Objectives

The primary objective of this tender is to appoint a qualified supplier with proven experience in heavy mechanical engineering, specifically in rotary kiln and drum alignment, to support Foskor’s Drying and Dispatch Maintenance teams. The goal is to enhance plant availability, reliability, and efficiency by conducting accurate drum and kiln alignment surveys, routine inspections, and corrective actions. Additionally, the contract aims to leverage plant equipment performance to improve operational throughput, especially given current underperformance of the rotary driers.

Further objectives include ensuring minimal unplanned downtime, responding swiftly to emergencies, and maintaining plant quality standards while managing diverse customer requirements in international markets.

Scope

The scope encompasses:

• Provision of labour, tools, and specialized equipment for drum and kiln alignment surveys, inspections, and corrective procedures.
• Conducting routine and emergency alignment work, including adjustments during plant operation and shutdowns.
• Determining drum angles, calculating shim thicknesses, and adjusting alignments to meet approved drawings and tolerances.
• Aligning pinion and girth gears using industry-accepted methods such as laser alignment, ensuring gear root clearance and backlash are within specified tolerances.
• Commissioning of drums during cold and hot runs, with detailed reporting on findings, adjustments, and corrective actions.
• Regular review and definition of riding ring creep, crack repair procedures, and surface grinding processes.
• Proposing strategies for survey scheduling, remedial work, and spare parts management, considering the criticality of equipment.
• Routine condition-based inspections, emergency call-outs, and maintenance planning to prevent unplanned failures.
• Ensuring safety, legislative compliance, environmental considerations, and quality management throughout the contract duration.

Technical Requirements

The technical scope includes:

• Supply of skilled personnel: Kiln alignment specialists, boilermakers, welders, fitters, safety officers, site managers, and supervisors.
• Use of specialized tools and equipment such as laser alignment systems, grinding machines, welding gear, and general hand tools.
• Conducting detailed drum and kiln alignment surveys, including:
• Measuring drum angles and station-to-station alignment.
• Calculating and adjusting shim thicknesses for proper alignment.
• Aligning pinion and girth gears, ensuring gear backlash and root clearance are within industry standards.
• Commissioning drums during cold and hot runs, with comprehensive reporting.
• Implementing remedial procedures such as crack repair, riding ring surface grinding, and weld procedures.
• Proposing and executing strategies for survey scheduling, emergency interventions, and spare parts management, including critical spares provisioning.
• Adherence to safety, legislative, environmental, and quality standards, including compiling safety files, permits, and safety management plans.
• Routine inspections, condition monitoring, and emergency response readiness.
• Reporting: Formal documentation of survey findings, adjustments, corrective actions, and commissioning results, signed off with quality guarantees.
• Compliance with Foskor’s safety policies, legislative requirements, POPIA, and environmental commitments.