Objectives

The primary objective is to strip, repair, and refit one reclaimer slew gearbox (X1, tanker side) at the Port Elizabeth Multi-Purpose Terminal to restore full operational capability while adhering to strict safety, quality, and environmental standards.

Scope of Work

• Remove the existing slew gearbox from the reclaimer.
• Service all bearings using components that strictly match OEM or approved drawing specifications.
• Replace all oil seals.
• Perform a comprehensive crack test or metallurgical analysis on the gearbox output shafts.
• Repair one output section in accordance with manufacturer drawings.
• Deliver the completed service within an eight-day lead time following purchase order issuance, with contractor personnel remaining onsite until the final day of the scheduled shutdown.
• Submit a detailed Quality Control Plan (QCP) identifying all mandatory hold, inspection, witness, verification, surveillance, and test points.
• Provide a project plan demonstrating eight-day completion, updated daily and presented at the 07:00 shutdown meeting.
• Supply all tools, consumables, site establishment materials, and dedicated cleaning crews for the full shutdown duration to maintain chutes, conveyor lines, and work areas.
• Proactively identify and rectify any additional critical areas beyond the initial scope.

Technical Requirements

• Gearbox Specifications: PARAMAX® 9000 Series Reducer, Type PVD9075R-LL-280, Serial Number H9081246. All repairs must align precisely with these OEM parameters.
• Quality Assurance: A comprehensive QCP must be approved prior to work commencement, covering every critical control and testing phase.
• Warranty: A minimum twelve-month warranty applies to all labour and replaced components from the commissioning date.
• Safety Documentation: Complete safety file submission including a project-specific Health and Safety Plan, Hazard Identification and Risk Assessment (HIRA), task-specific Method Statements, Safe Work Procedures, competency certificates for supervisors, elevated work and fall protection training records, PPE policies, equipment inspection registers, incident management procedures, and a staff training matrix.
• Environmental Compliance: Environmental Management Plan, Aspects and Impacts Register, waste/water/fuel/spillage management protocols, environmental officer credentials, emergency spill response procedures, and daily environmental inspection checklists.
• Regulatory & Administrative Compliance: Valid company registration, SARS PAYE, UIF, COIDA Letter of Good Standing, relevant SETA accreditation, and signed contractor execution plans aligned with client specifications.

Term Explanations: QCP (Quality Control Plan) is a structured engineering document detailing mandatory inspection and testing checkpoints to verify work meets design standards. HIRA (Hazard Identification and Risk Assessment) is a systematic workplace hazard evaluation with corresponding control measures. COIDA refers to the Compensation for Occupational Injuries and Diseases Act, requiring proof of statutory employer liability coverage. Rio-Carb is a specialised carbon-based wear-resistant composite used in bulk handling equipment; the client will supply associated liners and welding consumables.

Skills and Competency Requirements

• Qualified mechanical technicians and engineers with proven experience in heavy industrial gearbox overhaul, precision bearing installation, and shaft crack testing.
• Certified supervisors and safety officers capable of developing task-specific method statements, conducting daily progress reviews, and enforcing site protocols.
• Personnel formally trained in elevated work practices, including safety harness usage and emergency rescue procedures.
• Competent individuals authorised to develop and implement fall protection and confined space work plans where applicable.
• Dedicated environmental officer with documented qualifications to oversee compliance with spill prevention, waste segregation, and site restoration protocols.
• Skilled cleaning crew available for the full shutdown duration to maintain chutes, conveyor lines, and general work areas.
• All appointed personnel must possess valid competency certificates, completed induction records, and up-to-date occupational health fitness clearance.