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Doc Number: PD_PDWL_NAT_URS_034 Revision: 03 Page: 1 Classification: External Use

PRODUCT DEVELOPMENT - WHEELS

USER REQUIREMENT SPECIFICATION

DOC. NO.: PD_PDWL_NAT_URS_034

USER REQUIREMENT SPECIFICATION FOR THE SUPPLY OF A WHEEL MPI TEST JIG FOR TRANSNET ENGINEERING WHEEL BUSINESS

Compiled by: Allucious Mothusi

NDT Specialist

TE National Wheels

Approved by: Ryno Kotze

Principal Engineer

Product Development (Wheels)

Transnet Engineering

Date: 14 August 2017

The information contained herein is the sole property of Transnet Engineering. It may not be used, disclosed or reproduced in part or in whole in any manner, except with the written permission of and in a manner permitted by the proprietors.


TABLE OF CONTENTS HISTORY OF CHANGES ...................................................................................................... 3

DOCUMENT CONTROL ...................................................................................................... 4

1. BACKGROUND AND SCOPE OF WORK......................................................................... 5

2. SPECIFIC REQUIREMENTS ........................................................................................... 5

3. OPERATING ENVIRONMENT ....................................................................................... 6

4. EXECUTION OF WORK UNDER THE CONTRACT ........................................................... 6

5. COMMISIONING OF THE EQUIPMENT ........................................................................ 6

6. SAFETY ...................................................................................................................... 7

7. GUARANTEE .............................................................................................................. 7

8 TRAINING .................................................................................................................. 8

9 MAINTENANCE .......................................................................................................... 8

10 PAYMENT .................................................................................................................. 8

11 OTHER TENDER REQUIREMENTS: ............................................................................... 9

Appendix A ..................................................................................................................... 10

Appendix B ..................................................................................................................... 15


HISTORY OF CHANGES First issue: 06 – 03 – 2017 Document No.: PD_PDWL_NAT_URS_034 The following changes are included in this revision:

Pages

Affected Revision #

Release

Date Description of Changes

5 3 14-08-2017 1.1 was changed

5 3 14-08-2017 2.1.1 added

5 3 14-08-2017 2.1.4 was changed

5 3 14-08-2017 2.1.6 was changed

5 3 14-08-2017 2.1.7 added

5 3 14-08-2017 2.1.8 added

5 3 14-08-2017 2.1.9 added

5 3 14-08-2017 2.1.10 added

5 3 14-08-2017 2.1.12 added

5 3 14-08-2017 2.1.13added

5 3 14-08-2017 2.1.14added

5 3 14-08-2017 2.1.15 added

5 3 14-08-2017 2.1.16 added

6 3 14-08-2017 2.2.1 changed

14 3 14-08-2017 Appendix A3 added


DOCUMENT CONTROL

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Supporting Templates:


1. BACKGROUND AND SCOPE OF WORK

1.1 This specification details the user requirements (URS) for a custom fabricated MPI test jig

for the Wheels Business. Appendix A2 gives a view of a more semi-automated equipment in use currently in the world today, to assist the contractor understand more of the process that will be conducted with the required equipment that Transnet Engineering is intending to install. Transnet Engineering requires a manually operated process as indicated in section 2 of this document.

1.2 This user requirement involves the fabrication, delivery, installation and commissioning

of the MPI test jig that will fit within the existing dark room. Photos of an existing dark room are shown in Appendix A1.

1.3 The tenderer must indicate compliance to each item in the attached feedback checklist

in Annexure B. An electronic copy of the requested format will be available from Transnet Engineering upon request.

2. SPECIFIC REQUIREMENTS

2.1 The MPI test jig must provide the following:

2.1.1 The MPI jig must be able to handle a wheel with diameter 1260mm and dimensions as per Appendix A3. Wheel weight is about 700kg.

2.1.2 Wheel to be rolled manually in the vertical position via a channel into the booth and into the bath.

2.1.3 Wheel to be rotated by a rotation device powered by a motor. 2.1.4 MPI fluid (wet fluorescent) will be applied onto the wheel with a pump and

flexible hoses. 2.1.5 MPI fluid to be trapped into a bath and circulated with the pump. 2.1.6 A coil is to engage the wheel and ensure continuous magnetisation during

UV light testing. 2.1.7 The jig must magnetise the wheel in 2 directions perpendicular to each

other. 2.1.8 UV lamp must be supplied. 2.1.9 The MPI test jig must conform to the requirements of the ‘Standard guide

for MPI testing E709 (latest)’. 2.1.10 The magnetisation cycle must ensure validation of all the section

thicknesses of the wheel shown in Appendix A3. 2.1.11 Demagnetisation of the wheel is required after the test. 2.1.12 UV light inspection will be done manually by the inspector. 2.1.13 Wheel to be ejected mechanically out of the bath and will be rolled

manually in the vertical position via a channel out of the booth. 2.1.14 The MPI jig must be operated by a maximum of 2 people. 2.1.15 The jig supplier must supply a MPI method statement that is certified by a

level 3 NDT technician. 2.1.16 Pre-and post-cleaning of the wheels will not be part of the scope of supply

and will be done as separate operations by TE.


2.2 The MPI test jig must be installed within an existing dark room with dimensions 4x4x2.5m (see Appendix A1). The opening on both side are 3 x 2m with strip curtains. Three phase power will be supplied by TE to the booth.

2.2.1 The tenderer must advise if the size of this booth will not be suitable for

installation of the MPI test jig and make provision for any modifications required.

2.3 Special Requirements: 2.3.1 Tenderer shall supply a suitable flame retardant cable and connect the

machine to a three phase alternating power supply distribution board / busbar which might not have associated control gear. TE shall only responsible for isolating the power and restoring afterwards. If only 220V power supply is required then this must be stated in the tender.

2.3.2 Tenderer shall be responsible for the connection and compliance of all electricity supply to the terminations of the machine from an existing network.

2.3.3 TE shall only be responsible for isolating and earthing the power prior to commencement with the work and restoring afterwards.

3. OPERATING ENVIRONMENT

3.1 The MPI test jig and dark room will be used in the wheel workshop.

4. EXECUTION OF WORK UNDER THE CONTRACT

4.1 Site inspection: A site meeting will be arranged by Transnet Engineering on the site where

the machine will be used. This will give the tenderers the opportunity to acquaint themselves fully with the location and environment of the machine. If the tenderer does not want to visit the site, they must request permission from Transnet Engineering in writing. Please take note that the contractor will take full responsibility for the installation and commissioning of the machine even if they were unable to attend the pre- arranged site visit. Tenderers will be required to attend the site visit with their own personal protection i.e safety shoes, ear plugs, reflective vests and safety glasses.

4.2 The contractor must at all times adhere to the access and control requirements as

specified by Transnet Engineering, when performing installation and commissioning.

5. COMMISIONING OF THE EQUIPMENT

5.1 The tenderer shall commission the equipment and provide a commissioning certificate

which shall be signed off by TE after successful completion.


6. SAFETY

6.1 All equipment and installation whether detailed in this specification or not shall comply

with the requirements of the Occupational Health and Safety Act 85 of 1993 as amended by applicable local authorities.

6.2 All tenderers shall ensure that they fully understand how the equipment will be used in the wheel shop. Induction courses are available and it is the responsibility of the tenderer to ensure that they attend an induction course at the plant where they will operate.

6.3 A safety management plan must be provided to the Project manager prior to starting the work.

6.4 All safety rules and guidelines shall be adhered to while on TE premises, and the tenderer shall ensure that all his staff wear the required PPE while on the TE premises.

7. GUARANTEE

7.1 The contract shall include the full commissioning of the equipment and hand-over to

production of Transnet Engineering. A time period is to be defined for the purposes of identifying all operation problems that might exist. Thereafter, a 12-month guarantee period will be given during which any fault and failures due to installation or design shall be fully covered by the contractor.

7.2 The tenderer shall clearly stipulate the nature of the guarantee and how long it will take

them to be on site if required.

7.3 The contractor shall supply a commissioning certificate, which clearly indicates the commissioning date. Production will not commence before this date. The guarantee period will also be effective from the date of the commissioning certificate.

7.4 In the event of a defect/failure being one which is inherent in the design and/or

manufacture, the Contractor shall be obliged forthwith to make good and remedy such defect. A defect may be declared inherent when it fail in operation in a 12 month period or when a particular component fails three times or more in this period after being rectified. An inherent defect can be declared up to a period of 12 months after delivery of the last unit. Once an inherent defect is declared during the guarantee period, the guarantee period will be delayed with such a time required to solve the inherent defect. Once the Inherent defect is solved and cleared, the guarantee period will continue and will be extended with the corresponding Inherent defect remedy period.

7.5 Should any defect be found which, in the opinion of Transnet Engineering is due to improper or faulty material, workmanship, design, a method of manufacture or from any other fault or neglect on the part of the Contractor, such defect / failure shall immediately be made good or remedied by the contractor at his/her sole cost.

7.6 Anything replaced as a result of clause 8.5 above, will again carry an as new guarantee from the date of delivery of the replaced / repaired component.

7.7 Should the Contractor fail, when called upon, to make good or remedy a defect (under guarantee or declared inherent) within a reasonable time, Transnet Engineering may


affect the repair and thereafter recover from the Contractor all costs and expenses associated with such repair.

8 TRAINING

8.1 The contractor shall provide training to at least 2 operators and 2 maintenance

personnel.

9 MAINTENANCE

9.1 The machine shall be supplied with comprehensive sets of manuals for operation and maintenance purposes (3 x hard copies and 1 x pdf copy) and these must include the maintenance spares required.

9.2 Information concerning the after sales back-up service and on-line assistance to be

provided by the supplier shall be supplied. 9.3 The contractor shall supply a proposed maintenance schedule for the useful life of the

machine. The availability of spares of the machine shall be guaranteed by the contractor for a minimum of ten years.

9.4 Preference will be given to tenderers that have, or are willing to establish maintenance

backup, within South Africa. This maintenance backup is to include the storage of spares at a South African location.

9.5 The contractor must clearly stipulate the nature of the maintenance contract and how

long it will take to have attendance on site. Transnet Engineering require a response time of not more than 24 hours.

9.6 The maintenance to be provided by the contractor as discussed in this section shall be

separately quoted by the tenderer.

10 PAYMENT

10.1 Payment will be based on performance and progress payments will only be made once

the as agreed milestones have been met. The following milestones would be considered by Transnet Engineering for payment:

i. The contractor has supplied a commissioning certificate. This certificate must clearly indicate the commissioning date, as well as a declaration stating that the equipment is ready for production.

ii. All requested information and actions have been taken as outlined in this document. iii. A responsible person as identified by Transnet Engineering’s National Wheel Business

Manager signs a document indicating that the work was successfully performed.


11 OTHER TENDER REQUIREMENTS: 11.1 The contractor shall further include the following in the tender:

i. The tenderer must indicate compliance to each item separately in the format of the

attached feedback checklist in Annexure B. An electronic copy of the requested format will be available from Transnet Engineering upon request.

ii. The period for delivery. iii. Commissioning period.


Appendix A1:

Figure 1: Outside and inside view of the dark room


Appendix A 2

Appendix A2 gives a view of a more semi-automated equipment In use currently in the world today,

to assist the contractor understand more of the process that will be conducted with the required

equipment that Transnet Engineering is intending to install. Although the process for Transnet

Engineering will be more manually operated as indicated in section 2 of this document. Further

clarities will be made known with more engagements with the potential suppliers.

Figure 1

In the picture above we have a wheel that has been loaded onto a mobile table using an crane, and

the table has some fictures and clamping device for holding the wheel in position. The mobile table

also contains an MPI solution/bath with pipes and valves for spraying the solution onto the wheel

during the inspection.

Figure 2

Figure 2 – Closer view of the table where you can see some of the devices as mentioned.There are

also some rollers for rotating the wheel during the spraying operation and also for the visual

inspection after the wheel has been magnetized.


Figure 3

Picture above shows the wheel inside the inspection booth before the coil is lowered onto the wheel

for magnetization.

Figure 4

Figure 4 – The coil is now in position and ready for magnetization


Figure 5

In the picture above the MPI bath/solution is being sprayed onto the wheel

Figure 6

The wheel is being inspected under UV light.


Appendix A3


Appendix B

No. Heading / Sub-section Comply Comments

Yes No

1.0 BACKGROUND AND SCOPE OF WORK

1.1

1.2

1.3

2.0 SPECIFIC REQUIREMENTS

2.1

2.1.1

2.1.2

2.1.3

2.1.4

2.1.5

2.1.6

2.1.7

2.1.8

2.1.9

2.1.10

2.1.11

2.1.12

2.2.1

2.3.1

2.3.2

2.3.3

3.0 OPERATING ENVIRONMENT

3.1

4.0 EXECUTION OF WORK UNDER THE CONTRACT

4.1

4.2

5.0 COMMISIONING

5.1


6.0 SAFETY

6.1

6.2

6.3

6.4

7.0 GUARANTEE:

7.1

7.2

7.3

7.4

7.5

7.6

7.7

8.0 TRAINING:

8.1

9.0 MAINTENANCE:

9.1

9.2

9.3

9.4

9.5

9.6

10 PAYMENT:

10.1

11.0 OTHER TENDER REQUIREMENTS:

11.1

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