Objectives

The primary objective of this tender is to strip, repair, and reinstall one (1) Reclaimer slew gearbox (X1, SEA side) to restore full operational capability. The work aims to ensure reliable material handling for manganese ore transfer while minimizing downtime during scheduled shutdown periods.

Scope of Work

• Removal & Disassembly: Safely extract the specified gearbox from the reclaimer structure.
• Overhaul & Repair: Service all internal bearings using OEM-approved or drawing-specified components, replace all oil seals, and conduct comprehensive crack testing/analysis on all output shafts.
• Reassembly & Installation: Repair output sections strictly per manufacturer drawings, rebalance components, and reinstall the gearbox to factory tolerances.
• Cleaning Services: Provide dedicated cleaning crews for the entire shutdown duration to maintain chutes, conveyor lines, and surrounding work areas.
• Timeline: Complete all activities within an eight-day window following purchase order issuance.

Technical Requirements

• Equipment Specifications: PARAMAX® 9000 Series Reducer, Type PVD9075R-LL-280, Serial Number H9081246.
• Project Planning: Submit a detailed execution plan prior to mobilization, confirming an eight-day schedule. Plans must be updated daily and reviewed at 7:00 AM shutdown meetings.
• Quality Control: Provide a comprehensive Quality Control Plan (QCP) outlining all mandatory hold points, inspections, witness verifications, surveillance steps, and testing protocols.
• Warranty: Minimum twelve-month warranty on all workmanship and replaced parts from the commissioning date.
• Site Logistics: The terminal supplies Rio-Carb liners, compatible welding rods, rubber skirting, standard steel plates, fasteners, site access, and establishment space. The contractor provides all tools, equipment, consumables, and labor.
• Safety & Compliance: Approved Risk Assessment and Method Statement (RAMS) required before work begins. All personnel must hold valid certifications, and the worksite must be clearly signposted with responsible personnel. Strict adherence to environmental protection standards is mandatory.

Skills Requirements

• Certified heavy-equipment mechanics and engineers experienced in industrial gearbox overhaul, alignment, and torque calibration.
• Qualified Non-Destructive Testing (NDT) technicians proficient in magnetic particle or dye penetrant crack analysis for high-stress shafts.
• Project coordinators capable of developing realistic schedules, tracking daily progress, and presenting status reports.
• Quality assurance specialists trained in manufacturing QCPs and managing inspection/witness points.
• Trained cleaning operatives familiar with port and mining plant hygiene and waste segregation protocols.
• Supervisory personnel holding valid safety certifications to oversee high-risk mechanical, lifting, and confined-space activities.
• All staff must demonstrate competency in port-specific safety regulations, emergency response, and environmental compliance.

Explanation of Technical Terms

PARAMAX® 9000 Series Reducer

A heavy-duty helical-bevel gear reducer engineered for high-torque, continuous-duty applications in bulk material handling equipment like stacker-reclaimers.

Rio-Carb

A proprietary polymer-composite wear liner used in chutes and hoppers to resist abrasion, reduce material buildup, and improve flow characteristics.

QCP (Quality Control Plan)

A structured documentation framework that defines mandatory inspection, testing, and approval checkpoints throughout a maintenance project to ensure engineering standards are met.

RAMS (Risk Assessment and Method Statement)

A formal safety document that identifies workplace hazards, evaluates risk levels, and prescribes step-by-step safe work procedures and control measures.