MORMUGAO PORT TRUST ENGINEERING (MECHANICAL) DEPARTMENT CME/MOHP/WORKS/04/2011

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Nov 25, 2013 (3 years and 10 months ago)

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MORMUGAO PORT TRUST

ENGINEERING (MECHANICAL) DEPARTMENT

CME/MOHP/WORKS/04
/2011



PART V


TECHNICAL SCHEDULE


NAME OF THE WORK
-

Th
o
rough cleaning,

washing
,

part painting,

st
ructural
and girder repairs/strengthening
of
2

nos. conveyor
structures (
S5 &

S
6
) of Shipping Section.


1.

JOB DESCRIPTION

:

MOHP is equipped with 8 nos. Barge U
nloader, 1 no. continuous Barge Unloader, 3
nos. Stackers, 2 nos. Reclaimers and 2 nos. Shiploader and 24 nos. connecting
Conveyors and 2
0

Nos. Houses.



1.2

The original steel structure supports of Shipping conveyor
s S5 & S6

found
corroded due to exposu
re to the saline atmosphere

were replaced/ strengthened to
maintain
stability of the structures
during
shutdown
-
2008,

200
9

& 20
10
,

now some

of
the corroded steel
structures of conveyors S
5

& S
6

were replaced
. Now
, some of the
corroded steel of
conveyors
S
5

&

S
6

are
also
required to be
strengthened

/
replaced

alongwith the strengthening of rail support
(girder)
structure of the conveyors
.


1.3 Shiploader rail support (girder) structure
,

commissioned in the year 1978,

has
been cleaned and painted
from
time to time as per necessity. Now they

are corroded at
several locations and need to
be
strengthened as per the scheme
indicated in the
tender
.


Approximate quantity of steel required is
109

MT



2

SCOPE OF WORK
:


2.1

Cleaning and Washing of
C
onveyors

Structures
of

S5 & S6

conveyor
:
-


a
)

Spillage accumulated
on and
around the conveyor decks, stringer frames,
return
/carrying side of conveyor S5 & S6
and other structures on above
Conveyor
s

are required to be cleaned thoroughly and wire brush
ed

wherever
required (such as on weld joint, splice joint
, etc.
). Contractor
shall

deploy
sufficient workers and get the
conveyor structures

cleaned thoroughly to the
entire satisfaction of the Port Engineer.


b
)

The contractor
shall

ensure the removed spilla
ge does not fall on the Long
Travel tracks/conveyors. Any spillage is accumulated on rail track/conveyor
sides same shall be cleared thoroughly after completion of work.


c
)

The removed spillage
shall

be the property of Port. The contractor shall shift
t
he removed spillage to nearby area to be designated by the Port.


d
)

All the critical welding joints and the splice joints sh
all

be cleaned using wire
brush.


e
)

Precautions should be taken to see that no part of any
conveyor

is damaged
while cleaning
.

MORMUGAO PORT TRUST

ENGINEERING (MECHANICAL) DEPARTMENT

CME/MOHP/WORKS/04
/2011




f
)

While cleaning the spillage accumulated over the cable tray precaution is to be
taken to see that cables are not damaged. This activity shall be carried out in
the presence of CME's representative.


g
)

All the structural members of the
conveyor deck
s

should be thoroughly washed
using
pressurized

jet of sweet water. All the critical welding joints and the
splice joints should be again cleaned using wire brush.

The water will be
brought / arranged by the contractor by
w
ater tanker.
Rain water collected

on
the belt conveyors should not be used for washing the structures.

h
)

Precautions to be taken to see that the water is not splashed on to the electric
panels equipment, and any other outdoor electrical installations on the
machine


i
)

All the motors
,

g
enerators
and conveyor idlers
should be properly covered
before spraying water on the
conveyor structures
. Contractor shall ensure that
water does not en
ter the electrical panels, JB's, idler bearings,
etc.

j
)

Tools required for execution of the contract

like shovels
,

g
amalas/
p
ickaxe,
Wire Brushes, water, water pump along with pressurized jet etc. shall be
brought by the contractor.

2.2


Structural strengthening & replacement

of corroded steel structures
of
conveyors
S
5 &

S
6

conveyor of Shipping Section

(
MOHP)


a.

Measure the length of the old channel, angle or flat to be replaced. All the
location where these replacements are required to be carried out will be
indicated by Port Engineer.

b.

The required corroded/damaged steel structural member, which is to be
replaced, shall be gas cut to the required length. A new member is to be
measured, cut as per the required dimension.

c.

The same shall be painted as per painting scheme
mentioned in the tender
.
Also the surrounding area of the gas cut portion
wherever paint
is
burnt due to
gas cutting is
to be painted by the stipulated painting scheme in the tender.

d.

Secure the steel member firmly in place by welding and/or bolting, as the case
may be, to the existing structure.

e.

As this portion where the replacement is to be c
arried out, is just above the
sea, all the necessary safety precaution are to be taken by the contractor for
ensuring the safety of his labourers by providing the
additional
safety gears

as
required
.

f.

Before starting the work, the Contractor shall assess th
e corroded steel
structures which require replacement alongwith the Port Engineer and get
thoroughly acquainted with the scope of work involved.

g.

If any spillage is found accumulated over the conveyor deck, cross structural
of conveyor or on walkway grating
s etc. shall be cleared thoroughly by the
Contractor before commencement of work.

h.

Following are the some of the major locations where the structural
strengthening and replacement of corroded steel structure is required to be
carried out.



MORMUGAO PORT TRUST

ENGINEERING (MECHANICAL) DEPARTMENT

CME/MOHP/WORKS/04
/2011



2.2.1

The

cor
roded

side stringers
, angles and

channels of conveyor

s
tructures

mainly
in the form of ISMC 200 x 75; 150 x 75,
ISA 65

x
65

x 8 angle, ISA 90 x 90 x
10
mm
,120x120x10

& steel plates of 10 mm thick

and M 20 x 70 H.T. bolts &
M16 x 75 H.T. bolts shall be suppl
ied and replaced by the contractor.

The actual locations of these replacements will be indicated by the Port
Engineer at th
e time of execution of the job.



Approximate steel required for this is
15
MT.


2.2.2

The above steel quantity / sizes indicated
are only for guidance and the actual
requirement of steel is to be measured at Site along

with Port Engineer at the
time of execution of the work or before commencement of work, and
accordingly, Contractor shall order steel qua
ntity

& sizes.



2.3

Repairs

/ strengthening to conveyor S5 & S6 girders ( Shiploader Rail
support)


S5 & S6 conveyor structure and Shiploader rail support structure at Berth no.9 are
supported on 3 main girders MG1
,

MG2
and MG3. In between these main girders
there are six cross gir
ders (CG1 to 6) which are inter connected by cross beams. (CB
1
-
6). The two main girders viz; MG1 and MG3 are corroded at bottom flange and in
the lower part of web and vertical stiffener
s and need to be strengthened.
The
following measures
are to be obser
ved
and all the work including welding will be
carried out as per the

following

recommendation
s

and drawings.


a
.

Provide an extra plate of 10mm thickness at the bottom of the existing bottom
flange.


This extra plate of 10mm thickness to be welded at the
bottom of the flange
(width
400
mm)

shall also be connected by Plug welds of 20mm dia in
scattered manner as shown in the drawing no.I
-
439/SS
-
02/R1.


At locations where edges of flange plate are damaged or have become zig
-
zag
in plan they shall be trimmed/g
round and made straight to create edge to
provide fillet weld.



Approximate steel required for this is 10mm plate


15 tons.


b
.

The bottom web portion of these main girders (MG
-
1 & MG
-
3) is also badly
pitted up to a height of approx. 300 mm on sea side (
outside) and upto 200
mm on land side (inside). These pitted surface
s

need to be ground properly to
remove corrosion, painted and new plates of 10mm painted on contact side to
be welded on both sides of the web just above bottom flange as splicing is
done
. In order to avoid welding coming on the same height on both sides, sea
side plate shall be kept 400 mm and land side plate shall be kept 300 mm high
or 300 mm and 200 mm high as the case may be (where corrosion is up to a
lesser height).

Refer detail 'A
' in the drawing no. I
-
439/SS
-
02/R1.


Approximate steel required for this is 10mm plate


25 tons.


MORMUGAO PORT TRUST

ENGINEERING (MECHANICAL) DEPARTMENT

CME/MOHP/WORKS/04
/2011



c
.

Most of the vertical stiffeners corroded in the lower 200 mm


300 mm height

shall be
cleaned and painted. However, additional stiffners
shall

be provid
ed
one on either side of the corroded stiffners upto a height of 500mm from the
top of the bottom flange to compensate for corroded vertical stiffners. I
n case
of the last two spans near DH
-
16, the stiffeners are corroded for almost the full
height
,
the e
xisting corroded stiffeners
of 10mm thickness & 60mm width to
be cut & replaced
.


Approximate steel required is 16mm thick plate


(
7

tons).


d
.

Badly corroded gusset plates to be cut and removed and new gusset plates to
be welded.



Approximate steel re
quired is 10mm plate


3 tons.


e
.

All the
corroded
angle cleats supporting the beams of 600 mm, 450 mm, 300
mm and 250 mm

shall be

cleaned painted and provided with
2

no
s
. plate
brackets at the supports of the beam.


Approximate steel required is M.S. pla
te
10 mm


1
0

tons.


f
.

Damaged and badly corroded cross bracings of ISA 75
x
75
x
8 and ISA
90
x
90
x
10 along with gusset plates of 10 mm thickness to be replaced.


Approximate steel required is
9 tons.


g
.

ISMB 250 & ISMB 200 supporting S5 & S6 conveyor structu
re,
shall

be
replaced wherever found badly corroded.



Approximate steel required is Fabricated I
-
Beam of above sizes


21 tons.


h
.

Some of the IS
MB 250/300 outside Drive house
15 are badly corroded and
shall

be replaced.


Approximate steel required is IS
MB 250/300


3.5 tons.


i
.

ISMC 200
x
75 and ISMC 150
x
75 and vertical support angles 90
x
90
x
10 of S5
& S6 conveyor structures
shall

be replaced wherever found corroded.


Approximate steel requirement:

ISMC 200X75


6 tons.






ISMC 150X75


5 tons.

ISA90X90X
10


3 tons.

M.S. plate 10mm


1 ton.

--

15 tons.


j
.

All the bolts

& nuts

connecting the various girders and bracings
shall
be
replaced with proper torque with torque wrench. These

HT bolts

& nuts

are of
size:


1)

M24X80mm

--

500 nos.

2)

M24X60mm

--

2800

nos.

3)

M20X60mm

--

1700 nos.

MORMUGAO PORT TRUST

ENGINEERING (MECHANICAL) DEPARTMENT

CME/MOHP/WORKS/04
/2011



k
.

All bolts, nuts and washers shall conform to IS
-
1367. All high tensile bolts,
nuts and washers shall be as shown in the drawing. The splice joint bolts shall
be of 10.9 grades. These splice joints bolts shall be either f
rom UNBRAKO,
TVS, GKW or PFL only. Necessary test certificates of these bolts shall be
produced to the Port well in advance

Approximate number of HT bolts

& nuts

to be replaced are 5000.
The bolts

& nuts

will be
arranged by the contractor
.


Total steel (10
8.5) tons rounde
d

off to (109) tons



l.

The new steel which shall be brought in for replacement for execution of
works
indicated in this tender shall
be
normal MS steel confirming to IS
2062
of SAIL/ /TISCO/ ESSAR STEEL/ VIZAG STEEL / JINDAL
STEEL / LOYLD
S Brand only. Any other brand of steel shall not be
accepted.

Contractor shall also produce necessary documentary proof such
as test certification for the structural steel purchased as well bills of
purchase of steel material from the reputed dealers to th
e Port site
engineer as and when necessary. The steel should have the embossed/
identification mark of the brand of steel. In case the steel does not have
the identification/ embossed mark, a sample of the same will be tested at
the cost of the tenderer. T
he steel will be accepted based on the test results
of the sample.


Sandblasting
/ Grit blasting

and Painting

m.

All the steel members to be
used for the strengthening work shall be sandblast
and
painted
as per painting schedule

mentioned in the tender.

The

paint shall
be arranged by the contractor.



Painting Schedule:

n.

The contractor shall prepare the steel structural surface to be painted
thoroughly cleaning all foreign materials adhering to the surface by means of
blasting with sand / copper slag. Use
of scrapper, wire brush is acceptable,
wherever blasting is not possible due to lack of access. After completion of
blasting operation, the blasted surface is to be primed with one coat of
Protectmastic
Aluminum primer

of Berger Paints or equivalent of As
ian
Paints, Jenson & Nicholson, Shalimar or Akzo Nobel Coatings within 4 hrs. If
this period of 4 hrs. is not observed due to any reasons whatsoever, the
surfaces indicated shall be sandblasted afresh before the coat of primer is
applied. The dry film th
ickness of 1 coat of primer shall be 60 microns. Then
the surface shall be painted with
2 coats of
Epiguard finish paint 533 or Epilux
4B of Berger or equivalent of Asian Paint, Jenson and Nicholson, Shalimar or
Akzo Nobel coatings
with minimum DFT of 100
microns of each coat by
brushing.



The contractor shall use any of the following specified brands of paints.



Protectmastic Aluminum primer



Berger Paint or equivalent Asian
Paint, Jenson and Nicholson, Shalimar or Akzo Nobel coatings.



Epiguard finish pai
nt 533 or Epilux 4B of Berger or equivalent Asian
Paint, Jenson and Nicholson, Shalimar or Akzo Nobel coatings.



MORMUGAO PORT TRUST

ENGINEERING (MECHANICAL) DEPARTMENT

CME/MOHP/WORKS/04
/2011




All primer (1coat) and finish coat (2 coats) shall have different shades for the
purpose of distinguishing. Both the coats of finish paint s
hall have different
shades. The above painting scheme will be applicable unless specified in the
technical schedule of the tender.



o
.

Welding electrodes shall conform to IS.814 (part


I & part
-

II) and only
Advani Oerlikon/Esab/L&T/IOL/D&H Secheron

sha
ll be used
.
The
contractor’s work will be stopped without notice for non
-
compliance of
above.


Following w
elding rods
are
to be used for repairs / strengthening
:


*

E6013 of Advani / IOL
make
or equivalent
for plate thick less than
12mm.


*

E7018 of Advani

/ IOL
make
or equivalent
for plates 12mm or
more.


p
.

Holes for all the bracings shall be drilled as per required size. Gas cut holes
will not be accepted.


q
.

Methodology and type of welding will be strictly as per the repairs scheme
as
mentioned in the

tender
.



The above steel is only for guidance and the actual requirement of steel is to
be measured at Site alongwith Port Engineer at the time of execution of the work or
before commencement of work, and accordingly, Contractor shall order Steel quantit
y
/ sizes
.


r
.


After completion of erection / installation of new conveyor structures, the
contractor shall repaint the structure wherever the paint is peeled off during
transportation / installation of the painted prefabricated structures.


s
.


The hook
s of the pull cord wire shall be removed while replacing the main
stringer/deck frames. New hooks along with the pull cord wire shall be refitted
as required on the stinger frame. Hooks shall be supplied by the contractor.
Pull cord wire required shall be
supplied by the Port.


t
.


Limit switch boxes fitted on the main stringer/deck frames shall be removed
while replacing the main stringer/deck frames and refitted on the new
stringe
r/deck
frames after providing new brackets for the same.


u
.


Care shall
be taken of the electrical cables running along the length

of the
stringer / deck
frames. If any cable is damaged during the replacement of the
cable structure
the same
shall be replaced free of cost by the contractor.


v
.


SAFETY PRECAUTIONS:
-

As t
he works are required to be executed in
s
itu
and during operation,

contractor shall take all the safety precautions and use
safety gears
during
execution of the work. Contractor shall see that no damage
is done to the respective machine/conveyor/houses or
any Port property while
executing the work. If any damage occurs, contractor shall rectify the same,
free of cost.

MORMUGAO PORT TRUST

ENGINEERING (MECHANICAL) DEPARTMENT

CME/MOHP/WORKS/04
/2011



w
.


Contractor's Engineer / authorized representative should be available at site on
day to day basis during the entire period of execution o
f works.

x.

Only IRS
/ISBT

approved / certified welders are to be deployed.
Certificates in this regard should be produced before commencement of
work. Contractor will not be allowed to work for non
-
compliance of
above.



3
.0

Mobilization & Completion Per
iod

The contractor shall mobilize
their staff
and resources
within a period of 10

days
and complete the entire work within 2
5
0 days
from the date of placement of
work order
, including mobilization period.


4.0

SHOP TEST AND
INSPECTION OF WORK


4.1

Inspect
ion of work

a.

The tendered work will be inspected by a Third Party Inspector appointed by
the contractor

at his

own cost. The

inspection will be carried out at the various
stages of work which shall be generally as per
the QAP.



b.

Various tests as provi
ded in the QAP shall be carried out in the laboratories
approved by Third Party Inspection agency/MPT. Cost of all tests as required
in the QAP and/or as specified by the Third Party inspector or MPT shall be
borne by the contractor.


c.

The contractor sha
ll get the certification and clearance from the Third Party
Inspector at every stage before proceeding to the next stage.


d.

Any remedial measures for the deficiencies, suggested by the Third Party
Inspector
,

shall be immediately carried out by the contra
ctor without any extra
cost to the Port.



e.

The contractor shall keep the Third Party Inspector as well as the Port abreast
of all the activities that are being carried out by him at his work site and shall
carry out each activity under intimation to the

Third Party Inspector and the
Engineer.

d.
After completion of
the
fabrication work
,

the

third party inspector will certify
the fabrication work which will validate the payment of bill towards
fabrication.


4.2

Shop Test


a.

In addition to above
, materials and workmanship shall be subject to test and
inspection at any time during regular working hours by the Engineer or his
representative. Access shall be available for inspection to all places where
MORMUGAO PORT TRUST

ENGINEERING (MECHANICAL) DEPARTMENT

CME/MOHP/WORKS/04
/2011



work is being done.

The contractor shall arran
ge for the material test and other
test at the written request of the Engineer .

All

welding work
shall be subjected
to gamma
-
ray or ultrasonic testing as requested by the Engineer or his
representative and test certificates shall be furnished.


5.0

QUALI
TY ASSURANCE PLAN

(QAP)

a.

The
work
shall be
executed
strictly in accordance with the specifications given
in this Tender document. The bidders shall submit in substantial detail, their
tentative Quality Assurance Plan (QAP) indicating all activities step

by step at
various manufacturing/fabrication/construction premises including that at site
to carry out the work to meet the requirement of this specification and
international standards / regulations / practices, to enable comprehensive
assessment of its
merits and reliability. This shall also indicate tentatively at
what stages of manufacturing / fabrication / construction of all items he
proposes the customer control points / inspections, according to which the
inspection by the Engineer or his represen
tative could be planned.



b.

In addition to above, materials and workmanship shall be subject to test and
inspection at any time during regular working hours by the Engineer or his
representative. Access shall be available for inspection to all places wh
ere
work is being done. Mill test reports shall be furnished by the contractor.
Where tests of materials by others are required, the contractor shall arrange for
such tests at the written request of the Engineer. All welding work and castings
shall be subj
ected to gamma
-
ray or ultrasonic testing as requested by the
Engineer or his representative and test certificates shall be furnished.



6
.0

GUARANTEE OF WORKS

a.

The contractor shall guarantee the contract work ex
ecuted by him on the
conveyor

and rail

support
structure and for the materials / consumable used
therein for a period of one year from the date of completion of entire work and
acceptance of the same by the Engineer
.

b.

All the defects /deficiencies noticed during the guarantee period
shall

be

rectified by the contractor by way of repairs /replacement either at site or at
contractor works etc., as found necessary by the Engineer. The decision of the
Engineer in respect of the above will be final and binding on the contractor.

All the defects /

deficiencies noticed during the guarantee period shall be
rectified by the contractor
at
free of cost.


7
.0


The contractor shall execute the work without
a
ffecting the loading
operation of shipping section
.





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