmosphere unless adequately protected.

On vertical or inclined cylinders, means shall be provided to prevent

rapid drop when hydraulic power is shut off. Complete locking of
cylinders shall be provided if slow movement would result in danger or
damage.

Where there is more than one hydraulically or manually controlled

device on any industrial equipment and where possible damage may
be caused by the failure of any one device to function properly, the
circuits shall be arranged with protective interlocks. When practicable
these interlocks shall interrupt all operations, provided such
interruptions shall not constitute a hazard to personnel or cause
damage to the equipment or work in process.

Electrically controlled hydraulic devices shall be applied in such a

manner that in the event of electrical circuit failure there will be no
damage to the equipment or danger of injury to personnel.

Circuits having two or more cylinders shall be designed to ensure that

all units operate in proper relationship, regardless of load variations.
 Sequence control by pressure switches alone shall not be used to
determine sequence of operations, except where the function of the
operation demands the use of such devices. Sequence shall be
primarily governed by mechanically actuated limit switches, hydraulic
valves or other position sensing devices.

Plunger type controls shall be drained to reservoir or vented to prevent

malfunction.

Hydraulic pumps shall stop automatically under the following

conditions.

♦ Loss of oil pressure.

♦ Excessive oil pressure.
♦ Operation of the EMERGENCY STOP.
♦ Excessive oil temperature.
♦ Low oil level.

Oil coolers shall start automatically on high oil temperature.

The following devices shall be provided at each power pack and should
be clearly visible and where applicable, easily operated with the power
pack cover in position :-

• Indicators:
Excessive oil temperature
Low oil level
Clogged filter indication

• An oil level indicator

• An oil temperature indicator
• An emergency stop push button.

The electrical system shall have provision for local control of the power
pack for maintenance purposes and remote control of hydraulic
devices for normal service.

PRESSURE SWITCHES.

Pressure switches shall be provided to limit the system pressure and

where necessary to ensure adequate boost pressure.

Pressure switches shall be of rugged construction suitable for industrial

environments.

Pressure switches shall have seals and relevant components

compatible with the hydraulic oil specified.
 A gauge tapping. 3/8 inch BSP shall be located near the pressure
switch to enable settings to be tested.

The external drain hole shall never be plugged.

The external drain line shall flow direct to tank, shall not be connected
to other return lines and shall be sized to ensure that back pressure
cannot affect switch settings. The back pressure can also cause teflon
diaphragms to fail. The minimum size of line shall be 6 mm bore and
the length shall not exceed 3m.

9.12.16 SURFACE TREATMENT.

Power packs, hydraulic components and hydraulic piping shall

be surface treated and colour coded, as specified.

9.12.17 EQUIPMENT IDENTIFICATION.

‘Traffolyte’ nameplates, or approved equivalent, with black lettering on

a white background shall be used to identify all components and
specify settings within the power packs and system. These shall
include relief valve settings, accumulator charging pressure, oil type,
direction of rotation, direction of flow, gauge identification and bleeding
procedure. Lettering shall be a minimum height of 8 mm. Nameplates
shall be screwed or riveted in position adjacent to the component.
Adhesive nameplates or lables shall not be used.

9.12.18 INSPECTION AND TESTING.

The hydraulic equipment shall be completely assembled and shop

tested prior to transport. All testing will be witnessed.

Shop running tests shall be carried out by connecting the power pack
to the hydraulic equipment with a piping run equivalent to the installed
condition or an equivalent hydraulic test load.

The hydraulic systems shall be given a complete functional check after

fully bleeding the hydraulic system. The systems shall be inspected for
leaks. All bearings, motors, pumps and other moving parts shall be
monitored for abnormal vibration, noise or free play, excessive
temperatures or inconsistent operation.

The hydraulic equipment shall be pressure tested to the relief valve

setting during which all seals and joints shall be checked for leaks. The
test pressure shall be applied for a minimum of 3 minutes after the
system has reached operating temperature. Any leakage shall be a
cause for rejection with subsequent correction and re-testing to follow.
 After operating temperature has been reached, the hydraulic drive
system shall be tested by running for a continuous period of not less
than 4 hours. During this test the system shall be subjected to
maximum rated flow and working pressure for a number of operating
cycles as nominated.

Instruments shall be provided to measure the hydraulic oil temperature

during the test 0 temperature in the tank shall be recorded at 15 minute
intervals for the first 2 hours and 30 minutes intervals thereafter. Oil
temperatures shall not exceed 700C.

After testing and before packing the power pack and other hydraulic
components shall be drained of hydraulic fluid and flushed with an
approved corrosion inhibitor. All openings, reservoir fillers and external
pipe connections shall be plugged or capped to effectively prevent
entry of moisture or other contaminants.

9.12.19 PACKING FOR TRANSPORT.

After testing of the hydraulic equipment, the system shall be drained of

all oil. The filters shall be removed and inspected. Re-usable filter
elements shall be cleaned. Throw away filter elements shall be
replaced with new elements.

Power packs shall be shipped as fully assembled units. It shall be

ensured that all components are correctly aligned and fixed in position,
all exposed connections are suitably sealed and protected. All items
shall be prepared for transport in accordance with the specified
requirements of technical specification.

10.0 ELECTRICAL REQUIREMENTS.

10.1 GENERAL

Power supply to the Reclaimer shall be taken at 3.3 kV from a

termination point at the mid-point of the machines travel A 3.3kV
reeling cable shall feed power from this mid-point to an on-board cable
reeler. The power derives from an impedance earthed 3.3kV system
with earth fault current limited to 400 Amps.

A 3.3kV cable from the reeler shall feed a 3.3kV vacuum circuit breaker
for the on-board dry cast resin 3.3kV/415V transformer.

The on-board 3.3kV/ 415V transformer shall comply with the

requirements of the relevant IEC Standard.

The point of common coupling shall be the cable reeler 3.3kV

termination point, where the actual fault level is nominally 50MVA.
 The power supply limits at the point of common coupling shall be :-

Voltage variation + 10%

Frequency variation + 4%

Using the above figures the voltage variation at the motor terminals
shall not vary more than 10%.

10.2 SWITCHGEAR.

The 3.3kV and 415V circuits shall be controlled from physically

separated panels.

The switchgear and control gear cubicles shall be naturally ventilated

and located within a switch room enclosure and shall comply with the
requirements of relevant Standard Specification.

Devices with high levels of heat dissipation such as power transformers

and motor resistor cubicles shall be mounted outside the switch room
enclosure and be equipped with sunshields.

10.3 3.3kV SWITCHGEAR.

An on-board 3.3kV vacuum circuit breaker shall be provided to

control and protect power supply to the on-board dry cast resin
3.3kV/415V transformer.

If the unit is installed outdoors, it shall be enclosed in an IP 65 rated

enclosure.

10.4 HARMONIC GENERATION.

The mobile machines shall comply with the requirements relevant I.S.
to minimise disturbances in mains supply networks by limitation of
harmonics caused by industrial equipment.

10.5 VOLTAGE DIPS AND HARMONICS.

The maximum voltage change at the 3.3kV busbar under motor starting
conditions, shall not exceed 10%.

Voltage transients on board the Machines shall not cause gas

discharge lighting to extinguish nor decrease lamp life. It shall be
assumed that lamps extinguish at 85% of nominal supply.
10.6 VOLTAGE LEVEL UTILISATION.

Voltage levels on distribution busbars on the machine during both

steady state conditions and transient conditions (such as motor
starting) shall not affect the normal operation of other devices
connected to those busbars.

10.7 ELECTRONIC EQUIPMENT POWER SUPPLY.

Electronic based equipment such as Programmable Logic Controllers

(PLC’s). Visual Display Units and Computer type equipment shall be
fed from a constant voltage transformer.

10.8 ELECTRICAL CONTROL VOLTAGES.

The relay, control logic and indication voltage shall be 48V DC with 5%
maximum ripple. The supply shall be derived from a voltage regulated
rectifier and shall be designed such that the output voltage cannot
exceed 60V DC under fault conditions. A common supply shall be used
for both the PLC and Motor Control Centre control circuits.

10.9 EQUIPMENT RATINGS.

All equipment shall be rated in accordance with the fault levels

specified.

As evidence that the equipment proposed and installed complies with

this requirement, the supplier shall provide :-

♦ Certified Test Certificates of a Registered Authority for all proprietary

components not specified in the approved list of proprietary items but
connected to the busbar system.
♦ Calculations substantiating the location of busbar supports or certified
Test Certificates of a Registered Authority stating the busbar system
offered has withstood the MVA specified fault level.

10.10 CABLE REELER/SLIP RING ASSEMBLIES (POWER CRD & CONTROL

CRD).

Each reeler shall be fitted with a slip ring assembly mounted at the
apposite end of the reeler from the drive mechanism.

Slip ring enclosures shall be vermin proof and have IP65 degree of
protection.

All cores within the cables shall be terminated at insulated slip rings
including :-
 ♦ The earth in the power cable and
♦ The cable earth and common signal earth for any
individually screened cores in the control cable.

The power cable slip rings shall be suitably segregated, with phase
barriers, if necessary to prevent any chance of a phase to phase short
circuit.

The slip ring assemblies shall have different inspection openings to

allow maintenance checks to be carried out.

All access doors into slip ring chambers shall be provided with a wire
reinforced glass insert for inspection and shall be locked by a Castell
key.

10.11 TRAILING CABLES.

Copper cored communication cables shall be supplied to provide

enough cores to satisfy the on-board requirements for telephone and
control system communication functions as well as the statutory
required hardwired interlocks.
The conductors in the power cable shall be copper and the voltage
drop in the incoming cables shall not exceed 2% of the nominal voltage
under full load conditions. The conductor insulation will be EPR ( Type
IE 3 to IS 6380/ 84 ) and sheath insulation will be black HD HOFRCSP
( Type SE 4 to IS – 6380/ 84 )

The cores supplied for the control functions will be screened stranded
copper conductors.

The power cable core insulation shall be colour coded, that is :-

♦ Power conductor insulation to be red, yellow and blue

according to the phase.
♦ Semi conductive elastomer insulated Earth conductor
insulation to be black.
♦ Earth core should be black.

10.12 CABLING.

All power cables shall have aluminium conductors unless otherwise

approved.

All cabling shall be mechanically protected throughout its length either

by enclosing in metal conduits and/or cable tray, or by utilising steel
wired armoured cables. All cable trays shall be heavy duty marine
graded aluminium.
10.13 EARTHING.

All pin joints and bearing joints shall have a flexible copper earthing
strap across the joint.

The flexible copper earthing strap shall be bolted to welded flanges on

either side of the joint and the complete installation shall be
equipotentially bonded.

10.14 EARTH SHOES.

The Reclaimer shall have two earthing shoes connected on two of the
support legs on opposite sides of the machine and they shall be
positively held to the travel rails. These rails shall be bonded to the
plant main earth grid. The earthing shoe shall be softer than the rail.

10.15 GENERAL POWER.

Two 100 Amp. 415V, 3 phase welding outlets shall be provided on the
machine one adjacent to the central chute and one in the vicinity of the
end of the boom.

A suitable number of 10 Amp 240 V AC earth leakage protected dual

socket outlets shall be provided such that no point at the same floor
level is more than 10 m (cable route) away from an outlet. A minimum
of two 240 V AC dual sockets shall be installed in both the lectrical
switchroom and in the control room.

Both the welding outlets and the general power outlets shall suit
standard Indian plugs.

10.16 LIGHTING.

High pressure sodium flood lights shall be supplied and installed to

provide a minimum lighting level of 100 lux over all stairways and
walkways and a lighting level of 30 lux over all machine working areas
such as discharge points and stockpile reclaim surface and bucket
wheel. The light fittings illuminating the machine operating surfaces
shall be readily accessible for adjustment, cleaning and lamp
replacement.

The machines shall be equipped with fluorescent lighting for access,

operation and maintenance with a minimum lighting level of 70 lux.

Lighting in the mobile machine switchrooms shall be a minimum of 150

lux. Lighting levels in the mobile machine control room will be a
minimum of 200 lux while the control desk will be a minimum of 300
 lux/ Lighting in the machine control rooms shall be capable of being
dimmed with no obvious flicker apparent to the operator.

Emergency lighting bulkhead fittings shall be supplied to ensure a safe

exit in the case of power failure.

All fittings shall be weatherproof and able to withstand direct hosing.

Access walkways clearances shall not be less than 2.5 metres from all
overhead structures.

10.17 EMERGENCY LIGHTING.

Fittings shall be of weather and dustproof construction and consist of

cast aluminimum body with polycarbonate diffuser, 1 X 13 W
fluorescent tube, integral transistorized control gear, charger and 24 V
battery in case of power supply failure. The battery shall be able to
supply power to the fluorescent tube for a minimum of 1.5 hours.
Perofrmance, construction and location shall also be in accordance
with an equivalent standard to Indian Standard Emergency evacuation
lighting in buildings – Design and installation”.

10.18 COMMUNICATIONS.

The Supplier shall allow sufficient space of no less than 1 m 3 within the
mobile machine control room for the installation of radio equipment and
antenna by others.

10.19 LOW VOLTAGE SWITCHGEAR AND CONTROL ASSEMBLIES.

Low voltage switchgear and control assemblies shall comply with

relevant Indian Standards.

Circuits shall be protected by circuit breakers and not combination

switch fuse switch units.

Due to the potential for flexing of the switchroom enclosure on mobile

equipment, withdrawable functional units shall not be used.

The assemblies shall comply with the following requirements.

• Motors 55kW and above shall be protected by a suitable

microprocessor based motor protection relay & bi-metallic
thermal over load protection as backup.

10.20 MOTORS.

All motors shall be 415 V, 3 phase.

 All motors larger than 50kW shall be equipped with anti-condensation
heaters. Motors greater than 50kW and below 200kW shall have inter
winding thermistors which shall be connected to the control circuit.

Each motor shall have local station i.e. a local start/ lock-off-stop
station which will act directly on the control circuit.

The main drive motors shall have not and lug terminations. Camlock
terminals will not be accepted. All motor connections must be clearly
stamped to show the connections and the markings must relate to the
drawings.

AC motors shall be in accordance with relevant Indian Standards and

shall be as a minimum.

♦ Squirrel cage, totally enclosed fan cooled (TEFC) with an IP 55

minimum enclosure.
♦ Of cast iron construction
♦ 4 pole unless approved otherwise.
♦ Ball and roller bearing mounted unless otherwise approved.

For variable speed AC motors, the motors shall be rated with due
regard for reducer cooling effects at the lowest value of specified
steady state speed.

All motors and drives shall be sized such that the required torque
produced by each drive does not exceed 100% of the rated drive
torque for longer than 10 seconds.

10.21 HARDWIRED INTERLOCKS.

The following hardwired interlocks shall be provided as a minimum.

♦ Emergency stop push buttons ( lockable type )

♦ Pull wire switches (balance type)
♦ Ripped belt detection.

The hardwired interlocks shall be wired directly into the conveyor

control circuit and where activated shall isolate the power supply to the
conveyor by electromechanical means.
11.0 CONTROL SYSTEM REQUIREMENTS :

11.1 GENERAL REQUIREMENTS

The machine shall be locally controlled via an operator control

desk located within the machine with all operator controls being
implemented via the PLC.

PLC control equipment in the switchroom shall be mounted in

cubicles with removable gland plates and front access, full height
hinged doors. Hinged doors shall have clear windows over input/output
racks, processor and auxiliary equipment locations to allow inspection
of all status indicators with cubicle doors closed.

Hinged doors will also be secured by means of an interlocked

three point roller type latching system with key lockable chrome plated
‘l’ shaped door handles.

In preparation for painting the cubicle shall be cleaned of all

burrs and sharp edges shall be rounded. The cubicle surface shall be
painted in accordance with the paint manufactures recommended
procedures. The colour of the finish coat will be made available to the
Supplier when the Contract is awarded.

All chips and scratches to the paint finish incurred during transit
and installation shall be made good.

All control wiring shall be PVC insulated 660V range, with

copper conductors manufactured in accordance with IEC 502. Unless
otherwise specified, the minimum size of all fixed and flexible wiring
shall be 2.5 mm Sq. (with the exception of electronic wiring). The wiring
shall be colour coded depending upon the voltage level the wire carries
in accordance with the following scheme.

Multi phase and single phase AC power, control and indication :

220V to 440V Brown

50V to 219V Orange
24V to 49 V Grey
up to 23V Violet

DC power, control and indication

Negative-all Voltage Black

Positive –
48V and above Red
24V to 47V White
 Up to 23V Pink

The Supplier shall follow an approved set of standard

instructions which relate to noise-free wiring practices. These shall
apply to all wiring cubicles and to interconnection cabling. Tenderers
shall indicate special cable requirement, if applicable.

The Supplier shall be required to ensure, during factory testing

of the control system, that electrical noise generated within the control
cubicles shall not create any problems during operation.

Where PVC insulated conductors are laid or secured to steel

supports, they shall be covered over their entire length with an
insulating material (i.e. Split PVC sleeving).

Where wiring is to pass through cut outs in panelling, the hole

shall be suitably bushed to the satisfaction of the Project Supervisor.

All control wiring shall be identified at each end of the conductor

with an approved type slip-on cable marking ferrule in accordance with
the approved drawings. Stick on type ferrules are not acceptable.
Cable markers shall be installed such that they may be read from the
front of the cubicle.

All wiring shall be terminated at panel mounted devices and at

terminal blocks by means of pre-insulated crimp lip blade type lugs.
The lugs shall be crimped using the manufacturer’s tools specifically
designed for the lugs.

Solder connections will not be accepted unless the design of the

device permits no other and is approved by the Project Supervisor in
writing.

All methods of termination and wiring must be approved by the

Purchaser before manufacture commences.

All electrical equipment mounted on or within equipment

enclosures shall be readily identified in the English language in
accordance with the relevant standard and this specification.

The Supplier shall supply complete wiring diagrams for the PLC
cubicles. These shall show the cubicles layout and the electrical
connections. The numbering of wires and the naming of items shall
correspond to wire numbers and item labels in the cubicle.

Each sheet shall detail the I/O on a single PLC I/O card. Each
field device shall be labelled uniquely. The label shall also identify the
type of device. Every wire number shall be shown with PLC I/O
numbers. The cable and core numbers shall be shown. These shall be
 cross-referenced to a cable schedule showing cable number, source
and destination, route, distance covered, core numbers, PLC I/O point
and the name of the field device.

The wire numbering system described herein shall only apply to

I/O cubicles that are supplied with I/O wired to terminal strips. On the
cubicle side of the terminal strip the wires shall be marked with wire
numbers which shall bear the same number as the program location
number of the I/O device. This number shall include leading zeroes
where these form a part of the program location number.

On the external wiring side the general plant wire number

system shall apply. The general plant wire number system shall also
apply where incoming cables are terminated directly at the I/O racks.

All control cables tray shall be vertical, as far as possible to

avoid build up. Supply include complete PLC systems.

11.2 OPERATOR INTERFACE

The operator interface for the mobile machine control desk will
utilize a HMI directly mounted on to the panel with fully shield industrial
key-board and mouse. In addition to this control desk must be provided
with push bottoms and joy stocks for operator control of the machine
.
The operator interface screens for the mobile machine
control desks will utilise a HM1 directly mounted on to the panel
with fully shielded industrial key board and mouse. In addition to
this control desk must be provided with push buttons and joy
sticks for operator control of the machine.

11.3 FIELD DEVICES

Field devices shall not be series connected in the field. All

inputs shall be connected directly to individual PLC terminals. Each
Statutory device shall be individually monitored by the PLC.

Field control and protection devices shall include, but not be

limited to, the following :-

♦ Local Start/Lock-Off Stop (LOS) station mounted adjacent to each electric

drive. The LOS button shall be mushroomed headed with key locking.
♦ General coverage LOS, located adjacent to machine bogies and each
point of access to the machine and accessible from the ground and
located in both the control cabin and in the Electrical Switch Room.
♦ Emergency stop lanyard and associated pull wire switch, (PWS) along
each accessible section of each conveyor and adjacent to travel drives.
♦ Underspeed detection equipment of each conveyor.
♦ Belt drift detection equipment on each side of each conveyor at both head
and tail ends.
♦ Proximity switches shall be used for conveyor underspeed protection.
♦ Limit switches shall be used for belt drift.
♦ Wobble lever operated limit switch for belt rip detection.
♦ A mercury tilt switch for blocked chute detection on each feed chute.
♦ Limit switches with back-up switches shall operate before device travel
limits re exceeded to prevent movement beyond the zone of normal
operation. The back-up switches shall be full current type arranged to
directly disconnect power to travel drive motors.
♦ Audible alarms / sirens to operate before the starting of any long travel,
luffing slewing or conveying shall be provided.
♦ Tilt switches for the detection of stockpile surface to protect equipment.
♦ Ultrasonic level devices to detect stockpile height.
♦ Every brake shall be fitted with a brake test push button and limit switch.
The limit switch shall be actuated in the brake fully released position. Limit
switches shall prevent operation of the driven equipment if the brake does
not release. The brake test push button shall be installed in view of the
brake to allow maintenance personnel to confirm the correct brake
operation.

Limit switches shall be used to determine:-

♦ Luff angle
♦ ExtremeTravel position (multi-tum type is required)
♦ Slewing Angle

Proximity switches shall be installed and arranged so as to

recalibrate the travel position encoder in at least two separate positions
equidistant along the length of the stockpile.

11.4 SOFTWARE REQUIREMENTS

All application software including equipment operating system

software provided by the Supplier under this contract shall remain the
property of the Purchaser and the Purchaser shall hold the copyright
for the software.

Developed software for the control system shall be divided into

functional blocks with each functional block performing 1% only. This
will ensure that the programme is simpler to trouble shoot and assist in
familiarization.

11.5 CONTROL SYSTEM SOFTWARE DOCUMENTATION &

MANAGEMENT.
 A full and comprehensive “functional specification” and
“software specification” shall be developed to be used as the basis for
the production of the control system software.

The machine control system shall be supplied complete with all

the software necessary to operate the machine.

The Supplier shall be fully documented in accordance with the

requirements set out below and shall be subject to a review and
approval procedure. The software shall be developed in a number of
stages – each stage being approved before the next stage can
commence.

Stage 1

Provision of detailed Functional and Software Specifications

covering the machines control systems. This may involve adding detail
and/or sections to the Functional and Software Specifications included
in Appendix 4J & 4K respectively.

These specifications will include the following information as a

minimum :

System configuration diagrams.

High level representation of sequence logic in flow diagram form.
High level representation of analog regulatory loops in functional block
diagram form.
Standard PLC ladder logic blocks.
PLC I/O lists
Data to be communicated to/from machines and fixed plant.

The information will describe how the Reclaimer will be

controlled for each operating mode and situation. This will also be used
to implement and manage the programming function. Approval of these
Specifications must be obtained before proceeding to Stage 2.

Stage 2

Coding of PLC logic and descriptive annotation of code.

Development and configuration of Operator Interface Software.

Stage 3

Through testing of all control system hardware and software.

This is to be done before the equipment is installed in the machine.
The testing is to be witnessed and approved by the Purchaser.

Stage 4
 Provision of a Control System Manual. The manual will describe
the control system in detail in relevant language for supervisors,
electricians and operators.

The Control System Manual shall provide a comprehensive

system description for use by maintenance and operating staff. It shall
include the following :-

Functional Specification
Software specification
High level representation of logic and control loops.
System configuration.
Description as how all the logic modules fit together.
Full description of data communications with remote equipment.
Full and final code and I/O listings including annotated software for
complex or non-standard code.
A comprehensive operating manual describing machine set-up and
operation in all modes.
After commissioning of the PLC code and Operator Interface
System, all redundant code shall be removed. The copyright for the
PLC and Operator Interface Software shall be vested with the
Purchaser at the completion of the project. The vestment of copyright
shall be confirmed in writing by the Supplier at the completion of the
project.

11.6 CONTROL SYSTEM TESTING

The equipment may be subject to examination at any time

during manufacture and testing prior to shipping.

The Test Plan shall include test items for Factory Acceptance
Testing (off line tests) and associated acceptance criteria including a
detailed software testing and acceptance program. It shall also include
on line commissioning procedures and appropriate commissioning
acceptance criteria.

The Control System shall be completely shop assembled,

loaded with the developed system software and tested before shipping
to site. Tests may be witnessed by the Purchaser. The Supplier shall
provide a minimum of seven (7) days notice before any FAT testing
commences. A test report is required regardless of witnessing of the
tests.

A final inspection certificate must be signed before any

equipment is despatched from the factory. Such a certificate shall not
constitute a Certificate of Acceptance.

All PLC components to be supplied shall be assembled and

installed in panels for workshop testing. The entire PLC hardware shall
 be energized continuously for a minimum period of five days during the
FAT period.

Testing of inputs shall consist of applying voltage (or current) to

all input terminals at the marshalling terminal, checking the operation of
indicators or individual cards and also checking input address status on
a program panel to confirm correct rack/card addressing.

Testing of outputs shall consist of forcing on (or setting) the

individual outputs and checking the output voltage (or current) at a
load resistor on the output terminals at the marshalling cubicle.

Testing of communications, both PLC-to-PLC and PLC-to-

Operator Interface shall also be undertaken. Communication testing
shall consist of testing of physical connections followed by data transfer
and function testing of the full system. The system shall be tested at
25% greater than the data loading expected under normal site
operation.

All software developed for the project shall be tested during the
FAT to ensure that correct equipment starting, stopping, sequencing
and fault and fault recovery operation is performed.

The results of all tests shall be recorded. Any equipment to

software which does not satisfy the tests 100% shall be rejected or the
test rewritten. If a test is to be repeated for any reason both the
original test results and the repeated test results shall be recorded and
the reason why the original test failed stated.

Upon completion, the equipment shall be inspected and tested

in accordance with the Commissioning Procedure, to demonstrate
compliance with the Contract Documents. Each inspection or test shall
be properly documented by the Supplier who shall then produce a
written report of the inspection and/or tests, within two weeks following
the inspection or test.

The Supplier shall submit to the Purchaser within 2 weeks of the

completion of commissioning a final Commissioning Report including
test results and data sheets.

The Supplier shall fully comply with directives from Statutory

Authorities requiring tests or inspection at any stage of the
commissioning.

12.0 ERECTION AND INSTALLATION REQUIREMENTS

12.1 GENERAL
 Particular attention shall be given by the Supplier to the
sequence of erection of structures and the installation of mechanical
equipment. A detailed erection programme shall be provided in the
form of a bar chart and explanation to fully describe how the Supplier
intends to manage and control the erection and installation to ensure
that timing and quality is met.

The programme shall be submitted prior to the commencement

of erection activities in accordance with the Documentation Schedule
and shall be subjected to review and approval by the Purchaser.

The programme shall include :

• Sequence of erection.
• Handling and carnage
• Details of temporary bracing and guying.
• Controls in place for early detection of poor quality or time
performance.

12.2 ERECTION OF STRUCTURAL STEELWORK

All work shall be carried out in accordance with relevant

standards, statutory Regulations and accepted good practice and good
workmanship.

Planning of erection procedure including the provision of all

necessary guying and/or temporary bracing shall be carried out to
ensure the safety and trueness of the structure under all conditions of
wind and erection loads occurring during the construction period.

Upon completion of work all temporary bracing and its

connections shall be removed, holes plugged and the steelwork
including the protective coating specified, made good.

During erection, the use of sledge hammers to drive or hammer

beams, or other steelwork will not be allowed.

Drift pins may be used only to bring together several parts, and
these pins shall not be used in such manner as to distort or damage
the metal.

Lift drifting necessary to draw holes together will be permitted,

but drifting to match unfair holes is not acceptance.

Holes that are badly punched or drilled shall be reamed out to

accept a bolt of larger diameter if approved. Otherwise the holes shall
be reamed out, plug welded, tested and redrilled to the sizes shown on
the Drawings.
 No holding or cutting of steelwork, other than as shown on the
drawings, shall be done without prior written approval.

The use of a gas cutting torch in the field for correcting errors
shall not be permitted.

All brackets, fittings and splices shall be accurately aligned

before bolting or stressing and shall be checked after bolting or
stressing.

12.3 BOLTING.

All bolts of 20mm diameter or greater shall be high strength

bolts Grade 8.8 in accordance with relevant standards. All other bolts
shall be grade 4.6 conforming to relevant standards unless noted
otherwise on the drawings. The length of each bolt shall be such that
the threaded portion will project through the nut for at least two
complete threads. All bolts, nuts and washers shall be hot-dip
galvanised. The nuts shall run “finger free” on the bolts after
galvanising of both.

A manual torque wrench shall be provided by the supplier on

site to allow checking of bolt tightness.

Loading indicating washers shall not be permitted.

Bolts in bearing shall be of such a length that no threaded

portion shall be within the thickness of the parts jointed, however, for
the design of bolts in bearing, at least one washer shall be placed
under the bolt thread or nut, whichever ids to be rotated. Taper
washers shall be used where the part under the bolt head or nut is not
perpendicular to the centerline of the bolt. Nuts or bolts subject to
severe vibration and vertical bolts in tension shall be locked in position
by an approved method.

12.4 TRIAL ASSEMBLY.

The Supplier shall trial assemble all critical interfaces and

connections. These shall include the following:
♦ Portal gantries.
♦ Boom seats and slew bearings.
♦ Conveyor boom.
♦ Counterweight boom.
♦ Bucketwheel.
♦ Mast sections and hinges.

12.5 ERECTION TOLERANCE .

 Notwithstanding any fabrication tolerance allowed by this
specification, the steelwork shall be erected so as to conform to the
appropriate tolerance allowed by ISS.

Stainless steel shims and packers shall be supplied to

undertake any other adjustments and corrective measures necessary
to ensure that the finished position of the steelwork is within the
required tolerance of the position shown or inferred on the Drawings.

12.6 EQUIPMENT INSTALLATION.

All equipment shall be prepared, installed, aligned, set,

lubricated and tested in accordance with this specification and the
equipment manufacturers recommendations.

12.7 COMPLETION OF INSTALLATION .

After completion of erection and installation, all oil lubricated

equipment shall be drained, flushed and refilled in accordance with the
equipment manufacturer’s recommendations.

Grease lubricated bearings and seals shall be inspected for

cleanliness and seal condition. All air shall be bled from lubricant lines
and seals provided with a purging facility shall be purged.

Any leaked fluid or lubricant shall be removed, and stained and

damaged paint work repaired.

The machines shall be in a clean, safe and tidy condition after

erection. All temporary staging and platforms shall be removed and any
construction debris and rubbish accumulated during erection cleared
away.

13.0 SURFACE TREATMENT AND PROTECTIVE COATING.

13.1 GENERAL.

All parts of the machines shall be surface treated during

manufacture to ensure their protection from the effects of moisture
during storage, transportation, erection and service.

The works of surface preparation and the application of

protective coatings and the inspection thereof shall be carried out in
accordance with this specification, the coating manufacturers written
technical literature and if necessary under the guidance of a technical
representative of the coating manufacturer. Prior to the application of
any coating to any part of the steelwork, witnessed procedure tests of
surface preparation and application of protective coatings shall be
carried out. These test shall be carried out using test pieces which
 provide a similar degree of difficulty as the actual work. When
completed and approved as acceptable procedures, these test pieces
shall be retained as reference pieces and shall be stored in a safe and
clean environment until the actual work that they represent has been
completed and accepted. The procedure relevant to each stage shall
be deemed to be approved and applicable for all similar operations.
Work subsequently found to be carried out in an operation which has
not been approved shall be rejected or improved to comply with this
specification at no additional cost.

13.2 STANDARDS.

Materials and workmanship shall comply with all relevant Indian

Standards and any relevant statutory Authority Requirement.

13.3 COATING SYSTEM.

The name of the materials stated in the materials specification

are to be regarded as those which designate the minimum acceptable
type, quality and performance.

Mixed system shall not be acceptable. All coats used in a

coating system shall be done using one brand and brands shall not be
inter-mixed at any stage.

If coatings are supplied in a mixed system, the steel thus coated

shall be re-blasted and re-coated in accordance with this specification.

13.4 ALTERNATIVE COATING SYSTEM.

Acceptance of any alternative coating system is subject to approval in

writing.

Experimental coatings or coating procedure or techniques are not

acceptable.

Any alternative coating system must be documented in full and

have a proven service life of at least that expected from the specified
coating system.

The service to be offered during coating operations by the

alternative coating manufacturer, in particular the practical experience
of the technical representative nominated to be responsible for the
project, should be stated in addition to the guarantees of his ready
availability to fulfil the various services as they become necessary
under this specification.

Notwithstanding any approvals which may be given for

alternative coating systems or brands in connection with this clause,
such alternative coatings shall comply in all other respects with this
specification. In addition, no extra payment will be made if, after
receiving the letter of acceptance, the alternative coating is found to be
unacceptable, and the approved system is then adopted.

13.5 MATERIALS.

All materials used in a coating system shall be deemed to carry

the manufacturer’s assurance of compatibility in the coating sequence
as specified.

All coating materials and thinners, if approved, shall be brought

to the site of the coating application in unopened containers as
supplied by the manufacturer.

Before commencing application of any coating, the

manufacturer’s certificates for each consignment of material delivered
shall be checked and the following data verified for compliance with the
requirements of this specification:

♦ Description of Material
♦ Vendor’s Reference Number
♦ Batch Number
♦ Quantity in Batch
♦ Date of Manufacture
♦ Manufacturer’s stated Expiry date.

Mixing, thinning and application instructions as nominated by

the coating manufacturer and/or herein specified, shall be absolutely
adhered to, and no other addition to the mixed coating shall be used.

Where necessary, the addition of thinners to any coating shall

be as recommended by the manufacturer and shall only be of the type
and quantity recommended.

The Manufacturer’s serialised batch reference number shall

confirm the age of all coating materials to be six months or less.

All materials, after delivery to the shop or site, must be stored in

a cool dry place in accordance with the requirements of relevant
standards Flammable and Combustible Liquid Code and any other
relevant Statutory Authority requirements.

13.6 SURFACE PREPARATION.

All steelwork, except for those items specifically designated to

be hot dip galvanised, shall be prepared and painted as herein
specified. All steel surfaces to be coated showing traces of oil, grease
or other contaminates shall be thoroughly cleaned with an approved
solvent, preferably with an approved emulsifying degreasing agent and
washed with clean water before commencement of coating application.

All steel surfaces to be coated shall dry abrasive blast cleaned

in accordance with I.S.S and clause 2 1/2 minimum (near white metal)
finish.

13.7 ABRASIVE BLAST CLEANING.

Abrasive blast cleaning shall be carried out by grit blasting using

compressed air nozzles. Metallic abrasive shall be capable of passing
a 1.18 mm AS sieve, and shall be sharp, hard and free from dust.

For all steelwork the blast cleaned surface shall have a profile of
not less than 25u or greater than 50u as measured by a probe type
surface profile gauge, or as established by the use of a compactor
gauge.

Only dry blast cleaning techniques shall be employed. Silica,

flint or ilmenite abrasives are not permitted.

The types and sizes of abrasives, and the equipment and

procedure, for each kind of work shall be such that the required
standard of cleaning can be achieved on any surface and that the
required standard of profile can be guaranteed on sample surfaces
originally smooth and unpitted.

Preliminary tests shall be carried out to establish a suitable

technique as described in the previous paragraph for such kind of
work. Provided this technique is adhered to with satisfactory results on
smooth unpitted steel, it will be accepted that the required profile
amplitude has been achieved throughout.

Attention is drawn to the difficulties of cleaning steel which is

badly rusted and pitted, and desirability of avoiding the use of such
steel.

Approved sets of reference plates may be used for the routine

estimation of surface roughness.

The compressed air supply used for blast cleaning shall be free
of water and oil. Adequate separators and traps shall be provided and
these shall be kept clean and emptied of water and oil. The design of
the compressed air system used for air blasting should be such that all
available technology be used to eliminate moisture, oil and other
contaminants associated with high pressure compressed air. The use
of refrigerated air driers is highly recommended and all filtration
systems shall be inspected and approved prior to the commencement
of any surface preparation work. In no case shall compressed air with a
temperature in excess of 1150 C be allowed. Air pressure at the blast
nozzle must not be less than 690 Kpa, and shall be regularly checked
with a pressure gauge.

Blasting operators shall at all times wear recognised safety

clothes and helmets. Helmets shall be ventilated with clean cool air
through an approved filter and regulator capable of removing impurities
and odours from the air supply.

Blast cleaning shall not be conducted when the steel surface is

less than 50C above the dew point or when the relative humidity of the
surrounding air is greater than 80%. A psychrometer to determine the
relative humidity shall be checked and recorded before the
commencement of all blasting operations and at other times as
deemed necessary.

Blast cleaning shall be permitted only during the daylight hours

except that rough blasting will normally be allowed during the night if
the surfaces cleaned during the night shift are reblasted to the
specified standard in daylight.

Maximum speed and most effective cleaning is obtained by

systematic, even blasting. Manual work should be blocked out in
square and each square blasted evenly until complete.

When blasting is carried out in the open, e.g. on site repair of

protective coating after site welding, it shall not be performed in areas
close to painting operations or where spent blast media may impinge
on soft or freshly painted surfaces.

All welded areas and appurtenances shall be given special

attention for removal of welding flux, particularly confined areas.

Welding spatter, slivers, and all surface defects including

cracks, surface laminations and deep pitting, likely to be detrimental to
the protective coating system, exposed before or after abrasive blast
cleaning operations, shall be removed by grinding, if required and if
necessary, and the affected area reblasted.

All fins at saw cuts, burrs and sharp edges shall similarly be removed.

Immediately after blasting operations are completed, the steel

surface shall be brushed down with fibre bristles or blown down with
clean dry air, giving particular attention to corners, intersections and
horizontal area where settlement of dust would be most likely to occur.

If the methods do not satisfactorily remove all dust from the

surface vaccum cleaning of the steel, shall be carried out.
13.8 CARE OF ABRASIVE BLAST CLEANED SURFACES

Abrasive blast cleaned surfaces showing scale, sharp gouges,

surface shall, laminations or other surfaces defects which only become
apparent after blast cleaning, shall be repaired by chipping or grinding
before the prime coat is applied. The surface under the defect thus
removed shall be cleaned to a class 2.1/2 minimum finish and where
necessary further blast cleaning shall take place to ensure compliance
with the specification.

Blast cleaned surfaces shall be kept free of any contamination

and shall not be touched by bare hands, and to this end, operators
shall wear clean gloves. Any areas inadvertently touched or handled
shall be reblasted immediately.

The application of the prime coat to abrasive blasted surfaces

shall commence within four hours of the blasing, and shall be
completed on that day, and before the surface temperature of the steel
is less than 50 above the dew point.

Generally, surfaces that are blast cleaned mid-morning, prior to

the midday break shall be primed prior to that break, and similarly,
surfaces blast cleaned in the afternoon shall be primed prior to
cessation of that days work.

Any work blast cleaned and left overnight uncoated, or any

surface which shows any trace of discolouration from any cause shall
be reblasted before the prime coat is applied.

For steel work abrasive cleaned in or near the open, any wetting
from rain during or after cleaning but before prime coating shall result
in the whole segment of steelwork affected being re-blasted.

13.9 APPLICATIONS FOR COATINGS – GENERAL .

The provisions of this clause shall apply to the application of all

protective coatings in the workshop.

Under no circumstances shall coatings be applied over moisture

on the surface of the metal or previous coating.

Effective controls shall be established to preclude blasting,

priming or top coating operations in unsuitable weather.

Work shall NOT be performed in the following circumstances :

♦ If the surface is wet or likely to become wet after blasting

or before prime coating or top coating.
 ♦ On surfaces where condensation is likely to form, i.e.
when the surface temperature of the steel is less than 50 C above
the dew point of the surrounding air,
♦ When the relative humidity of the surrounding air is
greater than 80%
♦ When the wet bulb temperature in the immediate vicinity
shows a difference of 7% or less from the dry bulb temperature
(standard wet and dry bulb thermometer)
♦ When the extremes of surface metal temperature exceed
350C or are lower than 100C.

Occasional spot proof tests to gauge physically the coating

thickness may be taken using a Tooke Gauge to cut into small section
of coating. Two tests may be carried out for each section coated, the
test piece being taken from the same area as the test for adhesion. If
the tests indicate that such areas do not comply with the Specification,
no additional costs will be allowed for any necessary repairs and /or
recoating.

All repairs to the coating to enable it to comply with the

specification shall only be carried out using techniques, materials and
procedures which have been approved in writing.

After application of each section of coating, carried out in a

continuous operation, it shall be checked for adhesion to the steel
and/or intercoat adhesion.

Adhesion tests shall be carried out for each section of the work
and shall be performed in accordance with the requirements of B.I.S.
‘Method of test for paint and related products’. Paint thickness in this
Specification, unless noted otherwise refers to minimum dry film
thickness. No coat shall anywhere exceed the specified minimum
thickness by more than 50%.

Where thickness exceed this limit, written proposals for the

removal of the excess and the reinstatement of the coating in
accordance with this Specification shall be submitted and no further
work performed on that section of work until approval of those
proposals is given in writing.

Where proof coating thickness tests and adhesion tests are

made and reveal that the coating complies with the specification, the
test area shall be repaired as herein specified for local scratch damage
to each of the relevant coatings.

No coating shall be applied until blast cleaned surface or the

previous coating has been inspected and approved.
13.10 APPLICATION OF PRIME COATING TO STEEL WORK.

All structural steelwork, except as specified otherwise shall

receive a complete prime coat in the workshop. Bolt holes shall be
coated completely through the thickness of the material. After the steel
surfaces have received the surface preparation specified herein, and
approval to proceed has been given in writing, the steel surfaces shall
be coated with the prime coat within the time limits specified above.

The prime coating shall be applied to all steelwork. Prime coating

shall be a two component liquid/slurry, moisture curing zinc rich ethyl
silicate coating.

The coating shall be applied by conventional air atomised spray

equipment to achieve a minimum dry film thickness of 75 um in one or
more coats, using parallel passes at a constant distance from the
surface, overlaping each previous pass by 50%.

The two part primer shall be mixed using mechanical equipment

in strict accordance with the manufacturer’s instructions. Immediately
following mixing coating material shall be transferred to an agitated
pressure pot and the coating kept in continuous motion such that the
pigment is kept in suspension until application is complete.

Coating material that has been mixed for longer than 6 hours
shall be rejected.

The applied coating shall be smooth and uniform without runs,

beads, pinholes or other imperfections. Areas of coating that exhibit
defects of a sudden or local nature of insufficient film build, shall be
blast cleaned and then recoated in accordance with this Specification.

Areas which exhibit insufficient film build ofany overall nature

may be sprayed with further coats to achieve the minimum specified
dry film thickness, provided that the surface is clean, dry and free from
foreign matter and that the adequacy of the existing profile to achieve
proper adhesion, is established on a test area.

Areas exhibiting low film thickness which after inspection are

considered inadequate for the adhesion of a further coat of primer shall
be ship blasted and the coating reapplied in accordance with this
Specification.

Areas which sustain local damage or scratching in the shop

shall be blast cleaned and recoated as follows :

♦ Before top coating :

 Damaged areas shall be blast cleaned to Class 2.1/2
minimum as specified herein and a further coat of primer applied in
accordance with this specification.

♦ After top coating :

Damaged area shall be blast cleaned to Class 2.1/2

minimum as herein specified, taking care to feather back top coat
only at the edge of the reblasted area, to allow new primer applied
in accordance with this Specification. Top coat shall not be
reinstated until a minimum of 48 hours after application of repair
primer. Extreme care shall be taken during repair operations to
avoid overblast damage to areas of sound coating. Any area
damaged by overblasting shall result in those areas being blasted
back to the substrate and recoated in accordance with this
specification.

In the case of a localised scratch or minor area of damage,

repair may be affected by feathering back top coats by sanding and
applying a further coat of primer by spray or brush, making sure that
the primer does not over coat of primer by spray or brush, making
sure that the primer does not overcoat surrounding topcoats. Top
coat shall not be reinstated until a minimum of 48 hours after
application of repair primer.

13.11 TESTING OF INORGANIC ZINC SILICATE PRIMER.

Ethyl silicate zinc primed surfaces shall be tested during curing

and prior to top coating. Curing time shall be as recommended by the
coating manufacturer but not less than 48 hours. Where the relative
humidity during the curing period has not exceed 70%, curing time will
be extended. Duration of extension will be determined by prevailing
weather conditions at the time the coating is applied.

Coating shall be tested for dry film thickness, hardness and

metallic zinc content as well as being visually scanned for other defects
such as mud cracking etc. Tests shall be performed in accordance with
the relevant section.

13.12 APPLICATION OF INTERMEDIATE COATING TO STEELWORK.

All steelwork which has been prime coated shall have an

intermediate coating applied in the workshop prior to delivery to site.
Intermediate coating shall be a two component high solids high build
polyamide curd recoatable coating containing micaceous iron oxide
pigment.

Before the specific intermediate coating is applied the entire

surface coated with the prime coat shall be checked for contamination
by dust, foreign matter or other contaminants. The intermediate coating
shall only be applied to thoroughly cleaned surfaces.

Any contamination of the surface shall be entirely removed prior

to application of the intermediate coating, by a thorough washing with
clean water, or other method which has been approved in writing,
depending on the degree of contamination.

The intermediate coating shall be mixed in strict accordance with

the manufacturer’s instructions. Any coating material which has been
mixed for longer than two hours shall be discarded.

The coating may be applied by airless or conventional air

atomising spray equipment to achieve a minimum dry film thickness of
100 um (175 um total thickness). As this coating is to be applied over an
ethyl silicate zinc primer attention is drawn to the necessity to apply a
tack coating initially to effectively seal the prime coating pores with
further passes to achieve the nominated minimum dry film thickness.
Reduction of the material after induction to produce a tack coating
consistency shall be in accordance with the manufacturers
recommendations.

The finished surface shall be smooth and uniform without runs,

sags, beads, pinholes, curtaining, bubbles or other imperfections. Any
such defect that occurs shall be removed by sanding the defective
coating, and the surface shall be removed by sanding the defective
coating, and the surface recoated in those areas with the same material.

Areas which sustain damage or scratching shall be reinstated in

accordance with the requirements of this specification.

Intermediate coating damage shall be repaired by feathering

back loose or damaged coating to a sound edge. Where the primer has
been exposed but not damaged, recoating shall consist of a further
application of intermediate coating in accordance with this specification.

Where the metal substrate has been exposed and depending on

the size of the area damaged, the damaged area shall be abrasive blast
cleaned or disc sanded to bright metal and prime and finish coats
applied in accordance with the Specification.

Notwithstanding the above provisions, the primer repair coating

shall be original primer. If the area to be repaired is of substantial nature
rather than a local scratch, the proposed repair procedure shall be
apprved in writing and shall be such that the adjacent intermediate
coating is :washed “ off a margin of undamaged primer to avoid
sandwiching of repair prime coat between intermediate coats.
 13.13 TESTING OF INTERMEDIATE COATING.

After intermediate coating has been applied, it shall be checked

for dry film thickness with an approved electronic film testing gauge.

The procedure to be adopted for determining the average film

thickness of the coating or combined coating shall be to take ten
readings at random for each 10 square metres of coated area and
calculated a mathematical average.

All coatings shall be at least be of the thickness specified. The

thickness of the coating under test will be determined as the difference
between the combined average thickness of all coatings as determined
above and the combined average thickness of the undercoating
previously determined for each particular 10 square metres under test.

Notwithstanding the above, not more than one reading in each

group of 10 readings of dry film thickness shall be more than 10%
below the specified minimum dry film thickness for a particular coating.

If five or more reading sin each group of 10 readings of dry film

thickness do not comply with Specification, then theara will be rejected.
Any proposal detailing methodology to be adopted for recoating or
overcoating the rejected area to enable it to comply with the
specification shall be approved in writing before any repair work is
carried out. Repair procedure shall be tested on a sample area first and
no repair work shall proceed until the test area is inspected and
accepted and approval is given in writing.

13.14 APPLICATION OF FINISH COATING TO STEELWORK.

All steel work which has been prime and intermediate coated
shall have a finish coating applied. Finish coating shall be a two
component high build polyamide cured recoatable epoxy coating.

Before the finish coating is applied the entire surface coated with
the intermediate coating shall be checked for contamination by dust,
foreign matter or other contaminants. The finish coating shall only be
applied to thoroughly clean surfaces.

Any contamination of the surface shall be entirely removed prior

to application of the finish coating by through washing with clean water,
or other method which has been approved in writing depending on the
degree of contamination.

The finish coating shall be mixed in strict accordance with the

manufacturer’s instructions. Any coating material which has been mixed
for longer than hours, even if still liquid, shall be discarded.
 The coating may be applied by airless or conventional air
atmising spray equipment to achieve a minimum dry film thickness of
100 um (275 um total thickness). The finished surface shall be smooth
and uniform without runs, sags, beads, pinholes, curtaining, bubbles or
other imperfections. Any such defect that occurs shall be removed by
sanding the defctive coating, and the surface recoated in those areas
with the same material.

Areas which sustain damage or scratching shall be reinstated as

directed.

Finish coating damages shall be repaired by feathering back

loose or damaged coating to a sound edge. Where the intermediate
coating has been exposed but not damaged, recoating shall consist of a
further application of finish coating in accordance with this Specification.

Where the metal subtrate has been exposed, and depending on

the size of the area damaged, the damaged area shall be abrasive blast
cleaned or disc sanded to bright metal and prime, intermediate and
finish coatings applied in accordance with this Specification.

Notwithstanding the above provisions, the primer repair coating

shall be original primer. If the area to be repaired is of a substantial
mature rather than a local scratch, the proposed repair procedure shall
be approved in writing and shall be such that the adjacent finish and
intermediate coatings are “washed” off a margin of undamaged prime
and intermediate coatings to avoid sandwiching of repair prime coating
and intermediate coating between sound intermediate or finish coats.

13.15 APPLICATION OF COATINGS TO INTERNAL SURFACES OF

SEALED AND
BOX SECTIONS.

Internal Surfaces – No Access

The internal surfaces of sealed steel sections, e.g. box

beams and columns, which shall have no future access shall be
abrasive blast cleaned as previously specified for steelwork and
have a pre-weld prime coating applied only. Primer shall be a
moisture cured two part inorganic ethyl silicate zinc coating applied
by conventional air atomising spray equipment to achieve a
minimum dry film thickness of 60 um. Application of this coating
shall be carried out as previously specified for steelwork.

Internal Surfaces – Limited Access

The internal surfaces of sealed steel section which shall

have limited future access, i.e. bolted access covers with gasket
seals or covers which are seal welded in place, shall be abrasive
 blast cleaned and have a prime coating applied as previously
specified for steel work. Primer shall be a self curing two pack
inorganic zinc silicate coating applied by conventional air atomising
spray equipment to achieve a minimum dry film thickness of 75 um.
Coating may be initially applied as a pre-weld prime coating, in
order to reduce abrasive blasting and associated cleaning
internally, however, coating shall be bought up to specified standard
after fabrication is completed particularly at weld out areas where
damage will be most severe.

Internal Surfaces – Unlimited Access

The internal surfaces of steel sections which will have

unlimited future access, i.e. access ways, control rooms, electric
switch rooms etc. shall be abrasive blast cleaned and coated as
previously specified for steel worl. Colour schemes will be detailed
in the schedule contained herein.

Testing of Coatings to Internal Surfaces

Coatings applied to internal surfaces of steelwork shall be

measured and tested as previously specified for steelwork except
that the pre-weld primer shall be inspected and tested prior to
fabrication and welding.

13.16 SURFACE PREPARATION AND APPLICATION OF COATING TO

MOTORS, GEAR REDUCERS, AND OTHER PROPRIETARY
EQUIPMENT.

Previously unpainted areas

Preparation :

All equipment, gear reducer, associated motors and

couplings, etc. which have not previously been painted shall be
cleaned and if necessary degreased as herein specified for steel
work. After cleaning articles shall be whip blasted to provide
sufficient surface profile. Any sharpedges fins or other defects of a
sudden or local nature shall be ground smooth or made good in an
approved manner.

Only dry blast cleaning techniques shall be used and all

precautions, controls on weather conditions and care of article after
blasting shall be observed as herein specified for steel work.

Extreme care shall be exercised when whip blasting around

seals, glands etc. and any machined face where fit-up to adjacent
components is required. In these instances areas shall be suitably
masked and/or protected against before blasting commence.
Application of Prime Coating

After articles have been blasted, inspected and approved,

they shall be prime coated with a two pack non-reactive high build
polyamide cured epoxy coating to achieve a minimum dry film
thickness of 125 um.

Coating may be applied using conventional air atomising or

airless spray equipment where airless equipment is to be used set
up shall consist of the following :

Nozzle Pressure: 15 Mpa

Spray Tip Orifice : 0.46mm

Any coating material that has been mixed for longer than 6
hours shall be rejected. Coating shall be smooth and uniform
without runs, beads, pinholes or other imperfections. Any areas
which exhibits defects of a sudden or local nature or insufficient film
build shall be blast cleaned and precoated in accordance with this
specification. Areas which exhibit insufficient film build of an overall
nature may be sprayed with a further coat to achieve the minimum
specified dry film thickness provided that the surface is clean and
dry and that the adequacy of the existing surface profile to achieve
proper adhesion by the overcoat is established on a test area. If the
surface profile is inadequate for adhesion of further coats the article
shall be whip blasted and the coating reapplied in accordance with
this specification.

Testing Primer

Primed surfaces shall be tested after curing and prior to

top coating. Curing shall be as recommended by the
manufacturer but not less than two days.

Coating shall be tested for dry film thickness and

adhesion as well as visually scanned for other defects. Tests
shall be performed in accordance with the requirements of AS
1580.

Application of Finish Coatings

All articles which have been primed shall be intermediate

and finish coatings applied prior to installation. Intermediate and
finish coatings shall be previously specified for steelwork.

Application and testing of intermediate and finish coatings

shall be as previously specified for steelwork.
 Previously Painted Articles

All equipment, gear reducers, associated motors and

couplings etc. which have been previously been supplied
coated in manufacturer’s finish shall be cleaned and overcoated
as herein specified.

Prior to application of coatings all articles shall be

cleaned of all dust, grease, oil and other surface contaminants
by washing with an approved solvent, preferably an emulsifying
agent and then rinsed thoroughly with clean water.

Application of Barrier Coating

After previously painted articles have been cleaned and

inspected they shall be coated with a quick drying high build
anticorrosive barrier primer to achieve a minimum dry film
thickness of 50um.

Coating may be applied using conventional air atomising

or airless spray equipment. Where airless equipment is to be
used set up shall consists of the following :

Nozzle Pressure : 15Mpa

Spray Tip Orifice : 0.43 – 0.53 mm

Coating shall be allowed to cure for a minimum of 24

hours prior to the application of finish coatings.

Application of Finish Coatings

All articles which have been primed with barrier coatings

shall have intermediate and finish coatings applied prior to
installation. Intermediate and finish coatings shall be as
previously specified for steelwork.

Application and testing of intermediate and finish coatings

shall be as previously specified for steelwork.

13.17 SURFACE PREPARATION AND APPLICATION OF COATINGS TO

ALLUMINIUM FABRICATIONS AND EQUIPMENT.

♦ Preparation

All aluminium fabrications, castings etc. shall be cleaned and

if necessary degreased using an approved emulsifying degreasing
agent and washed with clean water before commencement of work.
After cleaning articles shall be given a light whip blast to remove
 surface oxides and to provide sufficient surface profile for adhesion
of prime coating. Any sharp edge, fins or other defects of a sudden
or local nature shall be ground smooth or made good in an
approved manner.

Only dry blast cleaning techniques using inert blast media

shall be used and all precautions, controls on weather conditions
and care of articles after blast cleaning shall be observed as
previously specified for steelwork.

Extreme care shall be exercised when whip blasting around

seals, fitted joints etc and any machined face where fit up to
adjacent components is required. In these instances areas shall be
suitably protected against damage before blasting commence.

Application Of Prime Coating

After articles have been blasted cleaned, inspected and

approved, they shall be prime coated with a two component non
reactive high build polyamide cured epoxy coating to achieve a
minimum dry film thickness of 75um.

Coating may be applied using conventional air atomising

or airless spray equipment. Where airless equipment is to be
used set up shall consist of the following :-

Nozzle Pressure – 15 Mpa

Spray Tip Orifice – 0.46 mm

Any coating material that has been mixed for longer than
5 hours shall be rejected. Coating shall be smooth and uniform
without runs, beads, pinholes or other imperfections. Any areas
of coating which exhibit defects of a sudden or local nature or
insufficient film build shall be blast cleaned and recoated in
accordance with this specification. Areas which exhibit
insufficient film build of an overall nature may be sprayed with a
further coat to achieve the minimum specified dry film thickness
provided that the surface is clean and dry and that the adequacy
of the overcoat is established on a test area. If the surface profile
is inadequate for adhesion of further coats the article shall be
whip blasted and the coatings reapplied in accordance with this
specification.

Testing of Primer

Primed surfaces shall be tested after curing and prior to

overcoating. Curing shall be as recommended by the
manufacturer but not less than 24 hous.
 Coating shall be tested for dry film thickness and
adhesion as well as visually scanned for other defects. Tests
shall be performed in accordance with the requirement of
relevant standards.

Application of Finish Coatings

All articles which have been prime coated shall have

intermediate and finish coatings applied prior to installation.
Intermediate and finish coatings shall be as previously specified for
steelwork.

Application and testing of intermediate and finish coatings

shall be as previously specified for steelwork.

13.18 HOT DIP GALVANISING .

All steelwork items specifically designated to be hot dip

galvanised, shall be prepared and coated as herein specified.

All steelwork items to be galvanised showing traces of oil,

grease or other contaminant shall be be galvanised shall be dry
abrasive blast cleaned in accordance with – Part 4, thoroughly cleaned
with an approved solvent, preferably with an approved emulsifying
degreasing agent and washed with clean water before commencement
of work.

All sharp edges and corners shall be ground to a minimum

radius of 2.0 mm and all sharp irregularities, burrs, surface scale, slag
and spatter on welds, whether apparent before or after blast cleaning,
shall be removed before the commencement of coating application.

All steelwork items to Class 22 (near white metal) finish.

After cleaning steelwork items shall be not dip galvanised in

accordance with the requirement of AS 1650 Hot-Dipped Galvanised
Coatings on Ferrous Articles. A minimum coating mass of 600g./m 2
shall be achieved on all articles. It is not necessary to achieve specified
coating deposit on the inside of hollow section members.

After galvanising surfaces of all articles shall be smooth and

uniform with no defects, surplus zinc deposits, or other residues.

Testing of Galvanised Coatings

Coating shall be visually inspected for defects and tested for

coating mass and adhesion in accordance with the procedures set
out in AS 1650. The maximum area of defects shall not exceed
 0.1% of the surface area coated or 250 cm2 whichever is lesser.
Individual defects shall not exceed 40 cm2 .

♦ Repair of Galvanised Coatings

Any damage to galvanised coatings from handling, welding,

etc. shall be repaired by abrasive whip blasting the damaged area
and applying an approved cold galvanising compound.

Finishing Coating on Galvanised Articles

After inspection and testing galvanised articles which have

been designated to be top coated e.g. handrails, safety guards, etc.
shall be finished coated as herein specified.

Articles to be top coated shall be cleaned of any

contaminants and if necessary washed with an approved
emulsifying degreased agent. After cleaning articles shall be given
a light whip blast to remove surface oxides and to provide sufficient
surface profile (should have uniform grey colour) for adhesion of
prime coating. Any sharp edges, fins or other defects of a sudden or
local nature be sanded smooth or made good in an approved
manner.

Only dry blasted cleaning techniques using inert blast media

shall be used and all precautions, controls on weather conditions
and care of articles after blast cleaning shall be observed as
previously specified for steelwork.

13.19 COLOURS SCHEME FOR PROTECTIVE COTINGS TO

STEELWORK.

Prime Coatings : As supplied by the Manufacturer grey matt finish

Intermediate Coatings : Grey micaceous iron oxide.

Finish Coatings : As detailed in the protective coatings colour

schedule.
13.20 SCHEDULE OF PROTECTION .

System Location Description

A All steelwork 1. Abrasive blast clean to class 2 ½
except as minimum in accordance with
specified relevant standards to roughness
otherwise. profile specified.
2. Apply two component, liquid/slurry,
moisture curing zinc rich ethyl
silicate coating to achieve a
minimum dry film thickness of
75um. (Sigma Silicate MC)
3. Apply a two component, recoatable
high solids, high build, polyamide
cured, epoxy MIO, intermediate
coating to achieve a minimum dry
film thickness of 100um (175 um
total thickness), in two coats, one
tack coat and one build coat.
(Sigma SC Miocoat) Apply a two
component high build polyamide
cured recoatable coating to
achieve a minimum dry film
thickness of 100 um (275um total
thickness). (Sigma Silicate CM)
B Internal Surfaces 1. Abrasive blast clean class 2 ½
of sealed and box minimum in accordance with
sections no relevant standards to roughness
access. profile specified.
2. Apply two component, liquid/slurry,
moisture curing zinc rich
ethyl/silicate coating (sigma
silicate CM) prior to fit up and
welding to achieve a minimum dry
film thickness of 60 um.
C Internal Surfaces 1. Abrasive blast clean class 2 ½
of sealed & box minimum in accordance with
sections limited relevant standards to roughness
access profile specified.
2. Apply two component liquid/slurry,
moisture curing zinc ethyl silicate
coating to achieve a minimum dry
film thickness of 75 um.(sigma
silicate MC)
D Internal 1. Prepare prime, intermediate,
surfaces of and finish coat as detailed above for
steelwork system A.
unlimited access
E. Previously 1. Abrasive blast clean class 2 ½
uncoated minimum in accordance with
proprietary relevant standards taking care to
articles. avoid damage to machined
surfaces, seal etc.
2. Apply a two pack non-reactive
high build polyamide cured epoxy
coating to achieve a minimum dry
film thickness of 125um.
3. Apply two component, recoatable
high solids, high build, polyamide
cured, epoxy MIO, intermediate
coating to achieve a minimum dry
film thickness of 100um (225 um
total thickness), in two coats, one
tack coat and one build coat.
(sigma SC Miocoat).
4. Apply a two component high build
polyamide cured recoatable
coating to achieve a minimum dry
film thickness of 100 um (325 um
total thickness). Sigma silicate
CM.
F Aluminium 1. Light abrasive whip blast clean to
fabrications remove oxides and provide
articles or sufficient dey for adhesion of prime
castrings, etc. coating (should achieve a uniform
grey colour)
2. Apply a two pack non reactive high
build polyamide cured epoxy
coating to achieve a minimum dry
film thickness of 75 um.
3. Apply two component, recoatable
high solids, high build, polyamide
cured, epoxy MIO, intermediate
coating to achieve a minimum dry
film thickness of 100um (175 um
total thickness), in two coats, one
tack coat and one build coat.
(sigma SC Miocoat).
4. Apply a two component high build
polyamide cured recoatable
coating to achieve a minimum dry
film thickness of 100 um (275 um
total thickness). Sigma silicate CM.
 G (a) Galvanising Abrasive blast clean to class 2 ½
fabricated articles, minimum in accordance with
etc. relevant standards.
Hot Dip galvanise in accordance with
AS 1650
G (b) Galvanised Light abrasive whip blast clean to
articles specified achieve a uniform grey colour to
to be top or colour provide sufficient key for adhesion
coated e.g. of prime coating.
handrails or safety Apply a two pack non reactive high
guards build polyamide cured epoxy
coating to achieve a minimum dry
film thickness of 75 um.
Apply two component, recoatable high
solids, high build, polyamide cured,
epoxy MIO, intermediate coating to
achieve a minimum dry film
thickness of 100um (175 um total
thickness), in two coats, one tack
coat and one build coat.(sigma SC
Miocoat).
Apply a two component high build
polyamide cured recoatable
coating to achieve a minimum dry
film thickness of 100 um (275 um
total thickness). Sigma silicate CM.

13.21 PROTECTIVE COATING COLOUR SCHEDULE.

The colour schedule below is preliminary only and is subject to

final approval by the Purchaser.

ITEM COLOUR BS 381C

COLOUR
Structural steel work, equipment, Grey Blue No. 692
etc.
Handrails Golden Yellow No. 356
Equipment, excluding guards Primrose Yellow No. 310
Equipment Guards Light orange No. 557
Electric Motors Bright Blue -
Underside of floors, interior White -
surfaces of wall cladding
PIPELINES :
Fresh Water (Potable) Middle Blue No. 109
Process water (from pond) Emerald Green -
 Fire Fighting Systems Signal Red No. 537
Compressed Air Artic Blue B25
Hydraulic oil Brown TBA

14.0 OPERATIONS AND INSTALLATION MANUALS.

14.1 GENERAL.

This clause sets out requirements for manuals covering the

installation, operation, maintenance and commissioning of machine,
equipment and plant supplied under the contract.

14.2 MANUAL DETAIL.

Manuals shall be sufficiently comprehensive to enable

personnel to operate and maintain the equipment in an efficient and
workmanlike manner.

Manuals shall include descriptive information with figure relating

to individual mechanical, electrical and instrumentation items of
equipment provided to assist personnel in becoming familiar with the
equipment and its operation.

Manuals shall include clear and concise instructions so as to

allow proper and safe installation, commissioning, operation, correct
maintenance and compliance with the warranty.

Such information shall relate specifically to the equipment

supplied. Any information which does not pertain to the equipment
supplied shall be removed or deleted. Maintenance instructions shall
be in sufficient detail both in technical write up as well as dimensional
sketches to enable overhaul and replacement of all parts.

Manuals shall be prepare in an electronic form and shall be

supplied both as hard copies and on magnetic media as specified
herein.

14.3 SUBMISSION OF MANUALS.

Draft copies of all manuals shall be submitted for review and

approval. A copy of this draft will be returned with appropriate
comments within ten(10) working days after receipt. These comments
shall be incorporated into a revised draft manual, copies of which shall
be resubmitted (if so instructed) for a second review.

Any second or subsequent reviews will be within five (5) working

days of resubmission.
 At such time when the comments confirm that the manual is
acceptable a final manual shall be prepared and submitted.

14.4 ADDENDA.

Should it become necessary to modify, or add to, the final

manual at some later stage, e.g. to include “As-Built” information,
copies of the addenda shall be issued for inclusion within the existing
manuals. Such copies shall be clearly marked for inclusion in final
manuals.

If the addenda modify the existing manuals extensively,

instructions will be given to reissue the amended manuals completely.

14.5 MANUAL CONSTRUCTION.

The document(s) shall be A4 size, bound in 4-ring hard cover binders

to a standard and colour agreed.
 Binders shall not be filled to more than eighty percent (80%) capacity
(including final manuals).Separate volumes shall be used as instructed
for different equipment types or separate components in the machine.
 The spine of each binder shall be marked with an appropriate volume
description as agreed.
 All units shall be SI units.
 All information shall be in English.
 All data sheets for proprietary equipment plant shall be clearly
reproduced, readable and shall indicate the appropriate information
pertinent to the installation and future procurement.
 The title and document number (which will be issued) shall be
displayed on the front cover and spine of the document to enable the
manual to be included in the document register.
 A4 divider strips or pages shall be used to clearly separate distinct
logical sections of the contents of the manual.
 All documentation and manuals shall also be supplied in the form of
either. CDs or
High Density Tape Cartridges – 120 M byte removable tape
cartridge.

14.6 CONTENT.

The document(s) shall contain the following – as a minimum :

 Contents listing for the entire manual plus individual volume detailed
contents pages.
 Equipment specification including a complete system description.
 Functional description of its operation.
  Isolation Procedures for all forms of energy
(electrical, kinetic, potential, hydraulic compressed gases, etc.)
that could present a hazard or risk of injury.
 Material Safety Data Sheets.
Safe Working Procedures.
Erection, assembly, installation, precommissioning and
commissioning instructions.
Operating instructions.
Maintenance schedule and instructions, including
disassembly/assembly procedures.
Lubrication schedule, including details of lubricant types, initial
fill quantities and intervals, intervals and units of measure (e.g.
hours or tonnes carried).
Tabulation of all consumables, excluding lubricants (e.g. fuel
type and quantity, electrical components, chemicals, etc.)
Performance Specification (including commissioning data).
Certified test sheets for all tests specified in the Contract.
Drawings (reduced to A3 or A4 sze) shall include, but not be
limited to :

General arrangements.
Component Parts
Flow diagrams
P & Ids
Electrical single line diagrams.
Circuit diagrams
Cabling, wiring and termination diagrams.

Listing of all parts including proprietary catalogue numbers and

names. All parts shall be referred to by INDIAN standard description
and coding.
Software listing, if appropriate, and details of all software.
Trouble shooting guide.
Recommended settings and calibration details of any protection or
control device.
A copy of all approvals, licensing and compliance donation related
to the equipment to be provided.
Recommended consumables and spare parts lists (with current
pricing and delivery period) for :

12 months of normal operation and maintenance.

Insurance against breakdown.

15.0 TESTING COMISSIONING AND ACCEPTANCE

15.1 GENERAL

All iron ore required for testing of the machines will be provided by the
Purchaser. The Supplier shall be required to liaise closely with
 the Purchaser’s staff during the commissioning period to ensure
that long delays do not eventuate.

The Supplier shall prepare and submit for approval a detailed

commissioning and test plan in accordance with the Documentation
Schedule.

The Supplier shall perform the commissioning activities in accordance

with the commissioning programme as mutual agreed between the
supplier and the Purchasers.

The commissioning shall be conducted in four distinct phases.

# Pre-commissioning
# No load commissioning
# Load commissioning
# Acceptance tests

The Supplier fully complied with the requirements all statutory

authorities requiring tests or inspections at any stage of
commissioning, including all statutory requirements for the
commissioning of Electrical installation.

15.2 PRE-COMMISSINOING.

Upon completion of the machine the supplier shall carry out a static
and dimensional inspection to establish that all parts of the machine
are complete and dimensionally correct and in accordance with the
contact documents and the machine is ready for pre-commissioning.

The supplier shall take all actions necessary to ensure that there are
no loose parts, tools or any other foreign materials on the equipments
or in any position that could cause damage to any plant or personnel.

The PLC for the machine shall be pre-commissioned off-site in

accordance with the approved testing plan.

All electrical equipments shall be tested to ensure that it is in a shape

and operable condition. Test shall be carried out on the main
switchboards after installation and prior to connection of out going and
incoming circuits. Tripping devices insulation and protection equipment
shall be tested at this time.

Correct phasing and direction of rotation of all motors shall be checked

prior to operation of mechanical equipments.

Tests for earth resistance shall be carried out for the complete earthing
system of the machine.
 All hydraulic piping and equipments shall be checked for leaks and
loose connections and brackets.

All mechanical components shall be checked for correct assembly and

alignment.

All equipments requiring lubrication shall be checked for the adequacy

and correct type of lubrication.

Calibration of all sensing and measuring equipment.

All motors shall be un-coupled and run for eight hours continuously as
a heat test. The motors shall be re-coupled and the drive alignment
rechecked.

15.4 NO LOAD COMMISSIONING.

When the work as specified has been completed and made ready to
function as designed and to checking and testing of electrical
equipments after installation has been completed the machine shall be
run and tested by the supplier under no-load conditions.

No-load tests are intended to demonstrate that all components will

function successfully separately and as components of an integrated
machine in accordance with the requirements of the Contract
Documents.

During no-load commissioning of the machine the yard conveyor shall

also be put into no-load operation by the purchaser. The supplier shall
be responsible to ensure that the no load commissioning is carried out
in accordance with the agreed Commissioning Programme.

Additional test may be required by the purchasers representative as a

part of the testing programme.

• As a minimum requirement the no load tests listed below shall

be successfully completed for the machine.

• The bucket wheel shall be tested for continuous operation for

three hours without reclaiming and with ten starts per hour
• The slewing motion shall be tested for continuous operation for
one hour simulating the required operations.
• The backlash shall be measured and recorded for all slew drives
at the upper and lower part of the gear tooth.
• The luffing motion shall be tested for continuous operation for
three hours.
• Reclaiming shall be demonstrated in semi automatic mode for a
period of three hours.
 • The traverse drives shall be tested in coordination with the slew
& luffing motions to simulate reclaiming operations.
• Empty conveyor shall be operated & tested for belt troughability
and training for a total period of twelve hours including a
minimum four hours continuous running. During these test the
conveyor shall be tested for ten equal spaced starts per hour
and two consecutive starts .These shall be concurrent with
slew , luff and travel motions.
• All safety , protection and alarming indicating devices including
but not limited to speed switches , blocked chute indication,
thermal protective devices, high wind protection, positional limit
switches, annunciators, alarm horns, lights etc. In addition the
supplier shall successfully demonstrate the integrity and correct
operation of the control signals to & from the machine to the
point of termination.
• Testing of the fire detection & protection equipment
• Testing of the lighting system
• Measuring & recording of all motor current.

15.5 LOAD COMMISSIONING.

Load commissioning test shall demonstrate that the machine can be

successfully operated continuously at the design capacity and in the
various operational modes for periods of eight hours and in complete
accordance with the contract documents and the operating instructions.

The following time period and the tonnages shall not be taken onto
account for calculating the average stacking , reclaiming or direct ship
loading

• Stand-by periods
• Non operating periods due to machine external requirements or
faults.
• Material on belt and in buckets and time for starting sequence
including
• period of machine positioning if required after actuation of belt
• misalignment switches.
• Tonnage and time to recover from the immediate stop
instruction say from
• a yard conveyor interlock.
• Times to reposition the machine after “standby or stop periods”
• Tonnage & times for lower operating rate test periods.
• Times for minor adjustments or programming if these required a
stoppage
• of operations.
• Times to move the machine to another area of the stock pile.
 As a minimum requirement the tests described below shall be
successfully completed for the machine.

Additional tests may be required by the purchasers representative as

part of the testing progamme.

The Reclaimer traverse , slew & luff motions shall be tested for the
required reclaiming operations at the sustained output capacities. The
drive shall also be tested with the intermittent and repetitious starts,
stops and speed variations on a continuous basis for three hours for
reclaiming and stacking mode each. Motor currents shall also be
measured and recorded.

The boom conveyor shall be operated at various flow rates up to the

design capacity stacking/loading for a continuous period of eight hours
and tested for the following:-

• Central loading at the receiving chute

• Belt training
• Spillage of material
• Proper operation of belt cleaning equipment.
• Braking of fully loaded conveyor with the boom in the maximum
inclined
• and down position or hoist position.
• Starting of fully loaded conveyor with the boom in the maximum
inclined or
• down position or hoist position
• Accuracy and continuity of boom conveyor belt wire
• Central loading on to the yard conveyor
• All safety, control, protection and alarm indicating devices shall
be tested
• including conveyor interlocks.
• Motor currents
• Monitoring of noise & vibration levels for compliance with the
specification.

15.6 ACCEPTANCE TEST.

Acceptance Test shall be demonstrate that the machine can be

successfully operated continuously at the design capacity and in the
various operational modes for sustained periods in complete
accordance with the contract documents and the operating instructions.

As a minimum requirement the acceptance tests described below shall

be successfully completed for each machine.
 Additional tests may be required by the purchasers representative as
part of the testing programme and prior to the issue of the certificate of
the commissioning.

The acceptance test for the machine shall be conducted for a total
reclaim of 200,000 tonnes. During the tests the supplier shall
demonstrate that the machine can provide the specified range of
effective reclaim capacities for all reclaim modes.

15.7 COMMISSIONING SPARES

It should be noted that commissioning will carried out on site

at Paradip Port in the State of Orissa in India. As a result
suitable quantities of spare parts shall be made available by the
Supplier to ensure that no commissioning time is lost while
waiting for replacement parts.

16.0 TRAINING

The supplier shall make available experience machine operators for

the formal training of operating & maintenance personnel .

The training shall be sufficiently comprehensive to enable the

nominated persons to operate & maintain the equipment in a safe ,
efficient & workman like manner. Training in the maintenance of
equipment shall include routine maintenance level, brake down
maintenance level & other levels as required.

The instruction shall be fully qualified & conversion with the

installations and with the details contained within the approved
operating & maintenance instructions.

The supplier shall train selected personnel in the techniques &

requirements to train future personnel.

All training methods shall have a contained consistent with the

operating & maintenance instructions provided by the supplier.

All necessary training aids such as Videos, models, hydraulic

simulators etc shall be provided & retained by the purchaser for future
training.

Training manuals and guides shall be submitted for approval in

accordance with the documentation schedule.

The supplier shall make the site & his personnel available during the
erection & commissioning of the machine to allow the purchasers
 operations & maintenance staff to become familiar with the machine &
the installed equipment.

The supplier shall allow for a minimum period of 12 weeks for operating
& maintenance personnel for the machine during the erection &
commissioning of the machine.

17.0 SPARES

The Supplier shall provide initial spares list as enclosed by the

Purchaser in the Tender Document. Annexure – 2 to this Section – VI.

18.0 TOOLS & MAINTENANCE EQUIPMENT

A Complete set of specialized tools, implements and instruments

required to satisfactorily maintain or service the machine and their
equipment shall be provided for the machine. The tool shall be new &
of first class quality
 SECTION – VII

ANNEXURE – 1
A. MECHANICAL
SL No
Item Make
1 Helical / Bevel helical gear box ELECON / FLENDER / SHANTI / GREAVES
2 Planetary gearbox DROSTNER / FLENDER / ITALIAN BRIVENI
3 Fluid coupling VOITH / PREMBRIL
4 Flange coupling STUWEE / ELECON / PRECISION / GBM

5 Gear coupling FENNER / ELECON / HIGH CLIFF /

CONCORD / RATHI(LOV EJOY)
6 Pin bush coupling FENNER / ELECON / LOVE JOY

7 Slip clutch couplinig FLENDER / MARK-AEC

8 Disc brake STROMAG / BUBENZER / SVENDBORG
9 E.H. Thruster brake STROMAG / TECHNOCRATS /
STROMKRAFT / BUBENZER
10 D.C.E.M Brake BUBNZER / STROMAG / ELECTROMAG /
TECHNOCRAFTS / STROMKRAFT
11 Ball bearing/ Roller Bearing SKF / FAG
12 Slew bearing ROTHE ERDE
13 Hydraulic Cylinder REXROTH / VICKERS / HUNGER
INTERNATIONAL
14 Hydraulic Power pack REXROTH / VICKERS
15 Taper disc coupling RINGFEEDER
16 Rail clamps BENGAL TECHNOCRAFTS
17 Lubrication system (Motorized) PRAKASH / AFM
18 Conveyor pulleys/ Idlers ELECON / TRF / KALI
19 External scraper HOESCH / TECHNOFAB / SCROPIO
20 Modular skirt & skirt rubber /Rubber Liner TEGA / THEJO / TECHNOFAB / KAVERI
21 Manganese liner TISCO / SAIL
22 Belt scale POWER BUILD
23 Motorized liner actuator HEINLEHMANN / INDIANA /
ACTUATOR INDIA
24 Dust suppression system EAGLE AGRO INDUSTRIES / HARLEY / TPS
25 Air conditioning system CARRIER / BLUESTAR / VIDEOCON /
VOLTAS
26 Bearing Housing MCROCH / SKF / FAG
B. ELECTRICALS

SL.NO I T E M M A K E
HT Switchgear & Accessories
1. HT VCB Panel : ABB / SIEMENS / JYOTI
2. CT and PT (Panel mounted
type) Cast resin
- Up to 11 KV : PRAGATI / KAPPA / JYOTI
3. HT Busduct : ECC / STARDRIVE / C&S
4. HT HRC Fuses : ALSTOM / SIEMENS / C&S/
FUSEGEAR IND. LTD/
ENGLISH ELECTRIC
5. HT Insulators and Bushings : WSI /BHEL / JSI / MODERN

HT Transformers & Accessories

1. HT/0.433 KV Cast Resin : KEC / ALSTOM / VOLTAMP

Medium Voltage Switchgear and control gear:

1. L.T Air Circuit Breaker Distr- : GE POWER / L&T / SIEMENS / ABB
ibution Board(including circuit / CROMPTON.
breaker)
2. L.T. Busduct : STARDRIVE / ECC / C&S
3. MCC (Non-Drawout) : L&T / SIEMENS/GE POWER/
TECHNOCRATS /
HINDUSTAN
CONTROL.
4. MCC(Non-drawout for rating below: SIEMENS / TECHNOCRATS / C&S
and including 1000 A)/PDB/LDB/ / L&T.
pushbutton station

Motors:
1. LT AC Motor (General purpose) : SIEMENS / CGL / KEC
Drives and control equipment
1. Converter duty cast resin transformer: HOLEC / ALSTOM / VOLTAMP
(HT kV)
2. VVVF drive : SIEMENS / ABB / ROCKWELL

3. UPS : EMERSON / HI-REL.

4. Isolator : SIEMENS / L&T / ALSTOM / ABB

5. Moulded Case Circuit Breaker/MPCB: L&T / SIEMENS / ABB / CROMPTON

/
ANDRE YULE
SL.NO I T E M M A K E

6. HRC Fuse : SIEMENS / L&T / ABB

7. AC Power Contractor : SIEMENS / L&T / ABB / SCHNEIDER.
8. Bimetallic Relay : SIEMENS / L&T / ABB / SCHNEIDER

9. Single Phase Preventer : L&T / MINILEC / SIEMENS.

10. Resistor : SIEMENS/PEFO / ELECTROMAG

/ FRANKLEIN

11. Semiconductor Fuse : ALSTOM / SIEMENS / FERRAZ

12. Thyristor : SIEMENS / HIND / RECTIFIER / USHA

Control Desks and Control Devices:

1. Control Desk/Panel/Local Control : SIEMENS / L&T / ABB / PYROTECH /
Box. TECHNOCRATS
2. Control Switch : SIEMENS / KAYCEE / ALSTOM
/ L&T / TELE-MECHANIQUE
3. Push-button : SIEMENS / BCH / L&T /
TELEMECHANIQUE

4. Limit Switch : SIEMENS / JAY BALAJI /

TECHNOCRATS / JAYASHREE
5. Change Over Switch/Selector Switch : C&S / KAYCEE / SIEMENS / BCH / L&T.
6. Timer /Time Delay Relay : BCH / L&T / SIEMENS

7. Emergency Switch/Belt Sway Switch : JAYASHREE / AG SYSTEMS / JAI

BALAJI
/Pull Cord Switch/Belt Slip Switch
8. Control Contractor /Relay : SIEMENS / L&T / SCHNEIDER
9. Master Controller : GESSMANN / STROMKRAFT
/ ELECTROMAG / TELEMECHANIQUE.
10. Control Transformer : INDCOIL / SIEMENS / AEP / UNIVERSAL
MAGNETICS / INDUSREE
11. Voltage/Power/Current/Frequency/ : ABB / AEP / SIEMENS / ALSTOM
Energy Transducers
12. Indicating lamp (including cluster : BINAY / SIEMENS
LED type)
13. Hooter/Buzzer/Bell : GETCO / KHERAJ / EDISON / KAKKU

14. Solid State Annunciator : APLAB / L&T / PROCON /

CONTROL AND DYNAMICS /
MINILEC / ELECMECH
Sl. NO. ITEM MAKE

15. Non-contact proximity JSI/AG SYSTEM / ROCK WELL /

Limit Switch TELEMECHANIQUE/ NIVO
CONTROL
16. Zero Speed Switch JAYSHREE / TELEMECHANIQUE

Electrical Measuring and Testing Equipment.

Electrical Measuring Instruments.

1. Ammeter / Voltmeter / AEP /IMP / MECO /RISHAB.

Wattmeter / Var- meter
2. Watt- hour Meter ALSTOM / IMP / AEP
3. Electronic Meter ENERCON / PML / SEMS / SIEMENS.

Lighting and Power Wiring Equipment and Accessories.

1. Dry type Lighting TRANS INDIA / INDCOIL / AEP / KAPPA/

UNIVERSAL MAGNETIC .
2. Lighting Fitting PHILIPS / BAJAJ / CGL / GE
3. Switch Socket Outlet CGL / B & C / BCH
4. MCB MDS / STANDARD / SIEMENS / HAVEELLS /
L & T / FGE POWER.
5. Fuse Switch Unit SIEMENS / L&T / GE POWER.
6. Single- Core Flexible Wire KDK / FINOLEX / GRANDLAY
7. Lighting and Power panels MDS / HAVEELLS / TECHNOCRAFTS

Cables and Cabling Accessories

1. XLPE Cable FORT GLOSTER / UNIVERSAL / CCI

NICCO / INDUSTRIAL .
2. PVC Cable and Silicon Rubber/ FORT GLOSTER / UNIVERSAL / CCI /
HR / Butile Rubber Cable FINOLEX / NICCO / INDUSTRIAL
3. Cable Termination Kit RAYCHEM / CCI / DENSON
4. Cable Reeling Drum ELECTRO ZAVOD / TECHNOCRAFTS
5. Cable Lugs CONNECTWELL / PHOENIX / DOWELLS

Miscellaneous

1. PLC ROCK WELL / SIEMENS / ABB

2. Diode USHA RECTIFIER / BHEL / ROTENSHAN
3. Battery CHLORIDE (EXIDE) / AMCO /
AMARRAJA
4. Battery Charger CALDYNE
5. Battery ( SMF ) EXIDE / YASAKA
6. Braking Resistance Panel RESITEC / NERKHADE / FRANKLEIN.
General Instrument

1. Ultrasonic Level Gauge TOSHBRO ( MILTRONICS) / ENDRESS-

HAUSER / CHEMTROL (VEGA) / NIVO
CONTROLS / JAYASHREE / NIVO CON-
TROL.

2. Electric Actuator AUMA / IL ( BERNARD) / LIMITORQUE /

ROTORK / MARSH / PREPEC.

3. Pneumatic Actuator VIRGO / KEY STONE / L& T

Instrument Cables and Accessories

1. Screened Cables, Control DELSTON/ FINOLEX / SPECIAL

CABLES /
Cables & Compensating Cables ELKAY – TELELINKS / CORDS /
TOSHNIWAL / UDEY
Process Control Computer System
1. Computer Systems –PCs / COMPAQ / IBM / HP / DELL
Workstation / Servers

2. Computer Peripherals – Printers HP / EPSON / TVS / LIPI / SAMSUNG

/ Scanners / Plotters

3. Cables – Fibre Optics / Co-axial / LUCENT / as per ITS Recommended Vendors

UTP/
Intercom System
1. Loudspeaker Intercommunication PHILIPS/ MOTWANE /BOSCH
System

Communication Cables DELTON / HCL / RPG / USHA BELTRON /

SPECIAL CABLES / FINOLEX.
 INITIAL SPARES FOR RECLAIMER (3000 TPH)

MECHANICAL

Sl.NO ITEM Quantity

01. Long travel drive unit complete, comprising of gear 2 Sets.
box, motor, brake & coupling ( One for L.H.S. &
other for R.H.S. drive).
02. Slew drive unit complete, comprising of motor, 1 Sets
gearbox, couplings, brake & drive pinion.
03. Boom conveyor drive unit complete, comprising of 1 Sets.
G.B, motor & couplings. .
04. Bucket wheel drive unit complete, comprising of 1 Sets.
motor, gear box, couplings & gear pump unit.
05. Buckets, ready for use. 3 Nos.
06. Luffing drive unit comprising of motor, pump & 1 Set.
couplings.
07. Long travel drives bogie unit complete assembly. 2 Sets.
08. Long travel non-drive bogie unit complete assembly. 1 Sets.
09. Boom conveyor drive pulley with pillow blocks. 1 Sets
10. P.C.R.D. Spares

a) All chains and sprockets, master links, 1 Lot

rollers 1 No.
b) Main drive gear box. 1 No.
c) Layering gear box 1 Set
d) Slip-ring assembly with carbon brush
11. Consumables spares such as ‘O’ rings, gaskets, oil 1 Lot.
seals , packing , fusible plugs, various valves & high
pressure hoses with pressure gauges for luffing
system & other hydraulic system for 2 years trouble
–free for operation.

ELECTRICAL
Sl. NO ITEM Quantity
Automation spares
01 Spares cards for PLC panel like input card (D/A) , Out 1 Set
put card (D/A), Processor , power supply card and
etc.

02 Spares cards for V-V-V-F panel like control card, 1 Set

interface card, power supply card etc.

03 Spare cards & cables for communication system if 1 Set

there any remote or local type.
04 Spare special semiconductor fuses. 1 Lot
Power Circuit Spares
01 Spare, contactors for all the drives. 1 Lot
02 Spare, kit & coil for all the power contactors. 1 Lot
03 Spare overload relays for all the drives. 1 Lot
04 Spare MCCB’s for all the drives & incomer. 1 Lot
Control Circuit Spares
01 Spare control ACM Relays for all the drives. 1 Lot
02 Spare control auxiliaries like MCBs, push bottoms , 1 Lot
indication lamps , control fuses , metering instruments
etc for all control panels.

NOTE:
1. The above list is indicative only.
2. Wherever it is in “ Set “ or “ Lot “, the items covered in the set/lot
must be mentioned by the Supplier.
 PARADIP PORT TRUST

VOLUME - III

[ SECTION-VIII ]

SITE HEALTH AND SAFETY MANUAL

FOR
CONTRACTORS

DESIGN, FABRICATION, SUPPLY, ERECTION

AND
COMMISSIONING OF RECLAIMER
OF CAPACITY 3200 TPH
 CONTENTS
1.0 PURPOSE, SCOPE, RESPONSIBILITIES AND OBJECTIVE

1.1 Purpose
1.2 Scope
1.3 Responsibilities
1.3.1 General Responsibilities
1.3.2 Safe Work Practices
1.3.3 Counseling and Discipline
1.3.4 Training
1.3.5 Divisional/State Managers
1.3.6 Project Managers
1.3.7 Supervisors/Foremen
1.3.8 Employee Responsibilities

1.4 Objective
1.5 Accident Prevention Planning

2.0 PROCEDURES

2.1 Safety Legislation

2.2 Health & Safety Plan
2.3 Site Safety Establishment
2.4 Site Access
2.4.1 Restricted Access
2.4.2 Construction Access
2.4.3 Site Lighting
2.5 Public Protection
2.6 Employee Protection
2.7 Hygiene
2.8 Housekeeping
2.9 Health Assessment
2.10 Hazardous Material
2.11 Certificate of Competency
2.12 Plant, Equipment, Machinery
2.13 Subcontractors
2.14 Safety Promotion
2.15 Safety Induction Programme
2.15.1 Site Specific Induction
2.15.2 General Safety Induction/Training
2.15.3 Specific Task Safety Induction
2.15.4 Supervisor’s Safety Induction
2.16 Safety Training
2.17 Safety Meetings
2.17.1 Meetings – General
2.17.2 Toolbox Meetings
 2.18 Site Safety Audits
2.19 Disciplinary Action/ Termination
2.20 Health & Safety Rules/Procedures
2.21 First Aid
2.22 Emergency Procedures
2.23 Fire Prevention
2.24 Fire Control
2.25 Fire Extinguishers
2.26 Notification of Accidents
2.26.1 Statutory Notification
2.26.2 Internal Notification
2.26.3 Conduct at Scene of Accident
2.26.4 Notification Concerning Major Accident/Injury
2.26.5 Media Policy
2.27 Accident And Injury Procedure
2.27.1 Minor Injury
2.27.2 Possible Serious Injury
2.28 Accident/Incident Investigation
2.28.1 General
2.28.2 Action
2.28.3 Major Accidents
2.29 Rehabilitation
2.29.1 General
2.29.2 Contact with Employee
2.29.3 Contact with Treating Doctor
2.30 Management Reports

3.0 EQUIPMENT/TOOLS

3.1 Equipment Safety – General

3.1.1 Hand and Power Tools
3.1.2 Electrical Equipment
3.1.3 Oxy-Acetylene, Welding, Cutting and Heating Equipment
3.1.4 Explosive Power Tools
3.1.5 Explosives
3.1.6 Compressed air
3.1.7 Radiation
3.1.8 UV Radiation and Heat Stress
3.1.9 Plant Safety
3.1.10 Other Equipment

3.2 Welding and Cutting

3.2.1 Fumes and Lack of Oxygen
3.2.2 Gas Welding/Cutting
3.2.3 Arc Welding
3.2.4 General Safety Requirements for Welding and Cutting
Operations

3.3 Site Electrical Equipment

 3.3.1 Electrical Equipment and Installations
3.3.2 Inspection and Maintenance of Electrical Equipment

3.4 Materials Handling And Safe Lifting

4.0 HAZARD APPRAISAL CHECK LIST

5.0 TRAFFIC

6.0 DANGER AND OUT OF SERVICE TAGS

7.0 SECURITY

EXHIBITS

Exhibit 1 - Typical Work Methods and Procedures

Exhibit 2 - First Aid Facilities and Requisites
Exhibit 3 - Workplace Injury and Disease Recording Form
Exhibit 4 - Accident/Incident Investigation Report
Exhibit 5 - Notes on How to Organise and Run Site Safety (Tool
Box)
Meetings
Exhibit 6 - Agenda for a Tool Box Meeting
Exhibit 7 - Minutes of Site Safety (Tool Box) Meetings
Exhibit 8 - Daily Inspection Checklist

Note Reference to positions in this Manual eg Director, Project Manager,

Foreman etc. refer to Contractors personnel holding similar levels of
authority regardless of their title.

Reference to Client is to the Engineer’s Representative of Paradip Port

Trust or Paradip Port Trust as applicable.
PURPOSE, SCOPE, RESPONSIBILITIES AND OBJECTIVE

1.0 Purpose

To establish and maintain a base system for the project to ensure :

(a) A safe and healthy environment is maintained on each

contractor’s worksite;
(b) All contractor’s personnel receive adequate safety training.
(c) Injuries and accidents are promptly treated and reported.

1.1 Scope

This manual applies to all activities undertaken on the Paradip Port

Project site, including:
(a) Site establishment and inspection;
(b) Safety meetings;
(c) Personnel protection and accident prevention;
(d) Accident investigation and reporting;
(e) First aid requirements;
(f) Personnel training;
(g) Contractor’s management and client reporting

1.2 Responsibilities

The Health and Safety Plan (HSP) prepared by Contractors for contract
work on the Paradip Port Project shall include the requirements of this
Manual as a minimum.

Where Contractors have health and safety procedures/regulations

which exceed the requirements of this Manual, the Contractor should
not lower his normal standard to comply with this Manual.

1.3.1 General Responsibility

The Contractor’s Health and Safety Plan is to clearly define

levels of responsibility and accountability for safety at
management, supervisory and employee levels and list the
duties, responsibilities and authority of the safety representative.

All employees have a responsibility to take all reasonable

precautions to protect the work, workmen and the public from
accident or damage. The Contractor will comply with the Client’s
safety requirements, all applicable laws and regulations and
conform with the various industry codes, standards and
recommended practices. Project Managers will also be
responsible to ensure that all their subcontractors adhere to the
same requirements and standards.
 The Contractor’s Safety Officer will make periodic reviews to
ensure compliance with the above requirement, and will report
any unsatisfactory situation observed for immediate remedial
action.

Project Managers must inform their employees that they (the

employees) have definite responsibilities for their own safety
and for the safety of fellow employees, and that they are
required to observe and follow all established site safety rules
and safe work practices, and must comply with all work
directives for the tasks assigned, Project Managers will direct all
their employees that they (the employees) will be required to
report to work at all times in a fit and proper condition to perform
their job in a safe, competent manner.

1.3.2 Safe Work Practices

Specific safe work practices and procedures covering all of the

Contractor’s various work operations must be developed by the
Contractor. Where applicable, the contractor may elect to use
the practices and procedures set down in this Manual which are
the minimum acceptable standard for the topics covered.

Note : Safe Work Practices are defined as “ An agreed, set

sequence of operations, using guards, safety devices and
protective equipment, so as to complete a job safely and without
danger to health”. They can be classified broadly into three
types:

(a) Simple systems covering use of safety equipment;

(b) Formal procedures for carrying out work processes (e.g.
entry into confined spaces);
(c) Special applications (e.g. Tagout/Lockout systems).

1.3.3 Counseling and Discipline

Project Managers are responsible for monitoring the safety

performance of their employees, they are also responsible for
discipline. Where an employee is seen to be disregarding
established safe work methods or rules, the supervisor should
counsel the employee with a view to improving the employees
knowledge and attitude toward his own safety and the safety of
fellow employees.

Counseling on its own is often all that is needed to correct a

performace problem, however in some instances a written
warning may be called for or even dismissal. This type of action
must be carried out in accordance with the Contractor’s
Industrial Relations procedures.
 If an employee behaves in a manner which intentionally
endangers or is likely to affect the health or safety of others, or
is likely to cause serious damage to property, then that
employee must be suspended from duty pending an immediate
investigation by his supervisor into the matter.

Similarly, action will be taken in the event of

 Consuming or being in possession of intoxicating

liquor, drugs or betelnut at work;
 Being unfit for work due to the influence of drink or
drugs;
 Fighting with or assaulting a person or persons;

Additionally, action may be taken against an employee for failure

to observe rules and regulations contained in other statutory
regulations.

It is the responsibility of each supervisor to ensure that their

employees are made aware of and comply with the Client,
Contractor and statutory regulations at all times.

1.3.4 Training

Project Managers are required to provide adequate training for

all employees in the application of safe work practices and
procedures. Supervisors and Foremen will be expected to
provide safety training in their sections and give individual
instruction as needed to new workers, and to those found
working contrary to project standards. It is important that each
employee also be instructed about hazards associated with the
work site, and in particular those hazards unique to his job.

1.3.5 Divisional / State Managers.

The Divisional/State Managers

The Divisional/State Managers are responsible for the

administration and implementation of the Contractor’s Safety
programme for all operations under their control.

The responsibility of the Division/State Managers include :-

(a) Directing and maintaining the Company Safety

programme for the Projects under his control.
(b) Functioning as a representative of the Contractor when
necessary in matters concerning safety.
 (c) Appointing of the person responsible for safety for the
various projects under his control.
(d) Promote total job safety by employees, subcontractors
and all persons on projects under his control.
(e) In conjunction with the Safety Officer and as appropriate
establish Project Specific Safety Procedures in line with
any additional Client Requirements.
(f) Liaise with the Safety Officer in the development of
accident prevention methods, procedures and programs.
(g) Monitor that all new employees are given induction and
safety orientation instruction.
(h) Promote and maintain a high standard of feedback on
safety and loss control to all relevant personnel.
(i) Advise the Chief Executive and Safety Officer as soon as
possible of any serious accident or incident.
(j) In conjunction with the Safety Officer, review serious
accident investigations to determine causes, and future
corrective action.
(k) Ensure that accident records and statistical data required
by the Safety Officer, Client and Government Authorities
is being provided.
(l) Ensure that Project Staff make hazard analysis of
planned operations.
(m) Ensure that the required reports and safety data are
submitted to the Safety Officer in accordance with
procedural requirements.

1.3.6 Project Managers

The focal point of the safety programme is the Project Manager.

He will appoint the Project Safety Officer, who will ensure that
on a day basis the safety programme is implemented and
ensuring the effective accident prevention planning occurs.

Project Manager will prepare the HSP and be responsible for

ensuring that safe working methods and practices are
implemented and ensuring the effective accident prevention
planning occurs.

Project Manager will prepare the HSP and be responsible for

ensuring that safe working methods and practices are
implemented to those employees under their control and to
ensure that sufficient plant and equipment is made available and
properly operated and maintained to facilitate proper access and
enable any operation to be carried out safely.

The responsibilities of the Project Manager/Project Safety

Officer include :
(a) Giving due consideration to all safety factors during pre-
planning prior to the commencement of any new work on
site.
(b) Ensure that all Construction Procedures/Method
Statements incorporate appropriate safety requirements
and that the methods are safe and practical.

Evaluate these procedures and other work methods

during the course of the work and modify if appropriate to
ensure safe and practical implementation.
(c) Prepare the HSP and thereafter comply with the HSP,
Client requirements and other applicable laws and
regulations and ensure that copies of all applicable
Health and Safety Regulations are available on site.
(d) Function as a representative of the Contractor when
necessary in all matters concerning safety.
(e) Ensure that all new employees are given induction, safety
orientation instructions and the necessary training.
(f) Promote total job safety by employees, subcontractors
and all persons in the job vicinity.
(g) Make his position in the safety programme clear to
supervisory personnel, union representative and
employees and stress the importance top management
attaches to safety.
(h) Ensure that appropriate medical and first aid equipment is
available and that appropriate qualified personnel are
available to administer first aid and medical attention.
(i) Ensure that appropriate fire fighting equipment is
available in good working condition and that established
emergency procedures are in place in the event of fire or
other emergency.
(j) Provide and enforce the use of all necessary personal
protective equipment.
(k) Provide properly guarded and maintained tools,
machinery and equipment and ensure operators are
trained and operate the same in a safe manner.
(l) Ensure that proper safe access and lighting is provided
with all necessary barricades and signs around
excavations, openings and hazardous areas.
(m) Ensure good housekeeping conditions are maintained.
(n) Ensure that fire hazards are eliminated.
(o) Ensure at any time that work, or partly completed work, is
not left in an unsafe condition.
(p) Acquaint themselves on the competency of site personnel
to carry out their duties.
(q) Advise employees regarding the hazards of their jobs and
instruct them on how to do their work safely.
(r) Correct unsafe work habits of employees as soon as they
are observed.
 (s) Ensure that periodic tool-box meetings are held with all
wages employees and attend as appropriate.
(t) Ensure that all subcontractors are advised of their
obligations under applicable legislation, codes of practice,
the HSP and all conditions set out in the contractual
documents. Obtain the name of the subcontractors
representative responsible for safety on the project.
(u) Ensure that subcontractors meet their obligations under
applicable legislation and those set out in the contractual
documents and in accordance with HSP.
(v) Eliminate unsafe conditions under their control and
promptly report those they cannot eliminate to the party
or parties who created the unsafe conditions and to the
Divisional/State Managers and Safety Officer.
(w) Participate in consultations with the Clients Safety
Representatives and act on any recommendations or
observations made by the Client.
(x) Participate in consultations with appointed Trade Union
Representatives concerning safety.
(y) Participate in safety hazard spotting walkabouts on a
weekly basis in conjunction with the Client.
(z) By means of a Project monthly checklist evaluate his
projects compliance with the HSP and take corrective
action on any deficiencies found. This evaluation is to be
made each month during on-site construction.
(aa) Maintain necessary registers and accident records and
promptly file report as required by the HSP.
(ab) Submit reports and safety data to the Safety Officer in
accordance with procedural requirements.
(ac) Promptly investigate any accident which causes injury or
damage to property. Complete the Accident Investigation
Report and forward copies to the Divisional/State
Managers, the Safety Officer and Client.
(ad) Advise the Safety Officer and the Divisional/State
Manager as soon as possible of any serious accident or
incident.
(ae) Review all supervisors accident investigations reports for
completeness and if necessary, make supplementary
investigations to determine causes and action necessary
to prevent recurrence.
(af) Take note of and implement recommendations proposed
by the Safety Officer, insurance company, Clients
representatives,or other sources.
(ag) Ensure that the necessary support is given to the injured
worker and his family to enable an early return to work.

1.3.7 Supervisors and Foremen

A Supervisor or Foreman must consider that his employees look
upon him as the direct representative of management, and,
therefore interpret his attitude towards safety as that of
management. Supervisors and Foremen must accept the
responsibility for accidents occurring in the area under their
supervision.

The Foremen’s and Supervisor’s responsibilities as they relate

to safety and loss control include :-

(a) Set a good example by following safety practices in all

activities.
(b) Conduct job hazard analysis of operations in his area so
that he has a thorough knowledge of the hazards
involved and the precautions necessary to guard against
them.
(c) Make a daily physical inspection of his area of
responsibility to assure that safe working conditions are
being maintained.
(d) Ensure that proper personal protective equipment is
issued and is used when necessary.
(e) Explain the hazards inherent in his area of responsibility
to all employees under his jurisdiction, especially new
employees.
(f) Provide continual supervision of his employees, so that
they do their work in accordance with safe working
practices.
(g) Maintain good house keeping conditions.
(h) Eliminate fire hazards.
(i) Insist on proper use of tools, machinery and equipment to
avoid breakdown and accidents and ensure that they are
maintained in good working condition.
(j) Promptly isolate any tools, machinery or equipment not
suitable for safe operation, either for repair or disposal.
(k) Provide proper/safe access and ensure that all accesses
are maintained in a proper and safe condition and that all
necessary barricades and signs are maintained around
excavations, openings and hazardous areas.
(l) Provide and ensure adequate lighting is maintained.
(m) Make sure that physical and mechanical hazards are
promptly corrected. If corrective action is not within his
authority, report the condition to his Supervisor or the
Project Manager/Project Safety Officer.
(n) Be familiar with the emergency procedures developed for
the project so that he can provide the leadership required
to cope with serious injuries, fires, excavations, etc.
(o) Hold regular tools box safety meetings with the wages
employees under his control.
 (p) All injuries, no matter how slight, occurring in his area
shall be reported promptly for first aid. A record shall be
kept of such injuries.
(q) The Foreman must investigate all accidents and incidents
which occur in his area. He shall prepare an accident
investigation report in conjunction with the Project
Manager/Safety Officer on all cases involving doctor care,
accidents which result in property damage, and first aid
cases which result in a reduction in the injured person’s
work capability and/or in the event of recurrence, might
have serious consequences.
(r) Carry out a weekly Safety Inspection of his area of
responsibility and file a Daily Inspection Checklist –
Exhibit-8.

1.3.8 Employee Responsibilities

The Contractor has a responsibility to provide and maintain, so

far as is reasonably practicable, healthy and safe working
environments and work practices.

Employees have a responsibility in the course of performing

their work to:

(a) take reasonable care for their own safety and that of
other persons who may be affected by their acts or
omissions.
(b) Co-operate in the fulfillment of the obligations placed
upon the employer.
(c) Comply with instructions given for their own health and
safety and those of others and with health and safety
procedures;
(d) Use safety devices and protective equipment and not
render them inoperative;
(e) Report forthwith to their immediate supervisor any
situation which they have reason to believe could
present a hazard;
(f) Report any accident or injury to health which arises in the
course of or in connection with their work;
(g) Assist new employees in the proper work procedures and
to recognise job hazards.
(h) Not remove or interfere with anything that has been
provided in the interest of health and safety in the
workplace.
(i) Not engage in any of the prescribed occupations as listed
unless the relevant certificates or permits are held.
 1.4 Objective

In complying with the requirements of this Manual the Contractor’s

objective is to complete his work in the Paradip Port Coal Handling
Project without accident or incident by ensuring the following :

(a) Promotion of safe work practices and safety consciousness

among all project personnel and sub-contractors.
(b) Defining all areas of responsibility.
(c) Providing adequate and correct equipment along with protective
safety gear and ensure its correct use.
(d) That every employee on this project is informed and trained to
perform his job in a productive safe manner through a proper
induction course, effective job instruction and adequate
supervision.
(e) Implementing an accident prevention programme.
(f) Adhering to the requirements and recommendations of the
Statutory Legislation, the HSP and the Client.

1.5 Accident Prevention Planning

To assist in the planning of accident prevention the following guideline

is provided.

Item Description Frequency Responsibility

1 Ensure an adequate Health and Initially Project Manager
Safety Plan is developed.
2 Carry out the Health and Safety Continuous All
Plan
3 Manage accident prevention Weekly Project Manager &
programme Project Safety Officer
4 Ensure the safety plan is Continuous Foreman and Project
communicated to all on site Safety Officer
5 Set a personal example in safe Continuous All
working and stimulate interest
by the subcontractor’s foremen
and operatives in their
responsibilities
6 Review all construction methods Continuous All
and procedures during their
development and after their
establishment, for safe working
and inherent hazards that may
develop with their
implementation
7 Liaise with and seek advice from Continuous Project Safety Officer
management, client and
appropriate Government bodies
as required.
8 Comply with all safety Continuous Project Safety Officer
requirements of client and
relevant Government
regulations.
9 Ensure that all aspects of Weekly Project Manager and
prevention are adequately Project Safety Officer
discussed at safety meetings
and project meetings.
10 Ensure the presence of a safety Project Manager
officer or suitable stand-in at all
times.
11 Conduct Hazard Appraisals of Weekly Project safety Officer
the site, giving written notice of and Foreman
all findings and items inspected
to the foreman or supervisor in
charge of the area, with a
duplicate copy to the Project
Manager
12 Ensure the recommendations of Continuous Foreman
Hazard Appraisals are carried
out as soon as possible and
within the timetable set.
13 Carry out Hazard Appraisals Continuous Foreman
recommendations within the
timetable set.
14 Maintain and up-to-date list on Continuous Project Safety Officer
site of personal particulars on all
staff and employees
15 Liaise with and seek advice from Continuous Foreman
he Project Safety Officer
regarding sectional safety
requirements
16 Advise Foreman and employees Continuous Project Safety Officer
on protective equipment and
devices designed to prevent
injury
17 Co-ordinate fire control and Continuous Project Safety Officer
prevention activities
18 Ensure that checks are Continuous Project Safety Officer
established and carried out & Foreman
regularly on the stability of all
structures
19 Maintain a Safety Information Continuous Project Safety Officer
Board
20 Update displays of safety Fortnightly Project Safety Officer
posters
21 Maintain a current list of Continuous Project Safety Officer
emergency numbers at each
telephone
22 Set aside areas of storage of Continuous All
materials, scraps, etc. clearly
marked and set access paths,
roadways, platforms, ladders
etc. and maintain high level of
good “housekeeping”.

2.0 PROCEDURES

2.1 Safety Legislation

The Safety Officer shall monitor safety legislation developments

and advise Division/State Managers of changes as appropriate.

The Division/State Managers shall ensure that Project Managers

maintain a current copy of the relevant Legislation in the Project
Offices.

The Project Manager shall ensure that the provisions of the

relevant state legislation are complied with on site and ensure
that his subordinate supervisory staff are familiar with “Duty of
Care” requirements of the relevant legislation and at Common
Law.

2.2 Health and Safety Plan

A Health and Safety Plan (HSP) shall be prepared by the Project

Manager, in conjunction with the Safety Officer, and approved
by the Division/State Manager prior to the start of work on site or
when required by the contract documentation.

The HSP shall incorporate requirements of this Manual together

with the specific requirements of the contract specification.

The HSP shall include relevant work methods and procedures

such as :-

(a) form work and false work

(b) trenching and excavation
(c) lasers
(d) demolition work
(e) material handling
(f) rigging & crane work
(g) mechanical & electrical safeguards
 (h) hoisting appliances
(i) scaffolding
(j) temporary power

Refer Exhibit 1 for a list/description of Typical Work Methods

and Procedures for particularly hazardous work procedures refer
to Section 2.20

The HSP shall make specific reference to :-

 identification of risk areas

 proposals for design solutions to risk areas
 action plans to address risk areas

The HSP shall be reviewed at Safety Meetings during the

course of the Project in order to ensure that it remains relevant
and up-to-date.

The Division/State Manager shall arrange for the HSP to be

audited on a regular basis at periods not exceeding six(6)
months.

2.3 Site Safety Establishment

At the commencement of the Project, the Project Manager shall

arrange for the following activities :-

(a) Establish a list of telephone numbers for contacting

emergency services and organizations.

 nearest doctor
 nearest ambulance
 nearest police
 nearest fire brigade
 nearest office of the Division of Accident
Prevention (or equivalent)
(b) Discuss and emphasize the HSP and procedures with all
subcontractors prior to their commencement on site.
(c) Ensure that a HSP is developed and approved for the
Project prior to starting on site
(d) Establish Safety Induction Training Programme and
Facilities
(e) Establish Site Safety meeting day and time.
(f) Position the Contractor safety performance record board
adjacent to the main entrance of the site.
(g) Where required, appoint a qualified Health & safety
Officer and clarify his duties and procedures.
 (h) Display the site safety rules at each entrance to the site
or as appropriate.
(i) Exhibit mandatory safety signs at each entrance and at
strategic locations around the site.
(j) Ensure sufficient forms are available on site for reporting
and notification in accordance with procedures in the
HSP and Government Legislation.
(k) Establish the First Aid attendance location and stock with
necessary requisites.
(l) Provide a Register of Certificate Holders containing the
names of all First Aid Attendants and other persons
holding certificates of competency for prescribed
occupations.

2.4 Site Access

2.4.1 Restricted Access

Access to the Site will be restricted to authorized

personnel. All Site Visitors will be directed to the Site
Office, by way of signs and barriers, where a register
book will be signed at the time of entry and again at the
time of exit from the site.

Site Visitors will be given an evacuation plan and

escorted to the point of destination. Visitors are to be
accompanied at all times by Contractor’s personnel who
have received safety training on the site. If the contractor
requires visitors to go about their business/ activities on
site unescorted, then the visitor must undergo induction
and basic safety training.

Visitors will be refused entry to the site should they not

have the necessary protective clothing and equipment.

All children will be refused entry to the site or removed by

the Contractor if they appear on the worksite.

2.4.2 Construction Access

At all times throughout the Project, safe and protected

means of access will be provided for personnel.

The selection and use of access walkways, stairs,

platforms, hoists and ladders shall comply with the
relevant safety code.

Access for emergency evacuation of personnel shall be

shown in the HSP.
 2.4.3 Site Lighting

The Contractor will provide lighting to work areas where

Contractor employees are required to work.

Task lighting shall be provided by the relevant

subcontractor and shall remain in place until the task is
complete. The minimum illumination shall be stipulated
for each type of activity.

All bulbs and tubes will be provided with guards to

prevent damage to lights.

2.5 Public Protection

The public shall be protected from the normal dangers
associated with a construction site.

The methods adopted by the Project Manager to safeguard the

public are to be detailed in the HSP and may include :-

 Perimeter fencing or hording

 Warning lights and other lighting
 Restrictive or no access signs
 Gantry walkways
 Safety signs

2.6 Employee Protection

Personal safety equipment is to be supplied to every employee

by the employer whilst the work being performed by the
employee could be injurious to his health and safety.

Types of safety equipment may include :-

 Safety helmets
 Eye protection
 Respiratory protective equipment
 Hearing protection
 Life jacket and rescue equipment
 Safety footwear
 Hand protection
 Safety belts and harnesses

Safety boots/shoes and safety helmets shall be worn by all

employees at all times on site.
Other types of protective equipment will be given to the worker
as the need arises.

All employees of the Contractor will be provided with a safety

helmet, safety shoes, safety goggles and ear plugs and will be
required to acknowledge receipt of same.

All safety clothing and equipment shall be supplied in good

working condition. Personal protective clothing should be
cleaned and sterilized before re-issue.

To ensure their own safety employees must.

 Wear protective clothing or apparel where required

to do so.
 Wear safety shoes, safety helmet, safety glasses
and other safety items where indicated/required.
 Keep work site and work areas tidy.
 Use ear and hand protection where hazards exists;
be alert to operating plant/equipment and observe
warning signs;
 Use correct tools and safety apparel for the job;
 Maintain personal hygiene eg. Wash before meals.

When employees see a potential hazard or unsafe practice they

must do something about it.

 Tactfully alert a fellow worker when engaged in

unsafe practices;
 Share what they know and help others achieve
safe working practices;
 Report potentially dangerous situation or practices;
 Barricade, signpost or remove hazard where
practical.

A clean workplace is a safer workplace, so employees have

have a responsibility to keep their workplace and amenities
areas clean, And;

 Remove rubbish progressively;

 Stack and store materials;
 Keep walkway stairs and access ways clear;
 No open fires or burning of combustible materials;
  De-nail timber progressively;
 Keep toilets and wash rooms clean and hygiene;
 Wash with soap, prior to eating.

Jewellry, hair and clothing can cause serious personal injury if it

catches on something. So, employees must be aware of :

 Loose hair, clothing and neck ties. Make sure they are contained
appropriate to the work environment or removed.
 It is advisable not to wear rings, bracelets, watches, chains (leg/neck)
on the job.

2.7 Hygiene

The Contractor and each Subcontractor will be responsible for

the cleanliness of their respective site accommodation. Food
scraps are to be deposited into receptacles provided and
disposed of daily. All eating areas are to be cleaned daily.

The ablutions and cold water fountains shall be thoroughly

cleaned and disinfected daily.

Toilet and washing facilities will be provided in accordance with

the relevant regulation and shown in the HSP.

2.8 Housekeeping

High risk areas such as stairs and areas giving access to

working areas shall be cleared regularly.

The cleaning of specific work areas will be the responsibility of

the employer or supervisor of workers performing that specific
task.

These work areas are to be cleaned at the end of each day with
the rubbish being deposited into the rubbish receptacles
provided. Rubbish will be removed from the site as necessary
and disposed of in accordance with the requirements of the
Client.

2.9 Health Assessment

Employees shall undergo a medical review of either completing

a hand written questionnaire or undergoing a medical
examination.
 The reports generated shall be examined by the Employment
Officer and Supervisors to assess the physical condition of the
prospective employee so that they can be assigned to a suitable
job in which their disability, if any, will not affect their personal
efficiency, safety and health and also will not affect the safety of
others.

2.10 Hazardous Materials

Before any product of a hazardous nature is brought on to the

project site a Material Safety Data Sheet (MSDS) is to be
supplied to the Safety Officer.

The Safety Officer will maintain a register of MSDS of all

hazardous substances being used on the Project and shall
monitor their use on a daily basis.

Products requiring MSDS include, but are not limited to :-

(a) Paints and other surface coatings including mastics,

varnishes and solvents.
(b) Glues, adhesives and joining compounds (eg. Silicone,
sealants and encapsulants)
(c) Cleaning agents, disinfectants and deodorisers –
industrial and personal.
(d) Particle boards
(e) Cement and refractory products
(f) Pesticides and herbicides
(g) Pipe gaskets, seals, insulation ropes
(h) Welding fluxes/rods
(i) Gases – inert and toxic
(j) Chemical anchors
(k) Motor fuels, engine oils and lubricants
(l) Radioactive material
(m) Insulation material-heat and acoustic (eg. Fibrous
blankets/batts, boards, wool, dry powders for wet
spraying)

When a hazardous substance is first supplied to the workplace,

the Contractor shall advise all employees of the requirements
with respect to storing and handling the hazardous substance.

2.11 Certificate of Competency

Only persons with the necessary Certificate will be engaged in

the following occupations :-

 Crane chaser
 Demolisher
 Explosive Powered Tool Operator
 Plant Operator
 Scaffolder
 Crane Operator
 Dogman
 Machinery Operator
 Rigger
 Welder

Persons learning these occupations are required to take out a

learners permit and are required to be supervised by a person
who is the holder of the relevant Certificate of Competency.

The Safety Officer shall maintain a Register of Certificate

Holders containing the names of all employees (including
subcontractors) performing work which requires a Certificate of
Competency.

The Safety Officer will perform spot checks of persons

performing restricted occupations, checking names against the
Register of names supplied.

2.12 Plant, Equipment, Machinery

In order to facilitate the safe movement of personnel and

materials about the project site, various types of plant and
equipment (eg. Cranes, hoists, etc.) shall be used.

Before erection of all plant, it will be completely overhauled and

checked by an inspector or by persons having accreditation.

A Certificate of Registration is to be provided to the Project

Manager prior to any classified plant being used on the project.

All listing attachments, lift boxes, lift cradles, etc. will have its
design registered before being used on the project.

All crane operators shall make daily entries into the crane log
book which is to be signed off weekly by the crane operator and
Project Manager. The log book is to remain in the crane cabin.

All hoists shall include a log book which must provide full details
of all inspections and maintenance, giving details of who carried
out the inspections and on what dates.
 All electrical equipment shall be inspected and tagged by a
certified electrician at 6 monthly intervals and recorded.

All mobile machinery eg. Excavators, trucks etc. shall be

inspected prior to being used on the site. If the equipment is
inappropriate for the task, is not in good working order or is
unsafe to operate it shall not be used.

2.13 Subcontractors

The evaluation and selection of Subcontractors shall include an

assessment of their ability to perform work safely on site.

Subcontractors with good safety track records should be given

preference to those whose performance is questionable.
Documented evidence of the Subcontractor’s safety
performance is to be submitted and reviewed prior to award of
the subcontract.

The Subcontract Agreement shall include a list of site safety

instructions and in particular shall bind the Subcontractor to the
requirements of the HSP.

A safety plan is required from Subcontractors, outlining the

methods to be adopted to safely perform their tasks. The plan
shall be submitted to the Project Manager for review prior to the
Subcontractor commencing work on site.

The Project Manager shall obtain written confirmation from all

Subcontractors engaged on the site that they have given
adequate safety induction for their specific discipline to all new
employees. Furthermore, an assurance is required that all future
employees will receive adequate specific safety induction prior
to commencement on site.

2.14 Safety Promotion

The Project Manager with the aid of the Safety Officer will
assess the best methods to be adopted to promote and
publicize safety on each individual site.

Suggested methods include :-

 Training sessions
 Brochures and pamphlets
 Safety Newsletter
 Recognition Awards
 Management Example
 Films and Videos
 Posters and Notice Boards
 Accident Targets or Objectives
 Suggestion Schemes
 On-the-Job safety Programme

One of the most effective safety monitors is for management to

create the perception among the work force that high standards
of safety are demanded and that anything less is unacceptable.

The HSP shall list the methods to be adopted for this project.

2.15 Safety Induction Programme

The Project Manager shall ensure that the following Safety

Induction Programmes are implemented.

2.15.1 Site Specific Induction

All personnel are to b briefed on the Contractors HSP

prior to commencement of work on site. The purpose of
this meeting is to instil into personnel the work ethic of
“working safely” and their responsibilities towards their
workmates.

All employees on site shall receive further induction which

includes :-

(a) Introduction of Site Management personnel and

relationship/ responsibility to the Client.
(b) Location of first aid facilities on site.
(c) Names of first aid attendants
(d) Accident emergency procedures
(e) The importance of complying with the HSP and
what to do in the event of an accident.
(f) Introduction of Safety Officer/Representatives,
outlining their responsibilities and authority on site.
(g) Evacuation procedures (if applicable):

 Location
 Hoists
 Ramps

(h) Orientation including :

 Introduction to the project

  Project facilities
 Local customs, traditions and laws
 Conditions of employment
 Site rules
(i) Instruction that each employee is required to :

i) Recognise and accept responsibility for his

or her own safety and the safety of others
and also for preventing any damage or loss
to port trust property or otherwise and to act
in a safe manner at all times.
ii) Follow all established safety procedures
and participate actively in improving existing
procedures and in formulating new
procedures.
iii) Follow all regulations designed to increase
safe working practices and conditions.
Failure to observe regulations can be
grounds for instant dismissal.
iv) Report without delay all accidents, whether
to himself or herself or to plant, and to
complete the employee’s portion of any
report form
v) Wear and use at all times the protective
clothing and personal protective equipment
provided as and where conditions dictate
vi) Report immediately any unsafe conditions
or potentially unsafe conditions so that they
may be remedied.
vii) Use machinery, equipment, tools, etc. only
for their designed purpose.
viii) Adhere to all requirements specified in work
permits and attached certificates.
ix) Familiarize himself/herself thoroughly with
the safe working codes, practices and
procedures and adhere to them at all times.
x) Adhere to safe driving rules with respect to
speed, dust, road conditions, vehicle
maintenance, radio use and water supply.
xi) Work in such a manner as to prevent
environmental pollution.

2.15.2 General Safety Induction/Training

All employees shall be issued with a Safety Handbook

and attend training on basic safety.
 The Safety Induction should cover as a minimum the
following topics.

 Safety policy
 Statutory Regulations
 First aid facilities
 Personal hygiene
 Tagout/Lockout procedures
 Fire prevention
 Safety meetings
 General safety rules
 Accident/Incident reporting
 Emergency procedures
 Housekeeping
 Confined space procedure
 Personal protective equipment

On completion of the induction programmes all persons

present will be required to complete the induction record
card (attached to the handbook) which will be filed on
site. The employee will also be given a card which is to
be signed by the inducting officer as well as the employee
as evidence of his induction.

2.15.3 Specific Task safety Induction

Job-Specific Inductions

The objective of the job-specific induction is to ensure

that the employee has the ability to perform his job in a safe
manner and to ensure that he has a full understanding of any
potential hazards associated with his work or work environment.

The job-specific induction should be conducted by the

new employees’ supervisor, as he will have an intimate
knowledge of the work and work practices that the
employee will be involved in. The job-specific induction is
a very important part of the overall orientation / induction
programme. Apart from the specific job instructions
received, it is here that the groundwork is laid for the
future relationship between the employee and his boss.

2.15.4 Supervisor’s Safety Induction

 Management Safety Induction is to be provided to all
supervisory staff prior to their commencing work on a
project. Where possible, the Safety Officer will conduct
this training and in all other situations it will be conducted
by the Area Manager. The induction will include the
requirements of the Contractor’s operation to ensure
management staff on site have the necessary skills and
knowledge to allow the work under the contract to be
carried out safely, efficiently and competently and in
accordance with the HSP. This training will include, but
not be limited to the following :-

(a) Explanation and supervision of safe work practices

of employees under their control.
(b) Review of the HSP including detailed review of the
Safety Policy, the Supervisors responsibilities and
the employees responsibilities.
(c) Provision of effective communication between
management and the work force.
(d) Interpretation of occupational health and safety
legislation and work instructions.
(e) Complying with the Site Health and Safety Manual
for Contractors prepared by the Client.
(f) Induction of new and transferred employees.
(g) How to organize and run Induction Courses and
Safety Tool Box Meetings.
(h) Continual instruction of all (i.e. old and new)
employees when the necessity arises.
(i) Ongoing monitoring of work practices to detect and
correct any dangerous acts and conditions in the
workplace.
(j) Reporting and correct investigation of all
accidents, including those not involving personal or
property damage.
(k) Basic concepts and theories of accident
prevention.
(l) Cost effectiveness of safety planning.
(m) Carrying out workplace safety inspection/audits.
(n) Training covered by 2.15.1, 2.15.2 and 2.15.3
above.

2.16 Safety Training

All managers and supervisors shall ensure that all employees

under their control receive training in basic safety techniques
using Classroom and/or on-the-job instruction. Such training is
to include, but not be limited to :-

 Personal protective equipment

  Scaffolding/access/ladders
 Aerial work platforms
 Boatswains chairs
 Light duty suspended stage
 Barricades
 Barriers around excavations
 Roadway working
 Portable powered tools and equipment
 Mobile plant
 Cranes
 Gas cylinders
 Welding protection
 Housekeeping
 Perimeter guarding
 Hazardous materials
 Trenching and excavations
 Electrical safety
 Rigging and crane safety
 Fire fighting equipment
 Other items

The Safety and/or Personnel Officer shall maintain a register to

record the training courses given to all staff.

On the job training will include continuous supervision by

foremen of personnel during the works to ensure correct working
methods are used.

A rescue team shall be trained on site with a nominated vehicle

and driver for ambulance purposes. Several of the Contractor’s
staff and wages employees are to be holders of First Aid
Certificates.

2.17 Safety Meetings

2.17.1 Meetings – General

Safety meetings attended by representatives of the

employees will be scheduled and conducted by the
Safety Officer.
 The meeting shall be conducted at intervals not
exceeding two(2) weeks and conform to the following
agenda items :-

 Introductions
 Attendance
 Apologies
 Minutes of previous meeting
 Review of injuries, accidents and dangerous
occurrences
 General business
 Date of next meeting
 Closure

In addition to this meeting, the Contractor will be required

to attend a Project Site Safety Meeting involving all
Contractors held by the Client’s Construction Manager on
a monthly basis.

2.17.2 Toolbox Meeting

A programme of regular safety meetings shall be

implemented and regular “toolbox” meetings shall be held
with each crew, conducted by each supervisor and
reported to the Safety Officer. Exhibit 5, 6 and 7 provides
a guideline for “toolbox” meetings.

2.18 Site safety Audits

Regular site inspections shall be conducted to identify and

rectify dangerous situations.

Inspection Methods include

(a) Informal Supervisor “walk around”

This inspection should be carried out every day during

the course of normal supervision and should detect at
least the most obvious of hazards. The supervisor shall
endeavour to attend to the corrective action personally
and immediately.

(b) Systematic (or formal) Management Inspections

(i) Daily Inspection

 The Safety Officer shall carry out a daily inspection
of the work place to discover any unsafe or
unsatisfactory conditions.

The daily report – see Exhibit 8 – shall be

completed and issued to the Project Manager who
shall implement necessary corrective action.

(ii) Weekly Inspection

A full site audit shall be performed once each week

by the Audit Team and a Report issued to the
Project Manager.

The Audit shall include

- Project safety Officer

- General Foreman or Foremen
- A Client Representative

During inspection, the Audit Team should consider

questions such as

- What could fail ?

- What are people doing ?
- What might people do ?

2.19 Disciplinary Action/Termination

Refer to Section 1.3.3.

If poor safety performance persists, the employee shall be

interviewed and then given notice summarizing the particulars of
the issue and necessary corrective measures. The relevant
union delegate shall also be advised of the current situation and
enforcement procedure contemplated.

Failure to effect an improvement after issue of this notice may

lead to stand down or dismissed and the union delegate shall be
informed.

2.20 Health and safety Rules/ Procedures

Particularly, hazardous work procedures shall be documented

with the employee receiving verbal as well as written instructions
on how to successfully and safely complete the task.

The types of tasks which would require a written job

procedure/rule may include :-
(a) Working with flammable liquids, chemicals, epoxy resins,
etc.
(b) Removal of contaminated materials
(c) Work in confined spaces
(d) Working about live electrical installations
(e) Use of explosives
(f) Dismantling equipment
(g) Difficult or hazardous construction activity
(h) Any other activity that will place personnel other
Contractor’s personnel or the public at risk.

Safety rules/procedures shall be clearly presented and follow

the following format :-

- Purpose
- Scope
- Responsibilities
- Procedure
- References

The following considerations should be made when designing

safety rules/ procedures.

Objective What is the purpose of having the safety

rules ? What is being protected, etc. ?

Explicit The rule must not be open to opinion or

ambiguous in its meaning. It must be exact.

Measurable The rule must be measurable in that those

enforcing the rule can see clearly whether it
is being obeyed or not.

Operator Input Employees should be told of the risk and

asked for their opinion as to how the risk
can be controlled.

Enforcement Once a rule is approved it should always be

enforced.

Revision &
Approval Safety rules should be approved by the
Project Manager and periodically reviewed
to ensure they are still applicable.

Application Safety rules must be used consistently and

be uniformly applied across the various
sections or the operations.
2.21 First Aid

A facility for the administering of first aid is to be provided and

located in a readily accessible position.

First Aid facilities and requisites shall be provided in accordance

with Exhibit 2 “First Aid Facilities and Requisites”

The HSP shall identify the location of First Aid Facilities and the
name of the First Aid Attendant.

A First Aid Attendant with current qualifications shall be

available during working hours to attend to an injured person.
This person must be immunized against Hepatitis B virus and
must wear disposable surgical gloves when treating an injury.

All accidents and incidents requiring First Aid Treatment should

be recorded by the First Aid Attendant immediately after
treatment.

Note : The recording of this information is essential irrespective

of how minor the treatment provided.

The First Aid Treatment Record shall be produced at site safety

meetings where all accidents occurring in the preceding weeks
will be analysed with the view of preventing recurrence.

2.22 Emergency Procedures

Documentary emergency procedures shall be provided for :-

- Accident and Injury

- Fire

(a) In the event of an accident/injury emergency the following

should occur :-

- Secure any dangerous situation that

prevails at the scene of the accident.
- Arrange to call an ambulance and ensure
that a clear report is given as to the :

- type of accident
- location of accident
- number of casualties
 - Ensure that the injured receive, prompt
medical attention. Do not move patient
unless he is in danger. If Competent :-

- determine if the patient is breathing

and has a pulse.
- commence cardiopulmonary
resuscitation (CPR) as necessary
- Ensure that the accident is fully
documented. Do not change location of
objects at scene of accident.

(b) In the event of a fire emergency the following should

occur :-

- Raise an immediate alarm in the local area

by shouting “fire, fire” and direct attention to
the area concerned.
- Check all employees to ensure no one is
trapped.
- Get and use the right type of fire
extinguisher in the correct way. Remember
that fire extinguishers are the first line of
defence. Simultaneously, size up the risk
and if the fire appears to be beyond the
scope of the equipment or vital plant is
involved, send for additional support.
- If other men are in the area, get one of them
to raise the alarm by following emergency
procedures. Have other men get more of
the right type of extinguishers as back up.
- If a single employee is in attendance, and
the fire gets beyond the scope of his
equipment, leave trying to fight the fire and
raise the alarm by radio or phone.
- Evacuation paths and congregation points
are to be shown on sketches which shall be
given to all personnel at the induction
session and be displayed at each main
work area.
- First Aid procedure is to be given to every
Subcontractor and explained to every
worker at induction, a copy of which is to be
displayed in every crib room.
- Emergency services such as police, fire
brigade, ambulance shall be contacted and
informed of access to the Project in case of
emergencies.
 - An evacuation stretcher which can be safely
slung to a crane shall be stored at the First
Aid Room.
- Cranes and/or hoists shall be made
available should the need arise to evacuate
an injured person.
- The HSP shall include specific emergency
procedures and details.

Whilst workers are present on the site, the site

office will remain open so as to provide ready
access to phones in the case of emergency.

2.23 Fire Prevention.

Project Manager is responsible for establishing practices and

procedures for the prevention of fire and to fully instruct
employees in these safety practices. Such practices should
include (but are not limited to) the following.

- Don’t allow rubbish to accumulate. Work areas must be

kept clean and proper rubbish bins or containers
provided. Good housekeeping is the first principle of fire
prevention.
- Smoking, open flames, welding, acetylene and oxygen
cutting or fires are not permitted within eight meters of
fuel storage tanks, fuelling areas, LPG gas storage tanks,
battery charging areas or in any area or building
designated as a “No Smoking” area.
- “No Smoking” signs must be posted in hazardous areas,
and they shall be observed by all persons.
- Solvents must not be used near an open flame or other
ignition source or in an atmosphere that can elevate the
temperature of the solvent above its flashpoint.
- Particular care must be taken to remove any combustible
materials, suitable precautions shall be taken to ensure
that sparks, slag or hot metal will not ignite such material.
Where required a hot work permit shall be obtained prior
to commencing welding or cutting work.
- Spills of flammable liquids and excess grease must be
cleaned up immediately.
- Combustible material such as sawdust must not be used
for catching oil drips or for mopping up as this leads to
additional fire hazards including the risk of spontaneous
combustion.
- Materials such as oily waste or rags, which are subject to
spontaneous combustion must be placed on covered
metal containers until disposed of properly.
- Oxygen cylinders must not be stored near oil or grease.
2.24 Fire Control

In the event that a fire breaks out on the project site, the area
supervisor must take immediate control of the situation and take
all necessary actions to ensure the safety of employees and the
protection of plant and equipment.

Most fires have small beginnings and the best time to stop a fire
is when it is small. This can be done by making certain that
employees are given basic instructions on what to do in the
event of a fire and, that they all :

 Know how to give the alarm

 Know where fire extinguishers are located
 Know how to use each type of extinguisher
 Know what type of extinguisher to use on a
particular type of fire, and
 Know where fire hoses are located and how to use
them.
 Know the telephone no. of the CISF Fire Station.

2.25 Fire Extinguishers

Portable hand held extinguishers must be conspicuously located

along normal paths of travel so that they are quickly accessible
for immediate use.

Fire extinguisher locations are to be marked with appropriate

identification signs.

Interference, misuse or horse-play involving this emergency

equipment will be treated as a serious offence and appropriate
disciplinary action will be taken.

Employees are to be instructed in the use of fire extinguishers

and any other fire fighting equipment located in the project area.

Employees are to be instructed to report all fires immediately

and notify their supervisor if they have discharged or know of fire
extinguishers in need of servicing.

2.26 Notification of Accidents.

2.26.1 Statutory Notification

Where required by legislation the appropriate

Government Department shall be notified within 4 hours
 after the occurrence of an accident causing loss of life,
serious body injury, a work related illness or dangerous
occurrence.

Note : Serious bodily injury is defined as an injury that

causes death or disables a person to the extent that as a
consequence of that injury he is subject to a period of
admission to hospital as an in-patient.

2.26.2 Internal Notification

Immediately following an accident the Project Manager

and/or the Safety Officer shall investigate the cause of
the accident. Where possible the Project Manager shall
take immediate corrective action to prevent recurrence of
the accident.

2.26.3 Conduct at Scene of Accident

Where loss of life or serious bodily injury occurs, the

accident scene is to be left untouched until such times as
permission is granted by a Government inspector or
safety officer of Paradip Port or if an inspector is not
available, a member of the Police Force, except where
such movement is necessary to save life or relieve
suffering or to prevent danger to property or injury to
persons.

2.26.4 Notification Concerning Major Accident/Injury

As soon as possible after the occurrence of an accident

causing loss of life, serious bodily injury or causing
serious disruption to the area about the site, the Project
Manager/ Supervisor shall notify:

(a) Ambulance Service (injury only)

(b) Division/State Manager
(c) Appropriate Government Department
(d) Safety Officer
(e) Police (if death)
(f) Client’s Representative
(g) The relative of the worker died or injured.

2.26.5 Media Policy

After a major accident, it is usual for the media to arrive at

the site to cover the story. The site is to be closed to all
personnel, giving access only to Emergency Services,
Police, Government officials and the Client.
 The Project Manager or his representative should advise
the Media representatives that a Senior Representative
may supply details and information at a later date.

No other comments should be made by any site

personnel since statements made may be used against
those involved in future Common Law Cases.

2.27 Accident & Injury Procedure

The Project Manager or his nominee shall promptly investigate

all accidents to determine the real cause(s) and to initiate
corrective action. For all injury or disease sustained on the site
the “Workplace Injury and Disease Recording Form” – Exhibit 3
– is to be completed.

2.27.1 Minor Injury

In case of minor injury, the following procedure shall be

followed:-

(a) Treat the injury at the First Aid Facility.

(b) If necessary, obtain help from one of the First Aid
attendants.
(c) Report the injury to the Supervisor.

2.27.2 Possible Serious Injury

If a person has sustained possible serious injury, the

following action shall be taken :-

(a) A First Aid Attendant shall be contacted

immediately.
(b) In case of a serious injury, the patient should not
be moved other than to make him/her comfortable,
to prevent further injury and choking.
(c) If it appears that an ambulance is needed, the
Supervisor shall dispatch someone to inform the
office.
(d) The Safety Officer in conjunction with the Project
Manager will take control of the situation.
(e) Those required will remain with a First Aid
Attendant to assist as directed. All other personnel
shall vacate the area as directed by the
Supervisor.
(f) The Supervisor will direct a responsible person to
go to the closest site entrance to lead the
ambulance to the exact location of the accident.
 (g) The Supervisor will prepare a report of his
observations and involvement with the incident.
(h) Commence the accident investigation immediately.
Ensure that the injured person has been removed
from the site.

2.28 Accident/Incident Investigation

2.28.1 General

The benefits of a thorough investigation into the cause of

accidents/incidents include :-

(a) Prevent the recurrence of the same or similar type

of accident/incident.
(b) Reduction in damages to stock and equipment.
(c) Improved morale by corrective action.
(d) Reduction in lost time, delays and business
interruption.

An accident/incident is an unexpected variation from

normal processes of construction work or other activities
resulting in the potential (incident), or actual (accident),
damage to plant or equipment or the environment, injury
or illness to the Contractors’ or Subcontractors’
employees or any other person.

Accident/incident investigation is the systematic

observation analysis and evaluation of events that have
injured people and/or damaged property.

The three stages to an accident/incident investigation

are:-

Observation

Study of all factual evidence to gain a full description.

Analysis

Study of the description to identify related factors.

Evaluation

Study of the related factors to determine how these may

be controlled.
 Investigation must be kept objective, factual and free from
any attempt to assign blame.

Accident/incident prevention must be directed towards

the control of any difficulties found. A useful strategy is to
consider these under the following headings.

 Behaviour of Individuals (persons)

 Design of Plant and equipment (machine)
 Working environment existing at the time
(environment)

Not all accidents/incidents result in injury, and therefore, it

is necessary to distinguish between :-

 Non-injury accidents
 Injury accidents

It is important that the belief that “Each accident/incident

has a cause” is not down graded to the erroneous belief
that each accident/incident has only one “Cause”. Most
accidents/incidents occur as the culmination of a number
of related factors. Hence, the investigation should
consider these factors under the headings of Person,
Machine and Equipment and Environment. Without these
factors, the sequence of events culminating in injury or
damage cannot progress.

2.28.2 Action

The Accident/Incident Investigation Report – Exhibit 4 – is

to be completed for all accidents involving lost time
injuries on the site or incidents which could have resulted
in a lost time injury.

The investigation should be initiated promptly before the

scene changes, information is lost, removed or destroyed
and persons forget.

The investigator shall visit the scene of an

accident/incident. It is not possible to gain a complete
feeling for the situation without being present to observe.
Observance will also prompt questions as your mind
adjusts to the circumstances.

Photographs are very useful in recording the scene for

future analysis. Remember you may be familiar with the
area / activity, but it may not be as you remember on this
occasion.

The investigator should interview the injured person and

co-workers to get the background. If possible, take
statements from witnesses. This may require
considerable tact as co-workers or bystanders may not
want to become involved. It is most important to
accurately record statements which can be a valuable
check against inconsistencies.

Remember investigations must be carried out in an

objective manner and be based on facts – not opinion or
workplace gossip.

There is always the possibility of getting incorrect

information from persons who rightly or wrongly, have the
feeling of responsibility of guilt.
 2.28.3 Major Accidents

A more comprehensive report needs to be compiled for

accidents where loss of life or serious bodily injury is
involved and/or resulting in possible breach of duty of
both Legislation and at Common Law. Detailed signed
witness statements need to be obtained along with a
detailed description of the accident scene. Photographs
are very useful to record the latter.

The investigator should seek information relating to the

following questions.

(a) What time did the accident occur ?

(b) What was the injured person doing immediately
prior to the accident ?
(c) Was any other person working with or nearby the
injured person ?
(d) What type of clothing was the injured person
wearing (boots, eye protection, safety helmet, etc.)
?
(e) What equipment was he using ?
(f) From what equipment or on what surface was he
working?
(g) What were the weather conditions (rain, windy,
etc.) ?
(h) What instructions had been issued to the injured
person prior to the accident and by whom ?
(i) Who was the first person at the accident scene ?
(j) Who administered First Aid ?
(k) What remedial action had been taken, or is
contemplated to prevent recurrence ?

On completion of the report, it is to be forwarded to the

Safety Officer for analysis and filing.

2.29 Rehabilitation

2.29.1 General

If an accident causes injury or illness, the objective is to

restore the person to maximum function and complete
health as soon as possible. The Contractor is to be
committed to ensuring injured workers take up normal
duties at their earliest convenience with the appropriate
medical agreement.

2.29.2 Contact with Employee

 While contact should be maintained with any worker
absent from work, it is critical that contact is maintained
with employees if :-

(a) The injury is serious.

(b) Medical Certification is initially for three(3) or more
weeks off and has been issued by the treating
Doctor in full knowledge of the range of assistance
available from the employer.
(c) Time lost exceeds three weeks.

The purpose of such contact is to ensure that appropriate

support is provided particularly with claim processing and
that the injured worker is reassured that job opportunities
remain and that opportunities for selected duties are
known to them. Such contact should be the responsibility
of the Project Manager either by phone or in person and
on a regular basis.

2.29.3 Contact with Treating Doctor

Where injured workers are absent from work it is

important that the Project Manager maintains direct
contact with the treating Doctor. Such contact ensures
transfer of correct information regarding :

(a) Potential job modification.

(b) Opportunities for selected duties including
graduated work return.
(c) Actual or potential loss of function which
necessitates early rehabilitation referral.
(d) Remaining job opportunities.

2.30 Management Reports

Safety data shall be collected on Site by the Project Manager

and forwarded at the end of each month to the Divisional / State
Manager or his nominated Safety Officer for analysis and
evaluation.

The collection of data should include the following :-

(a) First Aid Treatment Record.

(b) Personnel accident and injury report. Record all injuries
for which first aid and/or medical treatment was
administered.
(c) Project Safety Statistics.
 In addition, the following data is to be sent monthly to the
Client’s Representative on site.

 Average number of employees on site;

 Hours worked – periodic and progressive;
 Minor injuries (MI) – periodic, progressive, periodic
frequency rate, progressive frequency rate;
 Medical Treatment Injuries (MTI) – same as MI;
 Lost Time Injuries (LTI) – same as MI;
 Serious Injuries/Accidents – fatalities, permanent
partial disability, permanent total disability, journey
injuries this month, journey injuries days lost this month;
 Number of Incidents;
 Number of disease cases.

The data is to be presented in tabular and graphical form

updated month by month on the one form. An example of the
form is available from the Client.

3.0 EQUIPMENTS / TOOLS

3.1 Equipment Safety – General

The nature of the project is such that extensive use of tools and
equipment will be required. The serviceability and methods of
use of these tools and equipment can have a direct impact on
the safety of project employees.

3.1.1 Hand and Power Tools

Hand held power tools such as scabbles, chisels,

grinders, etc. must be checked regularly and not operated
in a condition or manner that would cause injury to the
operator or others. And :

 Where defective, repaired by competent

trades person;
 Only operated with guarding in place.
 Used in conjunction with personal protective
equipment/clothing;
 Only be used with consumables that are
suited to the tool and application (eg. Correct size
and type of grinding disc);
 Hand tools that are used for striking or fastening such as
hammers, picks, axes, files and screwdrivers must be
checked regularly. And :

 Where defects are present they must not be

used;
 Where risk of falling be secured by wrist
strap or lanyard;
 Used in conjunction with personal protective
equipment/clothing.

3.1.2 Electrical Equipment.

Careless use of defective electrical equipment is

potentially lethal. The following must be observed :-

 Be installed and repaired by certified and

qualified persons;
 Electrical leads kept off the ground and on
stands;
 Double adaptors and piggy back fitting are
not permitted;
 Must not be used, if damaged;
 Use earth leakage devices where required;
 Must be covered during inclement weather;
 Report and remove from service all faulty
electrical equipment and power tools.

3.1.3 Oxy-Acetylene, Welding, Cutting and Heating Equipment

This type of equipment should only be handled by

trained and competent operators.

The following must be observed :-

 User must wear protective clothing and apparel;

 Cylinders must be secured in an upright position;
 Flash back arresters must be fitted;
 Combustible material removed from areas;
 Permit/procedures must be observed in high risk
work areas eg. Process plants, high fire risk areas;
  Regularly check all fittings, gauges, hose etc. and
replace if worn/faulty.

3.1.4 Explosive Power Tools

These tools use an explosive charge and are potentially

lethal. They must

 Only be used by certified and qualified

persons;
 Only be used by operators using safety
goggles and
hearing protection;
 NEVER be left in a loaded condition;
 Be inspected on a regular basis;
 Locked away when not in use;
 Have warning signs displayed in area of
use.

3.1.5 Explosives

Strict legislative controls govern the storage,

transportation and use of these products.

They must:

 Only be used, stored and transported by certified

and qualified persons and in accordance with
legislative requirements;
 Have warning signs displayed in areas of use;
 Be strictly controlled on to and off the work site;

3.1.6 Compressed Air

Compressed air has the potential to cause serious injury.

The following must be observed when using compressed
air or air powered tools :-

 Before use ensure hoses are correctly

connected and are not crimped, tied or damaged;
 NOT to be used to blow dust/dirt from clothes;
 Flow control valves should be fitted on supply
lines;
 Hoses should be protected from damage and
clear of walkways, doorways, etc.
  Horseplay with compressed air or air tools will
not be tolerated;
3.1.7 Radiation

Radiation can originate from radioactive substances and

irradiating apparatus. This equipment is used for the
examination of welds. In high doses, it is a hazard and
can damage health. The equipment must :-

 Only be used by certified and qualified

persons;
 Have warning sign displayed in areas of
use;
 Be strictly controlled on to and off the work
site;

3.1.8 UV Radiation and Heat Stress

Sufficient shade and water will be available at all work

locations. Supervisors and Foreman will be briefed on the
symptoms and treatment of heat stress.

3.1.9 Plant Safety

Vehicles and other equipment may be moved or used

only by persons who have an appropriate permit, licence
or certificate issued by a recognized authority.

Operator responsibilities are :-

 Look for overhead restrictions, such as power

lines, etc.;
 Look for trenches and pits;
 Be aware of poor or unstable surfaces or
roadways;
 Be alert to other workers, machinery and vehicles;
 Ensure that during repair or maintenance that
wheels, hoppers, bins, etc. are checked to prevent
rolling, collapsing or trapping operators or others;
 Ensure that all permits and procedures are
obtained prior to transportation of any load;
 Ensure that vehicles and plant are operated in
accordance with prevailing climatic and environmental
conditions;

Following damage to property or equipment :-

  Report all such matters to the workplace
manager;
 Ensure that damage does not constitute an
unsafe situation, if so take action to ensure the
safety of employees and public.

For cranes and lifting gear :-

 All cranes, hoists, lifting gear etc. must be

checked prior to use;
 Loads must be correctly slung by competent
persons;
 Warning signs must be displayed, where
required;
 Crane operators and dogmen/crane chaser
must establish a means of effective
communication;
 All clearances of powerlines etc. must be
checked prior to operations;
 Operations must ensure that persons do not
stand under slung loads.

3.1.10 Other Equipment

Other equipment eg. Ladders, scaffolding, props, etc. is

to be in accordance with statutory requirements or, where
non-exist, in accordance with industry standards and
such requirements are to be detailed in the HSP.

3.2 Welding and Cutting

3.2.1 Fumes and Lack of Oxygen

All welding and cutting operations produce fumes.

Adequate ventilation at all times is essential. When
working in confined spaces, extra precautions are
required. When welding, toxic fume hazards may arise in
some cases, and extra precautions will often be needed.
These hazards are caused by :-

 Welding/cutting coated (primed or plated)

base metal or alloys containing toxic elements;
 Radiated heat forming noxious gases;
  Flame heating heavy sections forming
nitrogen dioxide which has a “safe” ceiling
concentration of 5 ppm;
 Flame processes burning atmospheric
oxygen and adding large quantities of asphyxiating
gas to the atmosphere;
 Gas shielded processes adding inert gases
to the atmosphere and displacing oxygen, which
can also lead to asphyxia in confined spaces.

Specialist advice should be sought when dealing with

such hazards.

3.2.2 Gas Welding/Cutting

The gases commonly used are oxygen and acetylene.

It is not uncommon for minor “explosions” to occur during

welding or cutting. Some are more frightening than
harmful, but some can lead to very dangerous conditions.
There are three general groups of the hazards that can
arise.

Snapout can occur during use when :-

 Both regulators are at incorrect pressure;

 The torch nozzle is obstructed;
 The nozzle is held too close to the work.

Corrective Action

 Close both torch valves, oxygen first;

 Check regulator setting;
 Check cylinder pressures;
 Check nozzles;
 Relight;
 Ensure adequate gas flow.

Back fire can occur on lighting up when :-

 Regulators are not set to correct pressure;

 Light is applied before the flow of gas
mixture is properly established.
 Corrective Action

 Close both torch valves, oxygen first;

 Check cylinder pressures;
 Check and adjust regulator settings;
 Cool torch and check nozzle orifice for
obstruction;
 Relight.

Flash back is the most dangerous hazard. It is caused by

mixed gases in the hose(s). Usually this mixing of gases
occurs when the hoses have been disconnected from
regulators or torches, or when a new hose is being used
for the first time. Sometimes this is due to loose
connections. Usually one of the hoses will have burst and
possibly ignited.

Preventive Action

 The use of “flashback arresters” is strongly

recommended;
 Ensure that all connections are tight;
 Ensure that cylinder valves are open and
torch
valves closed;
 Set regulators to the required pressures;
 Purge each hose separately and
consecutively.
Open torch valve and allow gas to flow for
sufficient time to ensure that only pure gas
remains in the hoses;
 Close the valve for each gas as the
exercise is completed (This exercise should
be carried out only in the open, or in
extremely well ventilated areas)

Corrective Action

 Close both torch valves;

 Close both cylinder valves;
 Extinguish hose if alight;
 Remove acetylene regulator, if the “bull
nose” is sooty, there may be a dangerous
condition;
  If the “bull nose” is clean, replace regulator,
repair hose(s), or obtain new ones;
 Re-assemble equipment and hoses;
continue to work.

3.2.3 Arc Welding

Fires can be started by sparks, hot slag, etc. at a distance

from the point of welding or cutting. Remove flammable
materials from the vicinity of, and below the operations, or
use protective sheeting as appropriate. Take particular
care when penetrating spaces, etc. and that the “blind”
side is safe.

Electric arcs radiate both infra-red (IR) and ultra-violet

(UV) as well as light rays. Ultra-Violet and Infra-red is
invisible, but can be hazardous in a number of ways,
even when reflected.

UV decomposes some chlorinated hydrocarbon

degreasing agents and may form the poison gas
phosgene, even at a distance from the arc. Degreased
items must be thoroughly dried before welding and such
chemicals must not be used anywhere near welding
operations.

(IR, UV) causes, a painful but temporary form of

conjunctivitis, even if exposure is very short. This
condition is easily avoided by the use of suitable eye
protection. UV can also affect the skin like a bad sunburn.

Mains voltage supplies to electric welding sets and

auxiliary equipment can cause shock and burns and may
be fatal. Welding voltages can also be dangerous. All
electrical welding equipment should be checked by a
competent electrician before use.

Safe low voltage devices should be used for arc-welding

in particularly hazardous situations.

Preparation and repairing of welds usually involve

grinding and chipping. Eye protection must be provided
and worn for these operations. Protection must also be
worn when de-slagging welds. With some types of weld,
hot slag can fly off because of contraction as the metal
cools, so eye protection should also be used if it is
necessary to inspect a weld before it is cold.
3.2.4 General Safety Requirements for Welding and Cutting
Operations

Depending on the size, nature and location of the work,

and the proximity of other welders, employees must wear
personal protective equipment. This may include any of
the following :-

 Welding goggles
 Face shield
 Flameproof gauntlet gloves
 Safety boots and spats
 Leather skull cap
 Hearing protection
 Adequate work clothes
 Respiratory protection

Everyone in the vicinity of arc welding operations should

wear some degree of eye protection to protect from “arc
burn”.

During electric welding operations the arc should be

shielded whenever possible to protect the eyes of other
persons in the vicinity.

Only qualified personnel shall be allowed to use any type

of welding or cutting equipment.

All welding and cutting shall be done as far way from any
fire hazard as possible.

Oxygen and acetylene hoses must be kept clear of

welding/cutting area, slag can burn through hoses.

Fire extinguishing equipment shall be immediately

available where welding or cutting is being done.

A fire watcher must be used on each welding operation

where :-

 Combustible material is within 35 feet of the

welding of cutting operation;
 Highly combustible material is more than 35
feet from welding or cutting operations but subject
to falling sparks.
 A fire watcher must have “first aid fire” training and wear
protective equipment.

Any material that has been cleaned with degreasing

agents must be completely dry before cutting or welding.

A sign or other warning should be provided to warn

others of hot metal surfaces.

When working in any confined space where ventilation

might not be adequate or where there is a possibility of
poisonous gas being present, a welder shall wear
adequate respiratory protection and a lifeline, with an
attendant outside observing at all times.

When arc welding is to be suspended for any period of

time, such as during lunch or overnight, all electrodes
must be removed from the holder and the holders
carefully located so that accidental contact cannot occur.
The welding machine must be disconnected from the
power source.

3.3 Site Electrical Equipment

3.3.1 Electrical Equipment and Installations

All portable electrical equipment including lamps should
be approved and carefully examined before use on the
site.
 3.3.2 Inspection & Maintenance of Electrical Equipment

(a) General
All apparatus, systems and installations, including
cables, conduits and the like should be maintained
in good condition. To ensure this, they should be
regularly inspected.
Correct functional operation does not necessarily
imply compliance with the required standards of
safety.
(b) Inspections and Checks
All equipment, systems and installations should be
inspected when first installed. Following any repair,
adjustment or modification those parts of the
installation which have been disturbed should be
checked.

If there is at any time a change in the area

classification or in the characteristics of the
flammable material handled, a check should be
made to ensure that all equipment is of the correct
group and temperature class and continues to
comply with the requirements for the revised area
classification.

(c) Insulation Testing

Insulation testing should be carried out only when
no flammable gas mixture is present.

3.4 Material Handling and Safe Lifting

Many serious, painful and long lasting injuries occur while

moving material, equipment, etc. However, if we observe some
basic rules we can prevent injuries.
 Check the lift first;
 If load is too heavy, get help;
 Where possible, use mechanical equipment;
 When lifting, face load, keep back straight and lift
with legs not back;
 NEVER twist when lifting;
 When lifting overhead DO NOT over reach. Lift to
a platform, reposition then lift further;
 When group lifting nominate someone to “direct”
then lift and ensure the area is clear of obstructions.
4.0 HAZARD APPRAISAL CHECKLIST

Hazard appraisal is to be monitored continuously and reported as

necessary. Hazards may be identified by any employee during normal
work or as part of scheduled audits or supervisor “walk around”.

Seven steps to resolving a Hazard.

STEP 1 : Hazard noticed by employee(s)

STEP 2 : Employee(s) to rectify if qualified or competent to do so.
STEP 3 : If it is not possible to take immediate action to rectify the
situation, an appropriate barricade, notice or similar
means of warning to others shall be provided and the
Project Manager/Safety Officer notified. The Project
Manager/Safety Officer shall take immediate action to
remove the hazard.
STEP 4 : If there is no resolution achieved by action under Step 3,
the Project Manager/ Safety Officer must advise the
Divisional/State Manager without delay.
STEP 5 : The Managers and where appropriate, work group
representative shall attempt to resolve the matter by
consultation.
STEP 6 : If no resolution has been achieved after discussion the
Managers may request an independent Safety Officer to
assist in the resolution of the hazard.
STEP 7 : For issues involving more than one designated contractor
the Client Representative will nominate a responsible
officer to assist in the resolution of the hazard.

5.0 TRAFFIC

Safe conditions for the passage of vehicular traffic through or around

the worksite shall be provided as required. This shall include (as
required):

 The installation of prescribed traffic control devices;

 Minimal delays to the passage of traffic;
 The detour of traffic away from the Works or the construction of side-
tracks;
 The control of dust.

Entry of vehicles to site shall be restricted to :

 Vehicles and mobile equipment authorised by the Client;

 Business vehicles and mobile equipment periodically
required to enter on site so that work required by the contract
may be efficiently carried out;
 Drivers shall be fully and currently licensed and/or certified as required
by the appropriate Statutory Authority to drive the type of vehicle or
equipment which they are operating.

Vehicles and mobile equipment are not to travel over works completed
by the Contractor or others without written authorization from the
Client.

6.0 DANGER AND OUT OF SERVICE TAGS

When the project site reaches a stage where services including power
and water are being activated a Danger tag and Out of Service Tag
System or isolation tag procedure shall be introduced.
The purpose of the Danger Tag is to give personal protection to an
employee when working on equipment.
The purpose of the Out of Service Tag is to prevent use of unsafe and
inoperable equipment and prevent damage to plant and equipment.

To ensure compatibility across the different contracts on the project site

the Client shall review all such systems and changes that are required
to ensure a similar approach is being used shall be made by the
Contractor.

7.0 SECURITY

No overall security will be provided by the Client. Contractors are to

establish their own security to ensure the requirements of this Manual
are achieved and for protection of their own property and the Works.
Details of the Contractor’s security are to be included in the HSP.
EXHIBITS
 EXHIBIT 1

TYPICAL WORK METHODS AND PROCEDURES

1. Electrical Safeguards

All electrical equipment shall be maintained in good condition, being

inspected, repaired and tagged by a certified electrician at six monthly
intervals.

Double adaptors and piggy back plugs are not to be used in any power
outlet. Only double insulated electrical power tools will be permitted to
be used on the project.

Electrical equipment which is damaged or with guards missing will not

be used.

Electrical leads are to be raised off the ground or floor and secured at a
height of not less than 2 metres.

A core balance earth leakage devise is to be installed to all electrical

switchboards and tested prior to use daily by the relevant Foreman.

Scaffolding constructed with metal members shall not be set up within

4.5 metres of overhead electrical lines until the electric line has been
insulated against an electrical discharge.

An electrical line which crosses any road or way or other means of

access to the site shall be provided with a flagged Catenary wire at a
height of 1.5 metres less than the height of the electrical line.

2. Mechanical Safeguards

As soon as practical, the following safety precautions shall be taken :-

(a) Lift Wells

Mesh screening will be placed and secured to the front of all lift
well openings. The screening will completely enclose the
opening.

(b) Floor Penetrations

All floor penetrations will have 50 X 50 mm X 4 mm wire mesh

cast into the opening.
 When services pass through the penetration, only that portion of
the mesh will be cut out to suit the particular service.

(c) External Edge Protection

Edge protection to the floors, stairs and platforms will be

provided with a guard rail and mid rail the height of which will be
between 900 mm and 1100 mm.

(d) Protruding Reinforcing Steel

Vertical bars will be guarded by metal capping whilst horizontal

bars will be guarded by plastic caps.

Materials Handling

All major lifts will be performed by crane with all auxiliary materials
being transported and moved by the hoist and or trolleys, etc.

To aid the movement of materials by trolleys, as much material as

possible will be containerised, modularised or bundles strapped.

Obviously a great deal of manual handling is still required to be

performed by workers, and to this end, correct manual handling training
sessions will be conducted at the induction training session and at
regular intervals throughout the course of construction.

Formwork and Falsework

Engineering drawings and computations are to be on site prior to the

erection of any formwork. Formwork and falsework shall comply at all
times with the requirements of the Standards.

The stripping of the formwork is to be carried out in a systematic

manner, with materials stacked so as not to create an obstruction. Drop
stripping is not to be performed under any circumstances.

Workers engaged in the erection and dismantling of formwork and

falsework will be protected by external scaffolding which will be
meshed externally.

The scaffolding is to be constructed so that no materials will pass

through the scaffold or between the scaffold and the building.

All wall, column and core forms are to be provided with approved lifting
eyes.

Shear wall forms are to be provided with working platforms complete

with external meshing 50 mm X 25 mm X 3.15 mm wire mesh.
Safe access is to be provided on to all working platforms, with the
lowest platform arranged so as to prevent materials passing between
the building and the platforms.

Lasers.

Lasers stronger than Class 3A will not be permitted on the project.

A qualified Laser Safety Officer shall be appointed by the

supervisor/subcontractor using lasers, other than a Class I laser. The
identity of this person is to be notified to the Project Manager.

Scaffolding

(a) Construction

All scaffolding above 4.5 metres high, of a modular type, will be

erected by certified scaffolders.

Before leaving the scaffold, the scaffolder will ensure that it is

left in a manner which is safe for persons to work upon. Should
this not be possible, it is to be sign posted warning persons of its
incomplete state.

(b) Access

At all times safe access is to be provided to all working platforms

within the scaffolding.

(c) Edge Protection

On all working platforms above 2.4 metres a guard rail, mid rail
and toe board is to be provided. Provided that the mid rail and
toe board may be replaced with wire mesh of the size of 50 mm
X 25 mm X 3.15 mm dia. Wires.
 FIRST AID FACILITIES AND REQUISITES

Standard of Facility

For sites engaging up to 100 persons the following is required :-

A dust-proof cabinet in a readily accessible position clearly marked “FIRST

AID” with the name of the First Aid Attendant clearly printed on the cabinet.

For sites where the number of persons engaged exceeds 100, a casualty
room is to be provided and shall :-

(a) have a floor area of not less than 11 square metres;

(b) be located in a conveniently accessible position;
(c) have adequate ventilation and lighting;
(d) Contain :

ϒ A basin type washing point with reticulated clean water;

ϒ A stainless steel sink with reticulated hot and cold water;
ϒ A work bench or dressing trolley;
ϒ A cupboard for storage of enamel bowls and linen;
ϒ A dust-proof cupboard for storage of first aid requisites
and appliances;
ϒ Facilities for boiling water;
ϒ A couch, a pillow, 3 blankets and a hot water bottle;
ϒ A portable stretcher;
ϒ 2 upright chairs, an armchair, a small table and
moveable screen;
ϒ refuse receptacle.
 First Aid Requisites

The following first aid requisites shall be provided and maintained on all
sites :-

Item Quantities
No of persons employed
Sterile Combine Pressure Dressing Pads – Small 1-25 26-100
Sterile Combine Pressure Dressing Pads – Large 3 6
Gauze Squares, sterile 7.5 cm X 7.5 cm pkts of 5 3 6
Burn Dressings, sterile non-stick – Small 2 4
Burn Dressings, sterile non-stick – Large 6 12
Eye Pads, sterile pkts of 5 3 6
Eye wash solution (single use packs) 1 2
Bandages, elastic crepe, 5 cm 1 1
Bandages, elastic crepe, 7.5 cm 3 6
Triangular Bandages 3 6
Elastic Dressing Strips, pkts of 50 2 4
Adhesive strapping tape, 2.5 cm x 5 metre rolls 1 2
Antiseptic Solution (minimum 200 mls) 1 2
Scissors, stainless steel 1 1
Splinter Forceps 1 1
Drinking Vessel 1 1
Kidney Tray, Stainless steel 1 1
Safety pins, assorted pkts 1 1
Paracetamol tablets, pkts 10 1 1
First aid pamphlet, current 2 4
Sterile disposable needles (not to be re-used) 1 1
 EXHIBIT 3

WORKPLACE INJURY AND DISEASE RECORDING FORM

This form is to be completed and retained by the employer to provide

Workplace Injury and Disease Record Information. A copy is to be
provided to the Client Representative.
PERSONAL DETAILS OF Surname (Block Letters) ____________________________
THE INJURED WORKER Given Names (Block Letters)
_________________________
BASIS OF Sex : M/F Date of Birth ______________________
EMPLOYMENT Starting time * 0800-1730 hours
* 0600-1700 hours
* 1900-0700 hours
* Other, State:____________________

Shift Arrangement * Fixed, standard or flexible

hours
* Rotating shift
* 8 hours or less
* more than 8 hours (excluding
overtime)
JOB DETAILS
Description of occupation of job title
:_________________
Main tasks performed : _____________________________
________________________________________________
________________________________________________
________________________________________________

Training Provided * Induction Training

* Task specific training
* Both of the above
DETAILS OF THE * Neither of the above
INJURY OR DISEASE
Date injury occurred _________ Time injury occurred
____
(24 hour clock format)
Nature of Injury or disease _________________________
________________________________________________
________________________________________________
Bodily location of injury or disease
____________________
________________________________________________
Description of occurrence of injury or disease
In which part of the workplace did the injury or
disease exposure occur ? (eg. Machine shop, freezer
room, mine)
________________________________________________
________________________________________________
What was the worker doing at the time ?
(eg. Driving a fork lift truck, lifting bags of cement,
 typing)
________________________________________________
________________________________________________

DETAILS OF THE What happened unexpectedly?

INJURY OR DISEASE Include the name of any particular chemical,
Cont’d product, process or equipment involved (eg. Brakes
failed on fork lift truck, slipped on wet floor,
scaffolding collapsed, arm started hurting while
typing on a word processor)
_______________________________________________
_______________________________________________
_______________________________________________
How exactly was the injury or disease sustained ?
Include the name of any chemical, product, process
or equipment involved. (eg. Hit head on cabin of
fork lift truck, lacerated knee when landing on
ground, arm hurt after long period of typing)
_______________________________________________
_______________________________________________
_______________________________________________
LOST TIME INJURY/ (Additional questions to be answered for cases
DISEASE which result in a fatality or permanent disability or
where there was time lost from work of one or more
days/shifts. These questions should be completed as
soon as possible after the injury or disease is
reported).

Employee’s preferred language

______________________

Type of Employment * Full-time permanent

* Full-time casual
* Part-time permanent
* Part-time casual
Type of Employee

Wage/Salary earner * Trainee

* Casual
* Apprentice
(Note most employees * Other
will fall into this category)

Worker’s experience in task being carried out when

injury or disease occurred
Years ________________ Months ______________

Proportion of shift worked * 25% or less

* 26% - 50%
* 51% - 75%
* 76% - 100%
OUTCOME OF INJURY/ * Overtime
DISEASE
(The following questions are about information that is not
available at the time of the injury or disease. These questions
should be answered as soon as the information becomes
available. For some occurrences, such as where there was no
time lost, some of these questions will not be relevant.)

Rehabilitation * Required Date commencement of

Rehabilitation programme
____________
* Not required
 ACCIDENT/INCIDENT INVESTIGATION REPORT
This form is to be completed and retained by the employer to provide
the basis for accident analysis directed towards injury prevention. A
copy is to be provided to the Client Representative.
Initiator To To To To Manager

1. EMPLOYER Employer ____________________ Policy No.___________

DETAILS
Postal Address ___________________ Post Code _______
Business/Industry _________________________________
Number of Employees ______________ Job No._________
Surname (Block Letters) ____________________________
Given Names (Block Letters) _________________________
Address _________________________________________
Date of Birth _____________________________________

Surname (Block Letters) ____________________________

2. WORKER’S Given Names (Block Letters) _________________________
DETAILS Address__________________________________________
Date of Birth _____________________________________

What was the worker doing immediately before the accident ?

______________________________________
3. ACCIDENT What went wrong or what broke down ? _______________
DETAILS _______________________________________________
Describe how the injury was caused __________________
________________________________________________
Name of Doctor or Hospital : IN or OUT patient _________
________________________________________________

Time of Accident ________ AM/PM Date of Accident ____

Time worker ceased work ___AM/PM Date ceased work ___
Time first reported? ______AM/PM To whom _________
4. TIME OF Location of accident _______________________________
ACCIDENT Position _________________________________________

Part of body injured _______________________________

Nature of Injury _____________ Severity ______________
Has worker suffered similar injury ? ___________________
What work was worker doing when injured ?____________
5. INJURY DETAILS ________________________________________________
How long has worker performed such work? ___________

Name of person in charge and position ________________

________________________________________________
Has the person completed report ? Yes___ No ____
 Are there any witnesses? Yes___ No ____
6. OTHER DETAILS Has the injured worker resumed work? Yes___ No ____
If no, are there any alternative duties the worker can perform ?
_______________________________________
Is this is recurrent injury?___________________________
Was there a definable occurrence causing recurrence? ____
Has a Workers Compensation Claim been rejected? ______
Has at least one shift a day been lost from work? ________
Were other workers effected by the occurrence? ________

Changes to Induction/Ongoing Training ? Yes ___ No ____

Equipment/Machinery Modification ? Yes ___ No ____
Change to Work Procedures ? Yes ___ No ____
Change to Work Environment ? Yes ___ No ___
1. PREVEN- Job Re-design ? Yes ___ No ____
TATIVE
ACTION Time and Date investigation commenced _____ AM/PM ______
Time and Date injury was reported __________ AM/PM ______

Were you advised of the accident before the worker left site ?
Yes/No
2. SUPERVISOR Comments
_______________________________________________
___________________________________________________
__________________________________________________
What action has been taken, or recommended, to prevent a
recurrence.
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
Signed _______________
_________________________________________________
___________________________________________________
___________________________________________________
Signed _______________
3. SAFETY ___________________________________________________
OFFICER’S ___________________________________________________
COMMENTS ___________________________________________________
Signed ______________
___________________________________________________
___________________________________________________
4. MANAGER’S ___________________________________________________
COMMENTS Signed _____________

5. MANAGE-
MENT’S
INSTRUC-
TIONS
 EXHIBIT 5

NOTES ON HOW TO ORGANIZE AND RUN SITE SAFETY (TOOL BOX)

MEETINGS

Why Give Tool Box Talks

 We are responsible for the lives and well being of people working for us
– they have individual responsibility too.
 It is a basic never ending part of our job.
 We cannot bypass this part of our job but we can certainly lessen the
burden by sharing it with the employees.
 The best way to accomplish this is to have regular, effective,
stimulating, well remembered tool box talks.
 By giving good tool box talks, we communicate, educate and motivate.
We lead our whole team toward the site safety goals.
 The better our safety talks are, the better we will be doing our job in the
eyes of our boss and our men.
 Safety messages from above can get filtered, changed, etc. by the time
they reach the target audience. In a tool box talk we are talking direct
to the target audience.

HOWEVER, MOST IMPORTANT IS THAT SUPERVISORS AND FOREMEN

MAKE A DAILY SAFETY CONTACT WITH ALL THEIR EMPLOYEES AS
INDIVIDUALS AND TOOL BOX MEETINGS MUST NOT BE SEEN AS A
SUBSTITUTE FOR SUCH CONTACTS.

Better Tool Box Talks

Some principles of communication :-

 Communication is what we do to give and to get understanding about a

particular topic.
 Appeals to the gut (emotion) are communicated more readily than
appeals to reason – relate idea to their personal interest, their families,
their health.
 Repeat the message often and in different ways, especially with a
strong summary at the end.
 Keep it simple – often written material is complex. It often has to be get
the detail. Learn its meaning and say in your own words.
 Say it in your own words (gut to gut), this is much more powerful than
reading off a page. You must read over material and make summary
notes, do not memorise – hand out detail. When talking with own words
address the audience face to face making eye contact.
 Use visual aids where possible.
 A learner tends to remember :

10% of what he reads

20% of what he hears
30% of what he sees
50% of what he sees & hears
80% of what he sees, hears and does himself.
 See show and tell safety talk tips, Exhibit 6.
 Don’t try to cover too much, in one or two main ideas, aim for a
communication bull’s eye.
 Keep a file of information, objects, pictures, posters, damaged safety
equipment for your tool box talk – over time one can have a very
powerful “Library”.
 In closing your talk, answer the question the listeners always have.
 Tell them what you want them to do for special action.
 Give a prescription on how to do it.

Organizing Tool Box Talks

 The Supervisor or Foreman must give it.

 Prepare in advance so it is natural.
 Have visual aids where appropriate, i.e. samples or broken tools,
safety goggles, painted hats, wood with nails, metal parts etc.
 Have an assistant if possible

Supervisor

- Safety Officer
- Safety Delegate

 Stick to one or two topics with one of them being the main one.
 10 minutes on tool box talk proper, never read it off directly – have key
notes, if required.
 10 minutes on going over last weeks action items and reviewing this
weeks action items from the floor.
 Action items shall be posted in smoko huts.
 Lastly summarize key points of topic again.
 Specific additional topics may be advised by the Project Manager,
Safety Officer or Client. These shall be current but picked sufficiently
ahead to give foremen time to prepare.
 Practice ahead of time.
 This is definitely the most important safety meeting on site – without a
doubt – treat it that way.
4. Minutes of Tool Box Meetings

Minutes of Tool Box are to be recorded on the Report Form Exhibit 7.

 EXHIBIT 6

AGENDA FOR A TOOL BOX MEETING

The following items are to be discussed on a regular basis at Tool Box

Meetings. The frequency and content of these regular items will be
determined by the Project Manager and/or Safety Officer.

1.1 Items of general safety importance to the Total Work Site (generally as
advised by the Project Manager or Safety Officer).
1.2 Items of safety interest to the particular group (generally from the
Supervisor’s / Foreman’s own walk around or from Safety Talk Tips –
See Section 2)
1.3 Review differing items of the HSP each fortnight.
1.4 Employees responsibilities.
1.5 Frequently reiterate :

 Personnel search and no matches, lighters.

 No smoking regulations.
 Permit and Certificates regulations.
 Clothing requirements.
 Personnel protective equipment regulations.

Quote any instances where employees have not complied.

1.6 Review employees understanding of isolation tag procedures and
permit systems – have sample tags available.
1.7 Discuss use of hazardous materials on the work site.

Show-and-tell Safety Talk Tips.

In general examples or instances of unsafe work practices or bad

housekeeping around respective groups work areas shall be addressed, with
physical examples being exhibited were possible.

Otherwise, examples of show-and-tell safety talk tips can be as follows.

(a) Protection is the name of the game, whether it’s a fence around your
yard or a guard around a machine. Both serve useful purpose. Use a
piece of security screen mesh as a point of discussion on the value of
guarding. Just as the security mesh can protect your home from
intruders, so the various machine guards around the work place can
protect you from serious injury. Ask the men to report any that are
being bypassed or removed or any dangerous situation which should
be guarded but is not You may be surprised at the knowledgeable
answers you get.

(b) Quote recent examples of people in plaster casts. Ask your men how
come people have to wear this sort of thing. If any of them has worn a
 cast, have him tell some of the ways it was inconvenient,
uncomfortable, restraining or disadvantageous. Discuss accidents
involving slips, trips, falls and broken bones. Have the men identify
hazards in their workplace that could cause such accidents and ways
to eliminate them.

(c) Put your fingers in a loaded rat trap ? Not likely! Pull back the spring on
the trap and after your fingers are in a safe position, let it fly. You’ll
certainly get everyone’s attention when it slams shut. But more
important, you can equate the rat trap with the very real dangerous
hand traps in the area. The point : think of every unsafe position for
your hands as a possible rat trap and watch your fingers; they have to
last a lifetime. Make a survey of your area, pointing out all potential
hand traps.

(d) A few spools empty of thread strung along a rubber band make an
excellent model of the human spinal column. This “model” can be used
to illustrate the danger of moving an injured person, when the spinal
column should not be flexed. When the spools at either end are lifted,
the row will bend in the middle, simulating the flexing of the spinal
column. Moving an injured person with a broken back could sever the
vital spinal cord. Similarly, the spools can be used to illustrate how little
supporting strength the flexible backbone has, when “lifting”, unless it is
an almost vertical position.

(e) Exhibit two grinding wheels, a new one and a broken one. Have
dialogue about the proper way to check, install, use and maintain this
type of wheel. Review the deadly hazard of exploding wheels and the
need for consistent and correct use of guards, protective equipment
and work procedure.

(f) The heart pumps a full five quart of blood every 60 seconds. The loss
of one quart, a scant two pints, creates a very serious medical problem.
The danger of severe and rapid bleeding can be dramatized by using a
carton of water, coloured red with vegetable dye. Pour the contents of
the carton into a clear quart milk bottle while pointing out that the loss
of this much blood is life-threatening. After you have made your point,
show your listeners how to stop severe bleeding with direct pressure
on the wound.

(g) Obtain spare emergency or lock-out tag and bring it to your meeting.
Explain the system of emergency tags used in your company. Make
certain that each man knows what he should do if he finds one on a
valve or a switch. Explain any special procedures or precautions that
should be followed.

(h) A hammer with a cracked handle, a chisel with a mushroomed head, or

any similar defective tool used in your work is an excellent visual
contact for talk on hand-tool safety. Bring the tools to the meeting and
 pass them around. Explain the different kinds of injuries that could
occur because of their poor condition. If an accident has already
occurred, feel free to discuss it, especially if one of your crew was
injured. Tell the men what to do when one of their hand tools becomes
damaged.

(i) Bring a dart or two and a small target. Ask for volunteer to stand in
front of the target while you throw a dart. When the guys tell you, you
are crazy, you can tell them you are no crazier than the guys you have
seen standing, without eye protection, in front of the grinders, chippers,
or whatever other machinery you have. After all, a chip can blind as
easily as a dart. Discuss aspects of eye safety with the men.

(j) Display an electric tool or appliance with a frayed or cut cord. Explain
that this kind of defect can kill, and must be reported. A man touching
this cord could be electrocuted, especially if he were touching metal
piping or standing in water. Tools should be carefully checked by each
man before they are used.

(k) Safety glasses that have saved someone’s sight tell a compelling story,
especially if that “someone” works for you or works in your business.
Bring the safety glasses to the meeting and tell the facts about the
accident. Let everyone see the impact they absorbed. Those with vivid
imaginations can guess what the result would have been if the eye,
instead of the glass had been hit.

(l) Ask your men, without looking, to tell the location of the fire
extinguishers, and if they can which kind of fire each of the
extinguishers will fight. You may be amazed to find that almost no one
can answer the questions. Take this opportunity to take everyone on a
“Cook’s tour”. Stop at each of the area extinguishers and explain to
each of the men how it operates and what kind of fires it can put out.

(m) Use a stepladder. A stool and a wooden crate as aids for a discussion
of “steps to ladder safety”. Emphasize that no job is urgent enough to
risk breaking your neck by climbing up on furniture or equipment. Step
up to safety by proper use of the right kind of ladder. Avoid standing on
top steps of step ladder. Check ground on which ladder is placed.

Extension Ladders - always secured

- watch overhead powerlines
- always, in case of timber ladders, have
them facing the right way ie. Tension wire at
back.
- Always tie off.
- Check ground support.

(n) Somewhere around the work area there may be an old piece of lumber
with a big fat rusty nail sticking through it. Bring it to your meeting.
Show it to your men and tell them where you found it. The danger is
that the puncture inflicted by this nail may be filled with millions of
tetanus germs. Without proper cleaning, medical treatment and
possibly a tetanus shot, the wound could become infected with deadly
lock-jaw the possible result. Remind your kind crew to remove these
nails or to bend them over. Proper safety shoes with study soles are
another precaution.
 EXHIBIT 7

MINUTES OF SITE SAFETY (TOOL BOX) MEETING

HELD ON (Date) AT (Location)

PRESENT : Contractor’s
Supervisor/Foreman:________________________________
Contractor’s Project Manager/
Safety Officer
:________________________________

Client Representative
:________________________________

The following Contractor’s Employees :

Items Reviewed and Discussed : (write “NR” if not reviewed or discussed)

1. Review of Action Items from Last Meeting.

2. Items of General Safety Importance to the Total Work Site.

3. Items of Safety Interest to this Group (eg. Hazards or safety conditions

applicable to this group’s work area).

4. Review of Work Procedures

5. Review of Following items from HSP

6. Employees Responsibilities

7. Reminder Items

Tick as appropriate which item is reviewed and discussed.

 Personal protective equipment __________

 Housekeeping __________
 Electrical Equipment condition __________
 Gas bottle safety __________
 Special Client Requirements
eg. No Smoking Regulations __________
Permit and Certificate Regulations __________

8. Hazardous Materials on Work Site.

9. Show-and-Tell Safety Talk Tips.

10. Safety Hand Outs.

11. Other items.

12. List of Specific Action Items

Signature of Supervisor/Foreman_________________________ dated

__________
 EXHIBIT 8

DAILY INSPECTION CHECKLIST

CONTRACT __________________________________________________
WORK AREA COVERED
_______________________________________________
DATE INSPECTED
__________________________________________________
NUMBER OF EMPLOYEES IN AREA
______________________________________
NUMBER OF LOWER TIER SUB-CONTRACTS IN AREA
______________________

Items to be ticked off if found in a safe and proper condition. (Items not
applicable to be marked N.A.)

Any hazardous or unsafe condition to be reported.

Inspection to be carried out to conform compliance to HSP.

Personal Protective Equipment _____________

Scaffolding/Access/Ladders _____________
Aerial Work Platforms _____________
Boatswains Chairs _____________
Light Duty Suspended Stage _____________
Barricades _____________
Barriers Around Excavations _____________
Roadway Working _____________
Portable Powered Tools & Equipment _____________
Mobile Plant _____________
Cranes _____________
Gas Cylinders _____________
Welding Protection _____________
Housekeeping _____________
Fire Fighting Equipment _____________
Other Items _____________

Additional Remarks, Hazardous or Unsafe Acts/Conditions Seen _________

______________________________________________________________
Action Taken on Unsafe Acts/Conditions _____________________________
______________________________________________________________
_____

Signed_______________
Date ________________