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SCOPE OF WORK
FOR
STACKER &RECLAIMER
INSPECTION AND EVALUATION







Document No : RE-SOW-04
Revision : 0
Date of Issue : 13 June 2012





0 13 June 2012
Stacker and Reclaimer
Inspection & Evaluation
Allyn M Pijano Swamy
Rev Date Description Prepared By Checked By Approved By




NOTE: This document and all its contents is the property of Ma'aden. It is confidential and is given to you for a limited purpose
and must be returned upon request. Neither this document nor any information concerning it may be copied, exhibited or
furnished to others without the prior consent of Ma'aden.





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S/N CONTENTS
TITLE COVER
1.0 BACKGROUND
2.0 INTRODUCTION
3.0 PURPOSE
4.0 EQUIPMENT HISTORY
5.0 LANGUAGE AND MEASUREMENT SYSTEM
6.0 EQUIPMENT SPECIFICATIONS AND APPLICATION
7.0 MOBILIZATION
8.0 SCOPE OF WORK
9.0 TIME OF COMPLETION
10.0 CONTRACTOR RESPONSIBILITY
11.0 MPC RESPONSIBILITY
12.0 COORDINATION
13.0 SAFETY
14.0 TRANSPORT,ACCOMMODATION AND FOOD
15.0 MPC WORK SCHEDULE
16.0 PRICING SCHEDULE
17.0 GENERAL TERMS AND CONDITION















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1.0 BACKGROUND:
Maaden Phosphate Company (MPC) is one of the largest integrated mining and
processing complexes in the world. The Mine and Beneficiation plant are located at Al-
Jalamid in the North of Saudi Arabia and the chemical processing facility is located at
Ras Al-Khair north of Al-Jubail.
The plant facility in Al-Jalamid includes a rock phosphate mine, beneficiation plant, gas
turbine power plant, a residential village and all related infrastructure. It has the
capacity to produce 4.5 million metric tons of concentrate (dry basis) per year at an
average of 32.5% P2O5.

2.0 INTRODUCTION:
MPC Al Jalamid Plant wishes to hire the services of a competent company who is a
leading pioneer in material handling equipment inspection and condition assessmentof
travelling variable height boom stacker and bridge-scraper type reclaimer equipment.
MPC Plant is maintaining a crushed phosphate ore ( 9 mm size) stockpile of 90 000 tons
for storage and blending which are handled by a travelling variable height boom stacker
in one open pile and recovers by bridge-scraper type reclaimer equipment from the
other pile. The blended ore is conveyed to a surge ore bin and then it is feed to grinding
circuits consisting of four (4) rod mills.
Another bridge-scraper is installed at downstream of production line to recover
stockpile of filtered phosphate concentrate for drying into the rotary dryer as the final
product of P2O5.

3.0 PURPOSE:
The purpose of this document is to outline the requirements for the inspection and
condition assessmentof the existing Side Cantilever Slewing Stacker (one unit) and
Bridge-Scraper Type Reclaimer (two units) in order to determine its capability and
maintainabilityat designed operating capacity in a safe and reliable operation. These
equipment are important operational assets for the production demand of the plant.
Several pre-mature failures had already occurred in the equipment since it was in
service operation for almost two (2) years from the start of commissioning period in
2010.

4.0 EQUIPMENT HISTORY:
a) Side Cantilever Slewing Stacker:
1. Several repairs in motor for cable reel due frequent bearing failure almost
every month.
2. Cable had been cut frequently which have to be replaced every 3 months.
3. Weld cracks on steel structures.
b) Bridge-Scraper Type Reclaimer:



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1. Pre-mature failures had occurred several times in transmitting chain links
due to abnormal wear and rubbing with guides.
2. Structural failure of harrow from deformation and cracking.
3. Deformation of bridge structure and end carriage.
4. Weld cracks on bridge structure and end carriage.
5. Fabricated chain links as replacement are with inferior quality for the service
causing chronic failures.

5.0 LANGUAGE AND MEASUREMENT SYSTEM:
All documents and communications shall be in the English language.
All units shall comply with the International System of Units (S.I. Units).

6.0 EQUIPMENT SPECIFICATIONS AND APPLICATION:
The following given data are the only available information taken from manual supplied
by vendor.
a) Side Cantilever Slewing Stacker (1 unit):
Stacking Capacity = 1955 tons/hour
Rail Span = 6 meters
Traveling Speed = 7.5 ~ 20 meters/minute
Length of Cantilever = 35.6 meters
Angle of Luffing = -12 ~ 10.5
Slewing Speed = 0.119 rev/min
Slewing Angle = +/- 90
Reel Outer Diameter = 3200 mm
b) Bridge-Scraper Reclaimer (2 units):
Reclaiming Capacity = 1955 tons/hour
Rail Span = 40 meters
Scraper Chain Pitch = 500 mm
Scraper Chain Speed = 0.56 meter/sec
Total Scraper = 83 pieces (1000 mm span between scraper)

7.0 MOBILIZATION:
a) Contractor shall mobilize the manpower upon confirmation for the date of
assignment in-situ and issuance of notice to proceed for planned inspection and
testing.
b) Date and time mentioned here is almost certain, however any change due to above
mentioned condition should be notified well in advance.





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8.0 SCOPE OF WORK:
a) Inspection and Testing:
1) The survey shall as a minimum include the following:
a) Physical state and need for maintenance or repair of main parts and
structures.
b) Steel structures condition for signs of cracks, wear and extent of
corrosion.
c) Deflections or distortions of bridge structure, end carriage and other
support structures.
d) Sign of wear on wheels, rails, chain drive, buckets and linkages.
e) Signs of settlements of rails and condition of concrete support.
2) A detailed assessment addressing adequacy of the existing installation and
any necessary corrective actions.
3) A detailed assessment of the current maintenance program and maintenance
activities addressing the effectiveness of current maintenance and
identification of all opportunities and deficiencies.
4) Inspection will involve visual assessment but will also include operational
checks as functional testing (with and without load)of key areas such as
controls, hydraulic system, protective and safety devices, lightings and other
mechanical mechanism.
5) The inspection will involve a significant amount of data collection where
necessary it may also involve further testing of some mechanical, electrical,
instrument components including PLC programs and operation modes.
b) Final Report Content and Deliverables:
Following points to be included in the final report:
1) Detailed inspection report including results of visual inspection.
2) Photographic illustrative surveyfor location of defects found.
3) The current electromechanical and instrumentation condition of the
equipment.
4) The measures required to maintain the operational (running) hours of the
equipment prior for overhauling of major components, to include:
a) List of component in the system that will require repair.
b) List of component in the system that will need replacement.
c) List of component that will need modification.
d) List of equipment in the system that are sound and do not warrant repair
or replacement, to meet the extended running hours.
5) Cost benefit/cost effective of proposed replacement and modification.
6) Scope of upgradation and/or replacement to include the new specifications
of new equipment or parts.
7) Provide a planned schedule for equipment and components replacement.



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8) Recommendation of modification to existing component to improve the
performance and reliability of the equipment. The recommendation shall be
include the complete detailed procedure. If any modification is implemented
a performance test to be carried-out after implementation.
9) One-day presentation of the final report.
c) Preparation of Standard Procedures:
1) Standard installation procedure for reclaimer chain assembly.
2) Standard maintenance procedure for stacker and reclaimer.
3) Standard inspection and testing procedure stacker and reclaimer.

9.0 TIME OF COMPLETION:
a) The duration of assignment in-situ shall be completed in seven (7) calendar days
excluding the travel time.

10.0 CONTRACTORRESPONSIBILITY:
a) Assignment of two (2) specialists (one mechanical and one electrical & control)
b) To provide necessary tools and instruments for the execution of the job.
c) To provide all personnel protective equipment like hard hat, hand gloves, safety
shoes, safety goggles, etc.
d) Contractor has to prepare and submit the work schedule before starting the work.
e) Technical preparation of inspection and testing prior for visit.
f) Mechanical and instrument component removal, calibration, reinstallation and
testingshould be included in schedule in consultation with the authorized MPC
Engineer.

11.0 MPC RESPONSIBILITY:
a) Safety induction and issuance of gate pass for personnel.
b) Provide the issuance of the safety work permit before starting the job.
c) Arrangement of utilities like water, air, power & light at the place of work.
d) MPC will provide office for preparation of reports and safekeeping of personnel
belongings.
e) MPC will provide the necessary assistance of technician personnel.
f) Provide equipment manuals, drawings and history records.
g) Arrangement of scaffolding and tools as and when required.
h) Opening and cleaning of components for the purpose of inspection and testing.

12.0 COORDINATION:
a) The contractor shall coordinate with the designated MPC authorized engineer to
carry out the above job.



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b) The authorized Engineer from the employer shall be responsible for the execution of
the complete work, give all instructions and directions contemplated under this
contract relative to the execution of the activities.
c) Any differences or conflicts in regards to the work may arise, the decision of the
Engineer is binding and final.

13.0 SAFETY:
a) The local and international applicable safety standards shall be strictly followed.
b) Vendor safety instructions and warnings shall be observed.
c) Ensuring adequate safety training of contractor personnel and competency for
carrying out all the jobs.
d) Ensure contractor employees observe all site safety rules, e.g., personnel protective
equipment requirements, etc.
e) The contractor shall adhere to MPC safety regulations and shall be equipped with all
required Personnel Protective Equipment (PPE) for the job.
f) Contractor employees shall be aware of the hazards connected to their work and
shall take safety precautions before carrying out the job.

14.0 TRANSPORT, ACCOMMODATION AND FOOD:
a) Airline travel cost from home country to Saudi Arabia and vice-versa will be provided
by MPC.
b) Local transportation in home country will be at the expense of contractor and
charged to MPC.
c) Transportationin Saudi Arabia will be arrangedby MPC during the assignment.
d) Personnel accommodation and food will be arranged by MPC.

15.0 MPC WORK SCHEDULE
a) MPC normally works from 8:00 to 16:30 hours from Saturday through Wednesday.
b) Overtime time work by contractor in excess of 8 working hours shall be notified for
approval by MPC authorized engineer.

16.0 PRICING SCHEDULE
a) Contractor shall submit lump sum price for complete work and provide
BREAKDOWN prices for the following:
S/N BRIEF DESCRIPTION PRICE (SAR)
1
Assignment Daily Rate (8 working hours per day
for 6 days from Monday ~ Saturday)

2
In-house Engineering (8 working hours per day
for 5 days from Monday ~ Friday)




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3 Other expenses during travel
TOTAL AMOUNT

17.0 GENERAL TERMS AND CONDITIONS
a) Contractor is responsible for complying with all applicable provisions of Saudi Law.
b) Ensuring that the Contractor personnel are aware of and fulfill all requirements for
site access.