BID QUALIFICATION CRITERIA FOR SUPPLY OF 250t/32t EOT CRANE · BID QUALIFICATION CRITERIA FOR...

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BID QUALIFICATION CRITERIA FOR SUPPLY OF 250t/32t EOT CRANE

Bidders who are qualifying/meeting following Technical and Financial criteria are eligible to participate in the bid for supply of 250t /32t EOT crane. Bidder shall furnish all the information mentioned in the criteria with documentary proof and submit along with quotation. Bids of the parties which are not meeting the following criteria will not be considered for evaluation and will be rejected with out seeking any further clarifications. I. Technical Qualification Requirements:

The bidder should meet the following technical qualifying requirements and

shall submit relevant certificates to establish his credentials.

1. The Bidder should be an organization with long experience in having

executed contracts for design, engineering, manufacture, supply, erection,

testing and commissioning of D o u b l e g i r d e r E O T Cranes & Hoists

Package for last 25 years in India.

2. The firm should have successfully completed Design, Manufacture, Installation,

Testing and Commissioning of at least 5nos. of double girder EOT cranes of

capacity around 200t and above and Span equal to 20m and above during

last 7 years ending 31.03.2014. Bidders have to provide relevant certificates

from the Owners (end users) along with the submission of bid for

consideration of bid document.

3. The firm should have successfully completed Design, Manufacture, and

commissioning of EOT cranes with VVVF (VFD) drive & control systems at

least 05 no of cranes and at least one crane of capacity not less than 150t in

last 10 years.

4. The firm should have successfully completed Design, manufacture and

establishment of fail safe mechanisms & controls like Emergency disc bake

on rope drum (actuated in case of failure in power transmission line), wire rope

spooling monitoring and redundant (double) wire rope reeving system at least

in 2nos. of EOT cranes in last 10 years.

5. The firm should have experience and knowledge in the Design and manufacture

of EOT crane with dual drive hoist (Twin load path). It is preferable to have

completed realization of such cranes.

6. The firm should have successfully completed Design, manufacture, and

establishment of at least 05 nos. of EOT cranes ( not less than 100ton capacity)

with twin motor with planetary gearbox system for Hoist mechanism for last

10 years.


establishment of at least 04 nos. of EOT cranes (not less than 100ton capacity)

for ladle cranes (hot metal handling cranes) for reputed steel mills for last 10

Page 2 of 3

years.

8. The firm should have facility for inspection and testing of 250t EOT crane at

their factory.


establishment of high capacity EOT cranes (100t and above) to the satisfaction

of reputed third party inspection agencies like M/s MECON and M/s M N

Dastur.

10. Bidder shall furnish the details of their resources in factory like manpower,

machinery, quality system etc., for department to access their capability. Bidder

shall submit above information in the format given in “Questionnaire”

attached as Annexure to this BQR.

II. Financial Qualification Requirements:

The bidder should also meet the following financial qualification requirements:

2.1 The Bidder should have annual turn over of not less than a value of Rs. 10

crores. per year last three financial years ending 31-03-2014.

2.2 Firm should have undertaken and successfully completed following value of

works related EOT cranes at least in last 05 (Five) years :

Single work of EOT cranes not less than : Rs.750 lakhs.

(or)

Two works of EOT cranes, each not less than : Rs.450 lakhs (each)

(or)

Three works of EOT Cranes, each not less than : Rs.350 lakhs(each)

2.3 Bidder should possess a current Solvency Certificate from Nationalized Bank for

an amount of not less than 700 lakhs.

2.4 IT/ TDS certificate shall be submitted with Loss & Profit.

2.5 Bidder shall submit audited statement of financial status for last 03 years.

III. The following documents shall be submitted along with the application

for prequalification of Bid:

1. Firm establishment certificate and nature of work .

2. Detail of work of similar type completed during the last seven years ending

31.03.2014 ( for Sl. No.2)

3. Satisfactory work Completion certificates from the clients, with the work

order copies ( f o r S l . N o s . 2 & 3 )

4. Performance Report of EOT cranes established (with years of service) from

End users, with addresses and contact person with phone numbers.

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5. Documentary evidence (Technical details & drawings) for fulfilling special

technical conditions (Sl. no. 2, 3 4 & 5).

6. Copy of audited Balance Sheets for last three years

7. IT / TDS certificates for last three years.

8. Current Solvency Certificate.

9. List of EOT crane projects ( for capacity 100t and above / Span 20m and

above) completed for last ten years with PO copies

10. List, value, and work order copies of total projects under Execution with

Purchaser name and address.

11. Duly filled “ Questionnaire” (enclosed here with ) with signature, name,

phone no and company seal.

12. Structure and Organizational Chart

13. List of personnel with qualification & experience in the firm in the areas of

design, production, quality, safety, administration etc.,

14. List of Machinery & Equipments to be used for the work.

15. Any other relevant information which add value to above.

IMPORTANT NOTES :

1. Bidder shall furnish all the above details fully and explicitly. 2. Please note that the “BID” without above mentioned the documents/information in

support of the eligibility criteria will be summarily rejected.

3. NO further clarifications will be seeking in this regard.

IV. Bid Selection Procedure and Process of Pre-Qualification

Step - 1 : Short listing based on documents submitted, satisfying the all eligibility criteria

given above by the firm or individual along with their Bid / application. (Non-

submission of any document as given in above list within stipulated time leads to

rejection of Bid)

Step -2 : Subsequently Bidder’s competency, their technical achievements and financial

status will be evaluated suitable for this project. Feedbacks from Bidder’s clients will be verified.

Step – 3 : Visit to sites/EOT Cranes by technical team (ISRO or Third party) where Bidder

has established above mentioned capacity EOT cranes. Step - 4 : If required, visit will be made to their factory/ firm by technical team (ISRO or

third party) for accessing the capability of manufacturer. Step - 5 : Mean while, technical Bids will be opened and scrutinized for meeting all

technical specification and supply conditions.

ISRO-SHAR reserves right to verify the information/data furnished by Bidder. If

the same is found as fault or with any deviation the bid will be rejected.

Only those Bidders who are found suitable & meeting all above qualification

Criteria/requirements will be finally qualified for opening the Price Bids for

evaluation.

Annexure to Bid Qualification

QUESTIONNAIRE FOR DESIGN, MANUFACTURE, TESTING AND ERECTION & COMMISIONING OF HIGH CAPACITY EOT CRANES

(INFORMATION TO BE PROVIDED BY BIDDERS) Name & Address of EOT Crane supplier: Phone : Mobile : Fax : Email : Sl. No.

Items/ Information Specification/ details of items Remarks

1. Type of Industry (SSU, Medium, Govt, etc.,)

2. Year of Establishment

3. Annual Turnover (in Rs. lakhs) for last three years year ending up to 31-03-14

3.1 Turn over – 2013-14

3.2 Turn over – 2012-13

3.3 Turn over – 2011-12

4.

Orders executed during last 03 years, capacity of EOT Cranes, references are is to be mentioned. (Separate sheet can attached for this)

a. 2013-14 b. 2012-13 c. 2011-12

5. Quality Certification of company (ISO, TUV, etc.,)


6.

Nos. of EOT Cranes of capacity 200t and above and Span :20m and above manufactured during last 07 years ending 31.03.2014

7.

No of EOT Cranes of capacity not less than

100t with SIEMENS VVVF (VFD) drive &

control systems produced in last 10 years.

8. No of EOT Cranes of capacity not less than

100t supplied with Emergency Rope drum

caliper brake.

9.

No. of EOT cranes produced (not less than

100 ton capacity) with twin motor with

planetary gearbox system for Hoist

mechanism for last 10 years.

10. No. of steel mill cranes ( not less than 100 ton

capacity) produced for molten metal ladle

handling in last 10 years.

11. Shop floor Area Covered

12.

No of Employees (Supplier shall mention contract personnel separately)

a. Engineers b. Supervisors c. Technicians d. Quality control engineers Administrative staff

13.

Raw Material Sourcing: a. Steel Plates b. Rolled sections, Flats c. Forged Rods, Blanks d. Round bars (for Axles) e. Seamless pipes

14. Sources of Bought out components:

a. Electric Motors


b. Brakes Flameproof c. Gearboxes d. Couplings e. Limit switches f. Wire ropes

15. Details regarding out sourcing, if any, of manufacturing and fabrication works.

16.

Handling facility available: a. Over head /Gantry crane details

(capacity, span, lift). b. Mobile cranes

17.

Load testing Facility Available: a. Maximum weight available. b. No. of weights c. Total test load available.

18.

Welding /Fabrication Workshop (Type/ capacity/ Quantity of machines shall be provided)

a. MMAW machines b. GMAW machines c. Gas cutting m/cs d. Plasma cutting m/cs e. Welding Fixtures

19. Fixtures available for Welding of Girders of span more than 20m.


20.

Welding Professionals: a. No. of welders (MMAW) Qualification details Qualified by b. No. of welders (GMAW) Qualification details Qualified by c. No. of welders (TIG) Qualification details

Qualified by

21.

Details of Welding Inspection Equipment & welding inspector available with supplier ( LPT, UT, MPT, X-ray, etc) Any out sourcing can be mentioned.

22.

Forming Facilities available (with brief specification of each machine)

a. Shearing Machine b. Cutting machine c. Bending machine

23.

Machining Facilities available (with brief specification of each machine)

a. Turning Lathe (Conventional/CNC) b. Milling Machine (Conventional/CNC) c. Gear cutting/ hobbing machines. d. Gear Grinding machines e. Drilling Machine (Conventional/CNC) f. Cylindrical Grinding Machine

(Conventional/CNC) g. Any other machines


24.

Details of Inspection facilities / Instruments available (Brief description & specifications shall be provided)

25.

If third party inspection services are taken for manufacturing of EOT Cranes give details.

26.

Range of Capacity of EOT Cranes manufactured, till now (list with brief specs, & customers shall be provided)

27.

Maximum capacity of EOT Crane manufactured with dimensions, type, quantity, customer, and purpose of EOT Crane.

28.

Maximum dimensions of EOT Crane manufactured with capacity, Span, quantity, customer, and purpose of EOT Crane.

29.

Special purpose EOT Cranes manufactured, if any, capacity, dimensions, and customer

30.

Design facility available: a. Drafting & Modeling software

packages b. FEM software c. Other Softwares d. Design engineers (with qualification

& experience)

31. Painting facility available


a. Sand/ Abrasive blasting facility. b. Painting equipment c. Make of paints generally used.

32.

General stock level of Raw materials/brought out items in the factory:

1. Structural steel plates etc., 2. Alloy steel round bars 3. Bought out items 4. Paints, etc.,

33. Any awards or recognitions obtained through product excellence

34.

Collaborations with other reputed manufactures and OEMs with product details and Name of Principal supplier, country of origin etc.,

35. Any other relevant information in design, manufacture and testing of EOT Cranes

36. List of documents enclosed with this questionnaire

37. Any other information like to add (separate sheet can be attached)

Signature of competent person Name : Designation :

Date : Company seal :

SATISH DHAWAN SPACE CENTRE SHAR

SOLID PROPELLANT PLANT

Ref: SHPP 2013003090

TENDER SPECIFICATIONS OF 250t/32t EOT CRANE

Facility : Propellant Casting Facility

Sl.

No. Type of crane

Capacity

of crane

(ton)

Span

(m)

Height of

Lift (m)

Crane Travel

(m)

Duty

class of

crane

Quantity

( No)

1

Double Girder

Flame proof

EOT Crane.

250t / 32t 23.0 MH – 36m AH – 44m

~ 61.50 Class - II

of IS 4137 01

EOT crane shall be supplied, tested and commissioned as per the Technical Specifications, Terms & Conditions given in following pages of this document.

Ref : SHPP 2013003090

CONTENTS OF BOOKLET

Sl. No

Contents

Page No.

1

Full Technical Specifications cum Compliance statement, Terms & conditions of supply including codes and standards.

1 to 46

2 Annexure – 1A to 1D : Figures, EOT Crane Clearance diagram and dimensions.

47 to 51

3

Annexure – 2A : Location of VVVF Room and Plug-in locations for pendants in building.

52

Annexure – 2B : Schematic of Push Button operating station (Plug-in pendant)

53

4 Annexure – 3 : Quality Assurance, Inspection and Testing plan for EOT Cranes

54 to 65

5 Annexure – 4 : Details of EOT crane`s major components to be submitted by bidder along with quotation.

66 to 70

6 Annexure – 5: List of spare part to be supplied

71

TECHNICAL SPECIFICATIONS OF 250t/32t FLAMEPROOF EOT CRANE

SECTION – I

GENERAL SPECIFICATIONS

SDSC SHAR

SPP

250t / 32t FLAMEPROOF EOT CRANE

SPECIFICATIONS CUM COMPLIANCE STATEMENT

Page:1

A

B

C

Contact Person :

FAX No :

Mobile No : Email :

Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /

ACCEPTANCE

1

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

Bidder shall completely fill the following format of technical specifications & supply conditions with the

mention of required details. Bidder can add more information and details, if required, by attaching seperate

sheets, by giving point no. of this format. Inadequate /incomplete, ambiguous, or unsustainable information,

against any of the clauses of the specifications / requirements shall be treated as non-compliance to

tender and quotation will be rejected. Generalized statements like crane shall be manufactured "as per your

specifications" or "as per IS standards" or "as per enclosed specification" is not acceptable and Bidder shall

submit all the specifications by filling in the following FORMAT only, otherwise it is not valid.

Deviations with respect to specifications given below are not acceptable. However Bidder can submit /

suggest improvements, if any, seperately by indicating the clause no. in this specifications.

Design, detailed engineering, manufacture, inspection, shop testing, supply,

erection, commissioning & performance proving of Heavy duty 250T/32T

capacity, Flame proof, Top running, double girder EOT Crane as per IS 4137,

IS 807 & relevant codes & standards.

Supply, erection & commissioning of Emergency Disc Brake unit for the main

hoist rope drum, wire rope spooling & monitoring as per the specifications

mentioned in this document. (in Single drive Option -2)

Bidder shall submit complete information asked in Qualification Criteria and Questionaire for qualifying for

bid with all informations, certificates and earlier references of manufacture should be enclosed. The offer

meeting all the requirements & conditions in all respects will only be considered for further processing.

SCOPE OF SUPPLY

The scope of work shall also include procurement of all materials including

importing of components (from other countries) required for completion of the

work, coordinated planning for manufacture, inspection, painting, load testing at

supplier works.

Main Hoist (250t hoist) shall be provided with dual rope reeving system i.e., two

independent wire ropes shall be provided with balanced reeving system.

Packing, marking, loading on Trucks/ Trailers and safe transportation of EOT

crane & other necessary parts / items / accessories from supplier site to SHAR

site .

V.NAME & ADDRESS OF

THE Bidder :

Supply & Erection of Bridge gantry rail along with its accessories for bay length

of around 61.5meter. ( Gantry girder is in the scope of Department /

Purchaser).

VVVF panels shall be erected in a separate room at ground level and cabling

must be done to the EOT crane at gantry girder height of ~30m as per clerance

diagram enclosed.

Supply & erection of Drag chain power cable system for EOT crane as per the

specifications mentioned.

SDSC SHAR

SPP



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ACCEPTANCE

1.9

2 Quantity of Cranes : 01 No. (One)

3

3.1 Application

This Heavy duty EOT crane is used for handling of

hazardous / dangerous materials like rocket motors,

propellant containers, delicate flight hardware etc., for

positioning and assembly during process operations.

Failure of EOT crane & its components during

handling may result in loss of life and property.

Hence Bidder shall design, manufacture and erect the

crane with emphasis on quality, reliability and safety

and shall ensure smooth & reliable operation of crane

with long service life.

1.11

Bidder shall quote seperate cost for following each option seperately in

Price Bid.

Option - 2 : Single Hoist Drive, Planetary gearbox, Two motors, with

Emergency Caliper brake on Rope drum (Single load path) : The single-

hoist drive shall have one planetary gearbox with two drive motors, two

holding brakes on each input shaft of gearbox and one emergency caliper

disc brake located at the rope drum. The rope drum disc brake to act

as a fail-safe brake which acts in the event of coupling/ geartrain failure and

hold the load by monitoring overspeed of drum.

Option -1 : Dual Hoist Drive with two gearboxes and single drum (Twin

Load path) : The dual-hoist drive shall have a single rope drum, two

pallel shaft helical gear trains ( on each side of drum), two drive motors (each

gearbox driven by one motor) and at least two holding brakes located on

input shaft of geartrain and realted couplings. This shall ensure two

independendant load paths for main hoist drive and each of two independant

load paths shall be capable of driving & holding the rated load.

Erection, testing & commissioning of EOT crane shall be done as per the

Technical Specifications, conditions given below and also in accordance with

latest editions of IS: 4137, IS: 807 & relevant codes and standards.

Supplier shall arrange "Third party inspection Agency " for deisgn

approvals, inspection during manufacture, load teasting, and certfying

the EOT craneas per QAP.

Arranging the third party inspection is in the scope of supplier for the entire

scope of work as given above and as per QAP enclosed. Bidder shall engage

TPIA - Third Party Inspection Agencies like M/s Mecon,(or) M/s M.N.Dhastur

only. The finalization of third party agency shall be done on mutual agreement

between ISRO and Bidder.

Usage of EOT crane

Department reserves right to select EOT crane of either option-1 or option-2

based on the offers submitted by bidders.

Main hoist drive system shall be designed to provide assurance

that a failure of single component of hoist mechanism (Motor, Gearbox,

brake, coupling, wire rope) would not result in loss of load and uncontrolled

movement of the lifted load. This can be accomplished by the application

of a single or dual hoist drive unit in two optional ways described below.

1.10

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ACCEPTANCE

3.2Usage period & desired

life of crane

This heavy duty EOT crane will be put to use for 365

Days’ intermittent duty (Class II duty as per IS4137)

with CT, LT and Hoist movements. EOT Crane shall

be designed for minimum life of 30years.

4

4.1

4.2

5

Operating

Environment of Crane

/ Weather conditions

Operating environment is Indoor, near to sea (i.e.,

saline atmosphere), with ambient temperature of

50ºC and with relative humidity of 95%. Weather

conditions are tropical. Bidder shall consider above

while design of EOT crane, electricals, painting of

crane & related parts.

6

6.1 Type of CraneDouble girder, Flameproof, Indoor, Heavey duty EOT

Crane

6.2 Class & duty Class-II duty as per IS : 4137 and IS 807.

6.3EOT Crane capacity (in

ton)

250t (Main Hoist)

32t (Auxiliary Hoist)

6.4 Span 23.00 meters

6.5

6.5.1 Main Hoist (meters) Above FFL - 26m , Below FFL - 10m, Total : 36m

6.5.2 Auxilary Hoist (meters) Above FFL - 29m , Below FFL - 15m, Total : 44m

6.6

6.6.1

Main Hoist with dual

load path (two motors &

two gearboxes) Option-

1

2.0 m/min in main speed, and 0.2 m/min in creep

speed

2.0 m/min in main speed and 0.2 m/min in creep

speed with two motor in operation.

1.0 m/min in main speed and 0.1 m/min in creep

speed with one motor in operation.

6.6.3 Auxilary Hoist 2.5 m/min in main speed, 0.25 m/min in creep speed.

6.6.2

The EOT crane shall be equipped with flame proof electrical systems suitable

for operating in hazardous area classified as Zone 1, Gas group IIA/IIB, T4 as

per relevant IS 5572 / IEC standards.

Main Hoist with Single

Load path (Two motors

with planetary gearbox)

Option-2

Lift Height

MAIN PARAMETERS OF EOT CRANE

Hazardous area conditions

Operation Speeds ( meters/minute)

VVVF panels shall be provided in a separate room at the ground level and

cabling must be done to the EOT crane which is at a height of ~30m. The

VVVF panels shall be suitable for normal atmospheric conditions.

SDSC SHAR

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ACCEPTANCE

6.6.4 Cross travel 6.0 m/min in main speed, 0.6 m/min in creep speed.

6.6.5 Long travel 6.0 m/min in main speed, 0.6 m/min in creep speed.

6.7

Side clearance

(Distance from centre of

gantry rail to nearest

obstruction)

400mm (minimum) on both sides.

6.8

Head room available

(Vertical distance from

top of gantry rail to

lowest overhead

obstruction)

6.5 meters (maximum) (Refer clearance diagram).

6.9Distance from floor to

top of gantry rail~ 28.50 meters

6.10 Bay length in meters ~ 61.50 meters

6.11DSL Side Main Hook : 3.0m

Aux. Hook : 4.0m

6.12

NDSL side :

Main Hook : 3.5m

Aux. Hook : 2.5m

6.13CT DSL side : not more than 5 m

Non DSL side : not more than 5m

6.13 LT wheel base shall not be less than 1/5th of span.

shall be as minimum as possible for having optimum

LT hook approaches for better utilization of crane &

building.

Max. Width of crane not > 10.0m.

6.15

6.15.1

Main hoist drive system shall be designed to provide assurance

that a failure of a single component in hoist mechanism would not result

in loss of load and uncontrolled movement of the lifted load. This can be

accomplished by the application of a single drive or dual hoist drive

units. The wire rope drum, hook, hooknut, and load block structure are

exempted from this requirement. Supplier shall accomplish above failure

proof design feature in two optional ways described below. Bidder shall quote

seperate cost for each option (configuration) sperately. Department

reserves right to select any one configuration and place order.

Width of Crane

Main Hoist Drive

Hook Approaches

(Refer Clearance

diagram) (supplier shall

optimise these values)

6.14

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ACCEPTANCE

6.15.3A

6.15.3

Bidder shall quote separate cost for Emergency Caliper disc brake in the Price

bid for this option.

6.15.2

Department reserves right to select EOT crane of either option-1 or option-2

based on the offers submitted by bidders.

Option - 2 : Single Hoist Drive, with one planetary gearbox, two motors,

and Emergency Caliper brake on Rope drum (Single drive load Path): The

single-hoist drive shall have one planetary gearbox with two drive

motors, two brakes per motor on each input shaft of gearbox (total : 4 brakes)

and one emergency caliper disc brake located at the rope drum. The rope

drum disc brake is to act as a fail-safe brake which acts in the event of

coupling/ geartrain failure and hold the load by monitoring overspeed of the

drum. The planetary gearbox shall be sized for total full load drive torque of

motors with appropriate service factors as per class-4 of IS4137. Both motors

shall be driven through two VVVF drives with syncronization with proper control

& interlocks. There shall be two independent wire ropes, each shall be capable

of holding the rated load. Refer Schematic arrangement given in Fig .2

Motors shall be rated such that, when both motors running, main hoist speed

is 2 m/min and when one motor running hoist speed is 1 m/min.

Option -1 : Dual Hoist Drive with two gearboxes, two motors and single

drum (Twin drive Load Path) : The dual-hoist drive shall have a single

rope drum, two pallel shaft helical gear trains (on each side of drum), two

drive motors (each gearbox driven by one motor) and at least two brakes

located on input side of each gearbox (total: 4 brakes) and related couplings.

This shall ensure two independendant load paths for main hoist drive and each

of two independant load paths shall be capable of driving & holding the full

rated load. Each gear train shall be sized for the total full-load drive

torque of the motor with appropriate service factor as per class-4 duty of

IS4137. Both motors shall be driven through two VVVF drives with

syncronization with proper control & interlocks. There shall be two independent

wire ropes, each shall be capable of holding the rated load. Refer Schematic

arrangement given in Fig .1. Supplier can suggest & design alternate

configuration which meet above requirement with optimum hook

approaches.

Motors and gearboxes shall be rated such that each set of motor and Gearbox

will take full rated torque at rated speed i.e., 2m/min

Main hoist gearbox & rope drum shall be designed considering application and

torque of emergency caliper disc brake.

In case of any problem & failure in one load path, easy & safe switch over to

second/redundant load path shall be done smoothly without free fall and heavy

jerks. Proper arrangement shall be made for safe & reliable mechanical

decoupling of defective drive system.

Proper Electrical and drive interlocks shall be provided betweein motors and

brakes such that drive system is safe gaurded without damage, incase of

failure in one load path and to overloading of other load path.

Main hoist gearbox shall be designed for class -4 duty as per IS 4137.

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ACCEPTANCE

6.15.4

6.16

6.16.1

6.16.2

6.17

6.17.2

6.17.3

6.17.4Number of wheels for

LT drive

16 Nos & Drive wheels : 25% of total wheels i.e.

4nos.

6.17.5Diameter of wheels for

LT driveNot less than 710 mm.

6.18

6.18.1

6.18.2

6.18.3

6.18.4Number of wheels for

CT drive8 Nos., Drive wheels : 50% or 25% of total wheels

6.18.5Diameter of wheels for

CT driveNot less than 710 mm.

6.19Maintenance of CT

drives

Maintenance platform shall be provided for CT drives

covered with chequered plate.

6.20Type of bearings for

LT/CT wheelsAnti-friction, Double row Spherical Roller Bearings

6.21Type of mounting of

LT/CT wheels"L" type brackets

Two service brakes (Imported, flameproof brakes ) must be provided on either

side of input shaft of gearbox.

Wherever applicable the driving pinions shall not interfere with the removal of

wheels.

CT drive shall be provided with sufficient no. of drive systems. Helical parallel

shaft gearboxes, motors, and thruster brakes shall be used.

6.17.1

Drive size shall be selected such that Crane can be moved by two motors

drives with one VFD.

Auxiliary Hoist Drive ( conventional hoist system)

CT Drive

All the drive components shall be easily accessible and shall be designed with

interchangeable systems. (If twin drive is selected for CT)

Wherever applicable the driving pinions shall not interfere with the removal of

wheels.

Service brakes shall be located on Input shaft of gearbox. 2nos. of Imported

flameproof brakes shall be provided per motor.

Single motor with one Horizontal, foot mounted, paralle shaft Helical gearbox

of standard make mentioned in this specification.

LT drive shall be provided with four no. of drive systems at four corners of

crane. Horizontal foot mounted helical gearboxes, motors, and thruster brakes

shall be used.

All four corner drive components shall be easily accessible and shall be

designed with inter changeable components.

LT Drive

SDSC SHAR

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ACCEPTANCE

6.22Total Weight of EOT

Crane (tons) Bidder to Specify

6.23 Weight of trolley (tons) Bidder to Specify

6.24Weight of Bridge

Girders (tons) Bidder to Specify

6.25Weight of End Carriage

(tons) Bidder to Specify

6.26Weight of Electricals/

Panels (tons) Bidder to Specify

6.27 LT wheel load (tons) Bidder to specify

6.28 CT wheel load (tons) Bidder to specify

6.29Size of Cross Travel

Bridge Girder RailCrane rails not less than CR-120 as per IS 3443

6.30

Size of Crane gantry

rails (for Long Travel) -

Scope of Crane Bidder

Crane rails not less than CR-120 as per IS 3443


SECTION – II

MECHANICAL DESIGN AND DETAILS

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ACCEPTANCE

7

The design of components shall be done on the basis

of ultimate tensile strength, the value of stress factor

used shall be the product of the basic stress factor

and the duty factor for the appropriate mechanism

class as mentioned in IS:4137.

The design of all mechanical components shall be

done as per IS:4137 & as per this technical

specifications and also on the basis of minimum

ultimate tensile strength with factor of safety of not

less than 5.

7.1.1

7.1.2

7.1.3

7.1.4

7.1.5

7.2 Hoist hook type

Main Hoist : Ramshorn type hook with swiveling anti-

friction thrust bearing and safety latch as per IS:5243.

Aux. Hoist : Single Point hook with swiveling anti-

friction thrust bearing and safety latch as per IS 3815

& relevant standards.

7.2.1

7.3 Number of falls for HoistMain Hoist : ~ 24.

Aux. Hoist : ~ 8

7.4

7.4.1

7.4.2

Materials with less than 15% elongation shall not be used for any of

mechanical load bearing component except for electrical motors, panels and

hydraulic components.

Stress Concentration factors shall be considered in mechanical design for

calculating working stresses and also combination of stress concentration

factors shall be considered at required conditions.

No cast iron part should be used as load bearing member on the crane except

for electrical equipment. Similarly wood or combustible material and Bush

bearing should not be used in any part of the crane.

Rope Drum shall be of welded / fabricated type of IS:2062 steel with stress

relieved. Rope drum shall be designed as specified in IS:4137 in general.

Allowable stress in drum shall be 1/5th of UTS.

Rope drum diameter shall be minimum 40 times the diameter of wire rope.

ROPE DRUM

Factor of Safety

The hooks shall be free to swivel on antifriction roller thrust bearing of

adequate capacity and so constructed as to exclude dirt and also shall

be provided with a means for lubrication.

All mechanical components in Hoist ( vertical load path), shall be

designed for infinite fatigue life. Fatigue analysis shall be based on the

crane maximum rated load.

MECHANICAL DESIGN AND ELEMENTS' DETAILS

7.1

The stresses in all components of hoist mechanism and gearboxes should not

exceed 60% of yield point of the material for the component under break

down conditions of motor i.e. pull out torque of motor.

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ACCEPTANCE

7.4.3

7.4.4

7.4.5

7.4.6

7.4.7

7.4.8

7.5

7.5.1

7.5.2

7.5.3

7.5.4

7.5.5

7.5.6

7.5.7

Drum grooves shall be helical and machined with smooth surface finish.Drum

grooves shall be dimensioned as per IS4137.

Reeving system shall be divided into two separate load paths so that either

path will support the rated load and maintain vertical alignment in the event of

rope breakage or failure in one rope system.

In the event of failure of a drum shaft or bearing, the drum must

be retained on the trolley without falling.

MAIN HOIST WIRE ROPE - Double rope reeving system

In the event of a hook over travel, where the lower block contacts the

crane trolley structure, the ropes shall not be cut or crushed.

i). Sensing and automatic signaling of excessive rope load/displacement to

either side shall be provided.

ii). Provision, tooling and procedure shall be provided for adjustment of

wireropes to take equal load.

iii). The vertical displacement of the load, following a rope failure, shall be

minimized.

Upper block assembly and lower load block assembly shall be designed

such that the sheaves will be contained & maintain vertical balance of load

in the event of failure of single wire rope.

During hoisting & lowering hook block shall not oscillate/ rotate without load or

with load.

Length of the drum shall be sufficient to accommodate the rope in one layer of

the rope requisite for the specified lift and in addition rope drum shall be

provided with not fewer than three dead turns at each anchored end and at

least one spare groove at the other end when hook is at full height of lift

condition. Grooves shall be finished smooth and shall be rounded at edges &

corners.

Dual rope reeving system shall be designed such that the bottom load block &

hook shall follow a true vertical path ( true vertical lift) during hoisting and

during with No load & Full load conditions.

Fleet angle of wire rope from drum to sheave shall not be more than 2.5 deg

and drawings & calculations shall be provided in this regard.

Rope dead ends shall be clamped with minimum three clamping wedges

with two numbers of bolts on each clamp. The bolts shall be at the centre of

clamp and shall be wire locked.

Rope drum (for Main Hoist) in Option-2 shall have provision for accommodating

Emergency caliper disc brakes application on the rope drum flanges.

The design of the rope reeving system shall be such that a single

rope failure will not result in the loss of the lifted load. A load

balance sytem shall be provided on each rope system.

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ACCEPTANCE

7.5.8

7.5.9

7.5.10

7.5.11

7.6

7.6.1

7.6.2

7.6.3

7.6.4

7.6.5

7.6.6

7.6.7

7.6.8

7.6.9

7.6.10

No joints shall be used for wire ropes under this specification.

The equalizer sheave /Equalizer Bar shall be mounted above the trolley floor

and shall be easily accessible for maintenance from the floor of the trolley.

Equalizer Bar / sheave shall be made in such a manner that it can

turn or swivel to align itself with the pull of the ropes.

ROPE SHEAVES

Equalizer sheave diameter (at the bottom of groove) shall be minimum 18 to

20 times the diameter of wirerope for Aux Hoist.

All sheaves shall be mounted on special roller type sheave bearings.Grease

lubricated sheave bearings should be provided with individual grease

lubrication fittings and shall be easily accessible for maintenance.

Sheave grooves shall be machined smooth and support wire rope uniformly at

least 136° angle of contact over its circumference.

Equalizer sheave /Bar shall be arranged such that reeving equalization

shall not be restricted under normal operating conditions. Adequate free

movement to compensate for operational block swing and/or normal rope

stretch shall be provided.

All Sheaves shall have guards, which fit closed to the flange having a clearance

not more than 1/3rd rope diameter between sheave and inside of guard, to

prevent the wire rope from leaving the sheave grooves.

All the upper block sheaves shall be mounted above the trolley platform for

ease of maintenance and inspection.

Design of sheaves in general shall be as per IS:4137-1985.

All sheaves shall be of forged steel only.

The wireropes shall be of M/s USHA MARTIN make, Non-rotating type, Hotdip

Galvanized, Powerform, 35x7 construction, core : IWRC, RH, Regular lay,

preformed, Minimum tensile strength / Grade : 1960MPa.

Minimum factor of safety on wire rope shall be 10 on Minimum Breaking

Strength (MBS) of rope with two ropes combined together. With single rope

the factor of safety shall be 5 on the MBS of rope.

Auxialary hoist wire rope shall be single path & conventional reeving system

with true vertical lift as per IS4137. Wire rope shall have factor of safety of 8

on Minimum Breaking Strength (MBS). The wirerope shall be of M/s USHA

MARTIN make, Non-rotating type, Hotdip Galvanized, 35x7 or 34x7

construction, core : IWRC, RH, Regular lay, preformed, Minimum tensile

strength/Grade : 1960MPa.

Sheave diameters (at the bottom of groove) shall be minimum 29 times rope

diameter. Sheave fleet angle shall not be more than 2.5 degrees.

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ACCEPTANCE

7.7

A-1) Main Hoist (Twin

drive & Dual load path

Option-1)

Hoist drive shall be provided with two parallel shaft

helical gearboxes each driven by individual motors.

Standard make, Crane duty, Horizontal foot

mounted, Parallel shaft, Helical Gearboxes shall be

used in this option.

A-2) Main Hoist ( Single

load path/drive

Option -2)

Hoist drive shall be provided with a planetary gearbox

with driven by two motors. Standard make, crane

duty, Horizontal foot mounted Parallel shaft Helical

Planetary Gearbox shall be used in this option.

B) Aux. Hoist

Standard make, crane duty, Helical, parallel shaft,

horizontal foot mounted gearboxes, shall be used for

Aux. hoist motion.

Helical parallel shaft, Crane duty, gearboxes, shall

be used for CT & LT drives. LT drive shall be of

horizontal foot mounted gearboxes.

Travel drive gearbox ratings for bending strength and

pitting resistance shall be based on 2 times rating of

AC motor.

7.7.3 Make of Gearboxes

Heavy duty, and crane duty gearboxes of Elecon /

Shanti/ GREAVES (Premium transmission) /

Flender/ DB-Radicon / Sumitomo / Renold only.

Other make & Own make gearboxes are not

acceptable. Bidder shall confirm the acceptance.

Tender will be rejected for not meeting this

requirement.

1) Gearboxes selection shall consider starting torque

of motor (i.e., 2 times the Full load torque) of selected

motors.

2) The gearing shall be designed for strength,

durability, and momentary high overloads which

includes the loads imposed during starting,

braking and failure of components.

3) Due consideration shall be given for braking torque

in selection of Gearboxes.

4) In case of emergency disc brake, (in option-2)

Gearbox shall be designed to withstand its

application & braking torque.

5) The stresses in all components of hoisting

machinery and gearboxes should not exceed 60% of

yield point of the material for the component under

break down conditions (POT) of motor.

6) In design of gearboxes, due consideration shall be

given to creep speed and also ramping down of rated

speed (rpm) to zero speed through VVVF drives.

Gear Boxes for CT & LT

drives

Torque & Power rating

of Gearboxes / Pinions /

Gears / Shafts

Torque & Power rating

of Gearboxes / Pinions /

Gears / Shafts

7.7.1

GEARBOXES

7.7.4

7.7.2

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ACCEPTANCE

7.7.5

7.7.6

7.7.7

7.7.8

7.7.9

7.7.10

7.7.11

7.7.12

7.7.13

7.7.14

7.7.15

7.7.16

7.7.17

7.7.18

7.7.19

7.7.20

7.7.21

7.7.22

Sufficient clearance need to be maintained between gear of one stage to pinion

of next stage of non meshing sets to avoid interference.

Radial clearance between the gear box inner surface and the outside diameter

of the gears shall be at least 1 ¼ times the depth of the largest gear tooth

inside gear box or 20 mm whichever is higher.

Gearbox cover shall be split horizontally at each shaft centre line and fastened

and arranged so that the top half can be removed for inspection and repair

without disturbing the bottom half.

Vertical Gearboxes shall have an oil pump lubrication system when

vertical gearing exceeds of two reductions. Tubing/ Piping for gearbox

lubrication shall be provided with SS316/SS304 and must be properly clamped.

No hoses shall be used. Visual indicator for oil flow shall be provided in line.

The casings of gearboxes shall be made from structural steel (IS:2062) or cast

steel.

All gear boxes shall be totally enclosed and splash or forced lubrication system

shall be provided. Gearboxes shall have sufficient heat radiation area to

maintain lubricant at temperatures below maximum operating

temperature

All gear teeth shall be helical and with helix angle not less than 15°.

All gears shall be of forged alloy steel preferably case hardeneing steels.

Fabricated gearbox housings shall be made of minimum 10 mm thick steel

plate. All fabricated gearboxes shall be duly stress relieved.

Main hoist gearboxes for both options shall be designed & manufactured as

per class '4' duty of IS:4137.

Gearboxes with parallel shaft helical gearing shall be used for all motions.

All pinions shall be integral with shafts.

Gear teeth shall be cut in metric module system. All gear teeth shall be profile

ground to smooth with less error & for low noise while running.

The noise level at gear box must not more than 75-80 dBA measured at a

distance of 1m from the direct vicinity of the gear box. This is very important for

all the gearboxes, and any gearbox making more noise is liable to be rejected.

No oil leakage is allowed from gearboxes. Oil drip pans shall be provided

around the gearbox.

Drawings and dimensional details of gear boxes, selection criteria, power rating

& torque rating calculations, bearing details, data sheets from gearbox

manufacturer shall be submitted for TPIA / Purchaser (SDSC SHAR) approvals

during design engineering phase.

Gearboxes shall have fill and drain connections, BREATHERS, lubricant

level indicator, and shall have good accessesibility for checking, maintenance

and oil filling.

For all gearboxes lubrication shall be esured even at creep speed of motor and

from the intial start of motion (i.e. main or creep).

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ACCEPTANCE

7.7.23

7.7.24

7.8

7.81

7.8.2

7.8.3

7.9

Aux. Hoist : 1 motor and

2brakes.

7.9.3 Brake Rating Hoist.

Torque rating of each thruster brake shall be

minimum 2 times motor full load torque. Torque

adjusting provision shall be available in the Brakes.

Selected Brake shall have sufficient margin with

maximum catalogue torque rating.

7.9.4Braking distance/brake

path for hoist

Hoist components and brake shall be selected such

that the braking distance for lowering motion shall be

as IS4137 with one brake at full rated speed.

Necessary calculations shall be submitted in this

regard during design phase.

7.9.6 Brakes for CT & LT

Imported, flameproof Electro hydraulic thruster

brakes of above make, as per clause no 7.9.1, shall

be provided.

7.9.7

Torsional deflection of the shafts at torque corresponding to 1.33 motor rated

torque during acceleration shall not exceed 0.10deg./meter of shaft length.

Drive Shafts (LT & CT)

Brakes shall be mounted on the input pinion shaft of the gear boxes.

Shaft supports on plummer blocks of SKF / FAG / TIMKEN make only.

Imported Flameproof thruster brakes shall be used for all drives / motions in

EOT crane. Make of brakes shall be M/s Pincsh Bubenzer Bremsen- Germany,

M/s Galvi-Italy, M/s Wittonkramer-UK , M/s SIME-GKN Stromag-France.

Thrusters for all brakes shall be Explosion proof (Ex d), ATEX/ PTB Certified,

Make of thrusters : EMG, Germany or Brook crompton, UK. ATEX/ PTB/

Certificates shall be submitted for Approvals.

Open gears should not be used in any drive / motion. In case used for Main

Hoist Drive of Option-1, it shall be provided with firm metallic enclosure.

7.9.2

Brakes

Brake performance certificate, test certificate, and Exproof Certificate shall be

provided from original manufacturer of brakes.

Brake disc/ drum size and thermal rating shall be selected such that with the

duty cycle mentioned, the surface temperature shall not exceed "T4"

classification of hazardous area.

MAIN HOIST BRAKES

2 motors and 4brakes.

7.9.1

Two nos. of imported electro hydraulic flameproof

thruster brakes per motor with Manual release and

antiwear compenstor shall be provided (the second

brake is for redundancy).

Shafts shall be of 45C8 forged steel or alloy steel.

Realiable oil seal arrangement i.e., preferabley double stage oil sealing

arrangment shall be provided for shafts of gearboxes.

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ACCEPTANCE

7.9.8Brake rating for CT and

LT motions

Braking torque shall be checked so that it is capable

of arresting the motion within a distance in meters

equal to 10% of speed when travelling with rated load

at rated speed, provided there is no skidding.

7.9.9Manual release for

Brakes

Brake manual release mechanisms shall be

provided to permit drive movement during

power stoppage. Manual release shall be of

self-reset type, and operative only when held

manually in the release position.

7.9.9A

shall be made from forged/cast steel/ SG iron.

Drums shall be completely machined to smooth

surface and Statically & dynamically balanced.

Hardness of surface of finished drum shall be 38-43

Rc.

Width of the brake drum shall be 10mm more than the

width of the brake shoes.

7.11 Mounting of equipment

All the gearboxes, motors, brakes, bearing pedestals,

etc. shall be mounted on machined and levelled

surfaces.

7.12

7.12.1Couplings between

motors and gearbox

Flexible Full / half geared couplings. Make of

Couplings shall be of FENNER/ELECON/ Shanthi

Flexible Couplings

between gearbox and

rope drum for hoists

(For single load path/

Single drive)

Drum/ Barrel couplings of M/s Malmedie, Germany

shall be used for Main hoist an Aux hoist . Selection

criteria, service factor (as per ISO-M8 class), Torque

rating, drawing shall be submitted for approval.

Flexible Couplings

between gearbox and

rope drum for hoists

( For dual load path/

twin drive)

Suitable type of coupling (rating Class-4 of IS4137)

shall be used between Gearboxes and Rope drum

for Main Hoist such that incase of any failure in one

gearbox, the drum can be driven from other load path.

Aux. hoist shall be provided with Drum/ Barrel

couplings of M/s Malmedie, Germany

7.12.3

No oil leakage is allowed from thruster brakes. Oil drip pans shall be provided

under thrusters.

7.12.2

Brake drums

Couplings

All Couplings selection shall be based on the manufacturer's rating and

applicable service factors for heavy duty cranes compared to the applied

torque on the coupling and as per IS4137. Consideration shall be given to

motor starting torque, gear ratio, dynamic effects, brake torque etc.,

7.10

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ACCEPTANCE

7.12.4

7.14

7.14.1

7.14.2

7.14.3

Galvanized, high tensile fasteners of tensile quality

not less than 8.8 shall be used in crane parts, except

for Fit bolts of Girder. Make of all fasters shall be of

M/s TVS / M/s UNBRAKO

Maximum combined stresses induced in the

fasteners by normal operating loads (but not

including pretensioning loads) shall

not exceed 20% of the ultimate strength of

the fasteners.

7.16

7.16.1

7.16.2

7.16.3

7.16.4

7.16.5

7.16.6

Fasteners

Hoisting ropes shall be lubricated with lubricant approved by rope

manufacturer.

Adequate provisions/arrangements shall be made to prevent lubricants

falling from the crane.

Lubrication of Crane

Suitable provision shall be provided for lubrication of hook and sheave

bearings.

Trunion of wheel bogies shall be provided with suitable greasing points for both

the sides of the pins.

Wheel bearings shall be provided with suitable gearing points on both the sides

of wheel and shall be made approachable.

Track Wheels

Motor shafts shall be connected to gear extension shafts through flexible /

shock absorbing couplings. Geared couplings shall be used between gearbox

output shaft and intermediate shaft or end shaf and also for connecting

intermediate lengths of long travel and cross travel shafts. Between

intermediate shaft and end shaft and between end shaft and wheel axle, any

other special coupling which can give better and more reliable service may be

used after obtaining specific approval of the Purchaser (SDSC SHAR).

All crane wheels shall be made from forged steel C55Mn75 and minimum

surface hardness shall be 350 BHN for a case depth of 10mm. The wheels

shall be capable of taking up misalignments in span as specified.

All crane wheels shall be of double flanged with straight tread, with 12° taper

flanges, and accurately machined. Drive wheels shall be precision machined

and matched in pairs with minimum deviaion.

General design & sizing of wheels shall be as per IS:4137.Crane wheels of

minimum 710mm dia for both cross travel and long travel shall be used.

Necessary sizing & contact stress calculations as per IS:4137 shall be

submitted.

Semi centralized lubrication system shall be provided for all mechanixms in

EOT crane with easy approach for all pedastal bearings, couplings, wheel

bearings, gearboxes etc.,

7.15

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ACCEPTANCE

All keys where ever used should be of parallel keys

as per IS:2048 (Couplings / gear boxes / motor

shafts)

Material of keys shall be C45C8 or alloy steel.

Proper fits and tolerances shall be used between key

and key ways, such that key should not get loosened

in service life. Key end arrestors shall be provided.

Ball and roller antifriction bearings of approved make

SKF/ TIMKEN/ FAG/ INA only shall be used

throughout the drives except where specified

otherwise.Rated life of ball and roller bearings shall be not less

than total life (B10 or L10) in working hours not less

than 20,000 hrs .

Main hoist gearbox's bearings shall be selected based

on rated life given in class 4 duty of IS 4137.

Special consideration shall be given to

bearings which operate at low speeds. Certified

confirmation of the bearing's capacity at low

speeds must be obtained from the

manufacturer during design phase.

All bearings shall be provided with proper

lubrication or means of lubrication. Mounting fits,

tolerances and clearances shall be as recommended

by the bearing manufacturer.

Life of bearing shall be calculated in accordance with

bearing manufacturer’s recommendations.

7.18.1 Bearing Housings

All bearings housings shall be of STANDARD MAKE

(SKF/FAG/TIMKEN) and made of cast steel or

wrought steel or fabricated steel bolted to a rigid

portion of crane structure by at least 4 bolts. Housings

shall be split on the shaft centre line to permit removal

of the shafts. The underside of the base of each

bearing pedestal shall be machined and shall bear

upon a machined surface. Standard make Bearing

housings.

7.19

7.19.1

a)

b)

7.17 Keys & Keyways

Emergency disc brake shall be a device mounted on trolley and the disc brake

calipers should hold the main hoist rope drum flange, in case of any failure in

the hoist mechanical drive train between the high-speed shafting and the hoist

drum.

Bidder shall furnish cost of this brake along with accessories sperately in

the price Bid.

Emergency Caliper Disc Brakes of make : M/s SIME GKN Stromag, France

shall be provided on Main Hoist rope drum .

EXTRA SAFETY SYSTEMS TO BE PROVIDED IN MIAN HOIST MOTION

EOT CRANE (OPTION - 2)

Bearings 7.18

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ACCEPTANCE

c)

d)

7.19.3

7.19.4

7.19.5

7.19.6

7.19.7

7.19.8

7.19.9

7.19.10

7.19.11

7.19.12

Emergency Disc shall allow safe lowering of the load without electrical power

in an emergency situation. Hand pump with required flow and pressure shall be

provided to open the calipers in case of lack of electric power with required

safety valves.

The emergency drum brake system shall provide an independent means for

reliably and safely stopping and holding the load following a failure in the main

hoist mechanical drive train. The make of the emergency disc brake unit shall

be of M/s SIME GKN Stromag, France.

Hydraulic power pack shall be provided with flame proof electricals with ATEX

certification from Authorised body. Power pack shall be ST210-20 or better of

M/s SIME GKN Stromag.

The holding distance (free fall of load) of emergency disc brake after the failure

shall be limited between 200 to 300mm.

Braking i.e. closing of calipers should be done in following modes:

Procedure & Plan from OEM for safe gaurding the load and safely lowering the

load (with above conditions), in case of kinematic chain failure, shall be

provided during design and detail engineering .

A mode shall be provided in the system for safe unloading of load, if powerpack

fails during handling.

Hydraulically operated & spring applied calipers shall be provided of make : M/s

SIME STROMAG, France of model not less than SH-18B suitable for Exproof

environment. Caliper brake shall have ATEX certification by authorised testing

labs/ Agency.

7.19.2

2) When Emergency push button is pressed by operator.

Emergency Drum Brake System shall have massive thermal capacity for

allowing the lowering of the design rated load continuously from maximum

hook height at rated speed, without exceeding the temperature limits of the

brakes/disc in T4 classification.

When power to the crane is shut off, Caliper brake system shall not release

energy from storage device and thus does not set emergency drum brake,

unless there is a failure as defined above. Thus release of energy from the

stored device to set the emergency disc brake shall be in the event of “failure”

only.

The Hydraulic power pack must be the source for the disc brake unit. The disc

brakes must be applied by spring force and released by hydraulic oil pressure

from power pack.

The Emergency disc brake system shall work with the support of hydraulic

power pack unit.

Emergency Disc Brake system shall be suitable for operating in hazardous/

Explosive environment Zone1, Gas Group IIA/IIB, T4.

The over speed condition of drum (due to mechanical failure) is sensed by an

over speed sensor/switch. This shall actuate the spring allied & hydraulically

released Caliper brakes.

1) When there is overspeed in load lowering, due to failure in kinematic chain

of Mian Hoist Drive.

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ACCEPTANCE

7.19.13

7.19.14

7.19.15

7.19.16

7.19.17

7.20

7.20.1

7.21

Schematic arrangement of Emergency disc brake with model no. of M/s Sime

GKN Stromag, data sheets and hydraulic circuit shall be submitted along with

quotation.

Hoist Drum Rope mis-spooling monitoring on Main Hoist Motion :

Bidder shall quote separately for extra safety features that are to be provided in

crane i.e for emergency caliper disc brake for main hoist rope drum, and

wire rope spooling monitoring.

The wire rope spooling monitor is an electro-mechanical assembly that senses

improper or mis spooling of wirerope from drum grooves. Improper spooling is

sensed prior to wire rope damage. Since, wire rope damage and loss of the

load can result, if improper wire rope spooling is undetected, the wire rope

spooling monitor actuates the Failure Detection System (limit switches ) and

stops main hoisting motion.

Standard stainless steel tubing and fittings (SS 316) shall be used for hydraulic

lines of power pack. Make of tube fittings shall be of double compression ring

type of M/s Swagelok, M/s VOSS, M/s Parker only.

Safety interlocks with hoist motors/ drives shall be provided in the system, i.e.,

in case of emergency disc brake applied, main hoist motor shall be stopped

and shall not switch ON.

Power pack shall have access for easy maintenance and repair.

No oil leakage is permitted from the system. And also drip pans around the

hydraulic power pack shall be provided to avoid any oil spillage


SECTION – III

STRUCTURAL DESIGN AND DETAILS

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ACCEPTANCE

8.0

8.1Design of structural

work of Crane

The crane should be rigid, robust and of sturdy

construction. The design of all structures shall be

Class II as per IS:807 and as per this technical

specifications.

8.2

8.3

8.4

8.5

8.6 Material of structurals

All the structural plates used in fabrication of Girders,

Trolleys and End carriages, machine bases shall be

of minimum 10 mm thick of IS 2062 Gr. B.

8.6.1Covering chequered

plates

Trolley and platforms shall be covered with

Chequered plates of minimum of 6mm thick.

Shall be of double Girder Box Type construction

having Maximum rigidity.

For box plate girders in addition to the required full-

length diaphragms, short diaphragms shall be

inserted where required to transmit the trolley wheel

load to the web plates and to limit the maximum

stress in the trolley rail within safe permissible stress.

Girders shall be cambered and amount equal to the

deflection caused by the dead load plus one half of

the live load and the trolley.

8.8 Deflection of Girders

Deflection shall not be more than 1/1000 of span in

mm with safe working load, with trolley stationed at

mid span and excluding deflection due to dead load.

8.9 Girder Joints

No splice joint is permitted. Girder is to be of single

piece only. Number of weldable butt joints along the

total length of the girder should not exceed two.

8.10Ratio of span to depth

of Girder

For Box Girders Span to Depth ratio shall not exceed

18.

8.11Local Buckling of top

flange

Local buckling of top flange and compression

members shall be considered and necessary

calculations shall be submitted for approval.

8.12 End Carriages

End carriage shall be fabricated as solid box section

made from rolled steel plates IS:2062, except for

essential openings which shall be reinforced.

STRUCTURAL DETAILS OF EOT CRANE

All the bolts, nuts, washers etc., shall be heavy duty galvanized and shall be

protected against corrosive environment.

Black bolts shall not be used in the main structures of the crane.

Unless otherwise specified, only bolted or welded joints shall be used.

For welded construction such as that of bridge girders and carriages, trolley

frames, rope drums, gearboxes etec., all steel plates shall confirm to IS:2062 or

its equivalent.

8.7 Girders

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ACCEPTANCE

8.12.1

8.12.2

8.12.3

8.12.4 Rail Sweeps.

A rail sweep shall be provided in front of

each outside wheel. The rail sweep shall

project below the top of the bridge runway

rail.

8.13

8.14

8.15

8.16

8.17Structural bolted Joints/

Girder to End carriages

Fit Bolts ( as per IS:3640) with property class 5.6 and

reamed holes shall be used for all structural joints

between girder & end carriages, wheel L - bracket &

end carriages etc.,

8.18

8.18.1

8.18.2

8.18.3

8.19

8.20

8.21

8.22

The trolley frame shall be of rigid construction such that lifted loads do not

cause deflections that impair the proper operation of machinery.

Trolley shall be designed such that at the highest position of hook there shall

be a clear distance of 700 mm between the lowest point of trolley obstruction

and the highest point of bottom block.

End ties for cranes with more than four bridge wheels shall be of

rigid type. End ties shall be constructed of box sections in structural steel.

Equalizer bridge trucks shall be incorporated into the end carriage

design to promote equal sharing of bridge wheel loads, and equalizer

pins shall be provided between the equalizer trucks and equalizer beam

and/or the rigid bridge frame structure.

A rigid frame analysis shall be used to determine the proportions of the

loads resisted by the end ties and by the girders.

All electrical cables on trolley shall be so laid that they are not liable to be

damaged and can be easily inspected and maintained.

Lubrication of Bogie joint pins shall be from a centralized or semicentralized

lubrication points.

Safe access for maintenance and removal of all mechanical and electrical parts

must be ensured without any additional scaffolding.

Trolley

Details of Bogie joint of End carriages shall be provided along with quotation.

End ties shall be designed to accommodate up to 6mm difference in

elevation of the bridge rail between any wheels or pair of wheels without

exceeding allowable stresses.

End ties shall be designed to resist the loads due to crane

movement and the load combinations as per IS807 & IS4137.

All parts requiring replacement or inspection or lubrication shall be easily

accessible without the need for dismantling of other equipments or structures.

No parts shall be mounted under the trolley except for the gravity limit switch

weight. Top pulley block and all other pulleys, equalizer bars, fitments shall be

mounted on the top of trolley platform only.

The trolley frame shall be built up of rolled sections and plates to form a rigid &

robust structure and shall be arranged to afford maximum accessibility to

mechanical and electrical parts placed on it.

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ACCEPTANCE

Full length chequered platform of width 750mm shall

be provided for both bridge girders in order to

access for LT drive and CT cable tack for

maintenance and with hand rails of height 1000mm.

The platforms shall be jointed to Girders with

fasteners.

Additional maintenance accesss platforms on four

inside corners of the girder shall be provided between

inside faces of girder for repair & maintenance inner

LT wheel bearings & mountings of End carriage.

These platforms must not hinder with the CT hook

approaches.

8.24.1Hand rails along girder

platform

Handrails of 1000mm height shall be provided along

the length of the girder near to platform.

8.24.2Hand rails for around

trolley

Handrails of 1000mm height shall be provided on all

the four sides of the trolley.

8.25Maintenance of CT

drives

Maintenance platform shall be provided for CT drives

and shall be covered with chequered plate.

8.26Top chequered plate of

trolley

Chequered plate of 6mm shall be used all over trolley

except for openings required for the ropes for bottom

block etc., to pass. All the mechanical and electrical

equipment shall be placed above trolley top only .

8.27 CT rail wear plateFull length wearing plate of minimim 10mm should be

provided under the trolley rails.

8.27.1 Rails

All bridge and trolley rails required to transmit

vertical down and horizontal loads due to

operation, and shall conform to the IS3443.

8.28 CT rail welding

CT Rails shall be made continuous by welding

standard lengths. Welding shall be done as per

standard procedure approved by Third Party

Inspection Agency and Purchaser.

8.29 CT & LT rail clamping

CT & LT Crane rails shall be clamped to the girders

with double bolt clamping plates. The rail clamps shall

be spaced not more than 450mm apart. Rail clamps

shall be of Make : M/s GANTREX only.

8.30Rail stoppers /Wheel

ramps

CT & LT Rails shall be prevented from creeping in

the longitudinal direction by welded rail stops and

Wheel ramps.

8.31 Jacking pads

Suitable jacking pads should be provided on end

carriages and trolley for jacking up the crane & trolley

for changing track wheels & bearings .

8.32 Safety Pads

Safety pads shall be provided under the end carriages

and crab to prevent the crane/ trolley from falling

more than 25mm in the event of breakage of a track

wheel/axle or bogie pin.

Platforms8.23

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ACCEPTANCE

8.33

8.33.1

8.33.2

8.34

8.35Metric Component

Systems

All components including fasteners should be in

metric system only

8.36 Locking of All fasteners

Bolts in rotating parts shall be locked with spring

washers & lock nuts. All couplings & brake drums

shall be provided with "Fit" type bolts.

8.37NDT of Butt joints of

girders

All butt joints shall be 100% radiographed or

Ultrosonic tested for both compression and tension

joints.

Toe gaurds shall be provided for all openings, on

trolley and on bridge platforms with minimum height of

100mm.

8.39

Mounting of machinery

on machined bases on

trolley / LT

Parts of steel frames carrying machinery should be

provided with doubling plates (including stiffners) of

adequate thickness welded and machined to true

surface.

8.40

8.41

8.41.1

8.41.2

8.42Protection Gaurds for

rotating equipment

Guards: All the moving parts couplings, shaft should

be duly covered with guards as per safety norm.

Proper guard / cover / tray to prevent falling of bolts

from coupling etc should also be provided, wherever

required. The covers shall be strong enough to take

person weight ~ 100 kg.

8.43

Ladders

Approach ladder shall be of staircase type. Ladders shall be provided from

catwalk to end carriage and to LT platforms in all four corners.

Fasteners for pedestal blocks, motors, gear boxes etc., shall be easily

removable from the top of platform. Studs or body bound bolts shall not be

used as fasteners for mechanical items except for fixing covers.

End Buffers

Buffers shall be designed to absorb the kinetic energy released at 50% of the

full load rated travelling speed, the average rate of deceleration not exceeding

5.0 m/s² at 50% of the rated travelling speed.

Welded snugs shall be fitted against against the feet of all pedestals,

gearboxes, brakes etc., except motors. Motors shall be provided with alignment

screws for side alignment.

Spring buffers are to be provided on four ends of the bridge and trolley.

Buffers shall be rigidly bolted in place preferably along the Centre line of crane

rail or trolley rail as the case may be, such that the bolts are not in direct shear.

Toe gaurds

Approach ladders to be provided for reaching the trolley at two locations along

the span of the girder.

8.38


SECTION – IV

ELECTRICAL DETAILS

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ACCEPTANCE

9.0

All Electrical equipments shall be supplied for tropical

and humid climate (Temperature of 50°C & RH not

less than 95%) . De-rating of drive motors, power

cables etc., shall be done for ambient temperature of

50°C.

Flame proof electrical fittings and controls shall be

selected, assembled and tested as per relevant

Indian/ IEC standards like IS:5571, IS:2148, and

IS:5780. However for control circuit, intrinsic safe

modules of make : M/s. P&F shall be used.

9.2 Power supply condition

The power available at 415 Volts, 3phase, 4 wire, 50

Hz near by the Crane panel. The power and control

equipment selected shall be suitable for operation on

± 10% variation in the voltage and ± 3% variation in

supply frequency. Power source available to tap for

protective panel (where main power source is located

approximately 50m distance).

9.4Power Supply for

motors3 phase, 415 V, 50 Hz / A.C + 10%

9.5 Control voltage1 phase, 110 Volts AC, only for switchgears inside the

panel

9.6

For Push buttons,

Indication lamps, limit

switches in the field (top

of the crane) and all the

interlocks to the field

equipments:

24V, Intrinsic Safe Package Supply, Make : M/s P&F

9.7 DSL for LT & CT All cables for LT and CT are to be routed through

IGUS chain (plastic) with guided cable tray only.

9.8

9.8.1

9.8.2

9.8.3

9.8.4

9.8.5

9.8.6

9.8.7

Aux hoist panel – 1 No. (One)

Main Hoist panel - 2 Nos. (Two ) for individual motors.

The Electrical equipment shall conform to IS4137 and also to the latest Indian

electricity rules and regulations as regards safety requirements, earthing and

other essential provisions specified therein.

LT Panel - 1 No. (One)

Panels: (Non FLP), Make: M/s Rittal only. (Located in separate room at ground

level, suitable air conditioned units shall be part of the VFD panel).

CT panel - 1 No. (One)

Individual panels (nos.) to be provided as follows:

Protective panel – 1 No. (One)

9.1

Electrical equipment

environment

ELECTRICAL ELEMENTS DETAILS

Individual isolating switch (with SDF) to be provided for each panel.

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ACCEPTANCE

9.8.8

9.8.9

9.8.10

9.8.11

9.8.12

9.8.13

9.9

9.10Mounting of panels and

resistance boxes

Panels are to be mounted on the floor with required

anchored Bolts and nuts.

9.11 Switchgears Make: SIEMENS only

AC4 Duty

The contactors shall be able to withstand their rated

current for one second without welding / fusing of the

contacts

Manually operable

To be provided for all panels except protective panel.

9.14 Fuses

Hoist, Aux hoist, CT and LT power supply to VVVF

drives to be routed through Semi conductor fast

acting Fuses of adequate rating only. Semi conductor

fuses shall have a indicator for fusing.

Make: M/s Siemens

Qty: 6 Nos.

Input voltage – 110V / 230 V AC

Output voltage – 24 V DC

Current rating – as per the circuit load

9.16

9.16.1

9.16.2

9.16.3

9.16.4

Insulating barriers shall be provided between adjacent terminals.

Labels shall be of anodised aluminium with white engraving on black

background / computerized labels.

The bottom most row of equipment mounted inside the panel excepting

terminal strip shall be at least 350mm above the panel bottom cover to facilitate

inspection and repairs.

Power terminal blocks shall be separated from each by means of replaceable

insulated spacers.

Terminal blocks and lables

9.12

9.15 SMPS

Terminal blocks shall be of 750 Volts grade of the stud type and shrouded.

Contactors

TPNSFU with Semi

conductor fuses9.13

Provisions shall be made for label inscriptions for the easy identification of

terminal blocks.

A minimum clearance of 250mm shall be provided between the terminal strip

and the panel bottom cover to facilitate cabling.

Rubber mats of 2mx1m shall be provided before the all panels such that

persons stand on rubber mats during maintenance.

Individual Power Contactors are to be provided for each motion for controlling.

All the Panels shall be provided with space heaters to avoid moisture

condensation.

Panel lighting shall be provided and it shall be CFL or LED lamps only.

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ACCEPTANCE

9.16.5

9.16.6

9.17Motor protection circuit

breaker (MPCB)

To be provided for the motor which is not powered

viz. VVVF drive. (ie., Hydraulic power pack motor)

and all thruster brakes.

9.19

VVVF Drives

All the switchgear and termincal blocks to be covered with suitable electrical

protective cover.

ON/OFF/TRIP inscriptions shall be clearly marked over the individual panel

with clear marking of direction of the operation of handle apart from the

standard marking provided by the switchgear manufacturer.

Minimum clerance to be maintained as follows (IS 60947-1)

All the joints / tapping points of the terminal blocks / terminals shall be suitably

shrouded to prevent accidental contact.

Main Hoist – 2 Nos. ( Capacity of drive shall be suitable to motor kW selected

in Option -1 (Twin load path drive) and Option-2 (Single drive)

For Hoist motions, Control shall sense sufficient motor torque (or current)

before releasing holding brakes (i.e., torque proving).

The Control circuit shall be so designed as to ensure that brakes for all motions

are applied near about zero speed of rotation.

Make of VVVF drives : M/s. SIEMENS only.

CT – 1 No. or 2nos. Depending on drive motors.

LT – 2 Nos.

9.18

Drive shall be supplied with 20 % additional DI / DOs for future usage.

The rating of VVVF drive shall be one step higher than the calculated rating of

motor.

Aux Hoist – 1 No.

between phases - 25 mm

between phase and earth - 25 mm

All the live parts to be covered properly in order to avoid possibility of in advent

touching.

VVVF Drives shall have PROFINET Communication facility.

between neutral and earth - 19 mm

Safety in arrangements

Enamel Danger plates / stickers of size and descriptions as recommended in

the relevant IS, shall be provided on the Panel inscribed in Hindi and English

languages. The same is to be indicated in panel G.A dwgs after PO and before

proceeding for fabrication.

between phases and neutral - 25 mm

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ACCEPTANCE

Suitable input and output chokes are to be provided

for controlling the harmonics from VVVF drive to

source for all VVVF drives.

THD should not exceed 5 % and individual Harmonics

should not exceed 3 %.

It needs to be demonstrated at site during erection

and commissioning.

9.21 DBUSuitable size and rating of DBU for all the above

drives.

Dynamic braking resistors of suitable capacity/rating

shall be provided to all VVVF drives. For Hoist

motions DBRs shall be sized for a minimum of

150% of motor full load torque and it shall not be

less than the torque limit setting of the VFD in the

hoisting direction.

Necessary forced cooling needs to be planned.

Controlling of the cooling fans needs to be linked with

control supply ON.

The DBR panels shall be designed such that during

maintenance activities the entire door has to be dis-

asssembled for enabling the better access to the

components inside the panel.

Each motion shall have its individual panel.

Each side of the LT platform 2 Nos. of 1 phase, 230

Volts AC FLP switch cum socket with plug top and 1

No. on the Crab.

1 Power socket outlet shall be provided on the top of

trolley platform.

2 Nos. of 230 V AC power sockets with ON / OFF

switch shall be provided inside for the all the panels

except protective panel.

Separate control is required for the following:

Under Slung Lights (In pendent)

Socket outlets on the Crane platforms (In protective

panel)

Control circuits (In pendent)

9.24.1Training on Siemens

Drives

Training shall be offered for our engineers by M/s

Siemens about operation, maintenance and trouble

shooting of VVVF drives during commissioning of

Crane.

9.24 Isolating Switches

9.22Dynamic braking

resistances

Input and output chokes

9.23

9.20

Power Sockets outlets

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ACCEPTANCE

9.25

Hoist and Aux hoist motors shall be 8 pole with ~750

rpm speed.

Long Travel and cross travel motors shall be 8 poles

with ~ 750 rpm.

Bidder shall provide following details of motor like:

No. of motors / geared motors

Power of motor

Frame size

make

duty

no. of starts/hr

type and

No. of poles

amb.temp etc.

9.27

Details to be provided

related to motor

selection and

calculations

The Motors shall have preferably ZZ type bearings.

All the motors shall be housed with inbuilt thermistor and it is to be linked with

VVVF drive for necessary protection like switch OFF the motor in case of

increase in surface temperature more than T4 classification of hazardous area.

Hoist Motion - 2 Nos. (with required power/torque capacity suitable for Option -

1, Twin load path drive or Option-2, single load path drive )

In cases where sufficient clearance is not possible in front of terminal box for

facilitating maintenance / cable connections, terminal box shall be provided on

the top of the stator frame.

Aux Hoist Motor -1 No.

9.26 Speed rating of Motors

The Motors shall have both side extended shaft

Squirrel cage induction motors.

For accepting the input from VVVF drives, 60% CDF, min of with 300 starts per

hours, IP55, and Pull out torque of not less than 2.75 times of nominal value

and specifically designed for crane duty application .

Crane Motors with Inverter duty.

No of motors required

Cross travel - 2 Nos. (as per design)

Long travel - 4 Nos. (as per design)

Temperature classification - T4.

Flameproof (Zone 1, Gas group IIA/IIB, T4).

MOTORS

Hydraulic Power Pack Motor - 1 No. (For Option-2 of Main Hoist Drive)

Class of insulation - Class F

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ACCEPTANCE

9.28Current drawn by

motors

Maximum Current drawn by all motors with full load

should not exceed 80% of the full load rated current.

9.29 Torque Rating of motorsMotor full load torque rating shall be min. 120% of

calculated rating with duty factors as per IS: 4137.

Imported Electro Hydraulic flame proof Thruster

Brakes for

Main Hoist motion - 2nos. Per motor

Aux. Hoist Motor - 2 nos.

CT Motors - each one no. per motor.

LT motors - each one no. per motor.

Rating, duration and frequency of operation shall be

mentioned in quotation.

Main Hoist motors - 2 Nos.(one no. per motor).

Aux Hoist Motor -1 No.

Flame proof speed switch/ sensor (1no.) for main

hoist rope drum shall be provided for detecting over

speed of drum and actuating emergency disc brakes.

Shall have FLP / Intrinsic safe hollow shaft

incremental encoder for better dynamic performance.

The same to be used to achieve vector control mode

of operation.

All Encoders shall be of Flameproof / Intrinsic safe in

nature.

Encoders' signal shall be of intrisic safe only.

Screened cable as per manufacturer

recommendations shall be used for all encoders.

9.32

9.31

Interlocking of both push button stations shall be provided such that operation

of EOT crane shall be possible from any one of the push button station only.

Two nos. of Push button stations shall be provided which are mounted on of

movable type trolleys, and should have connecting socket of required no. of

pins with control cable of flexible type of length 30m. Trolley wheels shall be of

adequate size of reputed make : M/s.Rexello

Push button stations mounted on trolley (Quantity - 2 nos.)

Crane pendent connections shall be available at 3 locations in the ground floor,

shall be in junction boxes at two different locations and should have socket to

tap the connections to movable type pendent as mentioned above. The no of

pins are to be decided as per the number of connections. (Refer building

drawing attached).

Encoders for motors

Pendent control cable securing provision shall be planned i.e cable drum is to

be provided with winding and re-winding the control cable and plug.

9.30 Brakes

Push Button Stations shall also provide with 3-way Selector Switch for

selecting the hoist motors.

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ACCEPTANCE

Selector switches shall be of semi flush mounted

type.

Only the front plate and operating handle projecting.

Interlocking is to be carried out for selection of

command for all the motions.

Pendent level: Hard wired interlocks are to be

provided at push button station. For example when

Main Hoist UP motion push button is pressed Hoist

Creep / Hoist Down (Main and Creep) motions should

not be activated even if pressed and Vice versa.

Auxiliary contactor level: Hard wired interlocks are

to be provided such that when Aux.contactor operates

with respect to the motion selected, remaining Aux.

contactors with respect to other Aux. hoist motions

should not be operated.

In the VVVF Drive: It is to be programmed such a

way only one motion has to be selected for operation

at a time in the VVVF drive.

Selector switches

No. of push buttons and indication lamps shall be as per the Annexure -

2B

Crane ON indication Lamp – Powered through Intrinsic Safe circuit.

Cross Travel motion Right / Left - Main speed & Creep speed (with 5Hz)

Aux. Hoist motion UP / DOWN - Main speed & Creep speed

Main Hoist motion UP / DOWN - Main speed & Creep speed

PBS shall be provided with push buttons for controlling crane motions:

9.33

9.34 Interlocks

Pendent Shall be provided with Key way switch Lockable at OFF (for Control

ON command),

At least 30 % Spare Core shall be provided in PBS.

PBS shall also provide with 2-way Switch for Under Bridge Lights.

Emergency OFF (Lockable) ( One more emergency OFF shall be planned in

Bridge platform).

Long Travel motion Fwd / Rev - Main speed & Creep speed

All push buttons at Push button station are to be powered through Intrinsic safe

module only apart from other control elements like limit switch, over speed

switch, etc..,

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ACCEPTANCE

1. Selection of Hoist motor / each load path.

2. Rotary limit switches i.e hoist and lower, Gravity

limit switch

3. Emergency Disc Brake opening limit switches

4. Over speed switch of rope drum (option-2)

5. Wire rope mis-spool limit operation

6. Auxilary Hoist operation

7. Emergency Disc brake Solenoid MCB ON condition

– need to be interlocked for Hoist contactor.

8. Pressure switch of Emergency Disc Brake shall be

interlocked with Main Hoist Motors.

9. Thruster Brakes' MPCB condition.

10.Provision shall be made for two extra interlocks

for future usage.

1. Rotary limit switches i.e. Aux hoist and lower

operation limit.

2. Gravity limit switch

3. Main Hoist operation

4. Thruster Brakes' MPCB condition.

5. Provision shall be made for two extra interlocks for

future usage.

1. Right and Left limit switches for respective motion

of the drive.

2. Brakes' MPCB condition.


future usage.

1. Forward / Reverse limit switches for respective

motion of the drive

2. Brakes' MPCB condition.


future usage.

Cross Travel VVVF

drive ON command is to

be interlocked with the

following.

9.38

9.35

9.36

Auxiliary Hoist VVVF

drive ON command is to

be interlocked with the

following.

9.37

Main Hoist VVVF drive

ON command is to be

interlocked with the

following.

Long Travel VVVF drive

ON command is to be

interlocked with the

following.

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ACCEPTANCE

Indication lamps shall be provided for all 3 phases for

the protective panel.

Control ON / OFF (based on the pendent push button

control) indication lamps shall be provided on the

protective panel.

Indicating lamps shall be of Cluster LED type only,

provided with translucent lamp covers.

Lamps and lenses shall be easily replaceable from

the front.

Cluster LED module shall be suitable for direct

operation on 230 V, 50 Hz AC in general except the

indication lamps planned in push button station.

Indication lamps in push button station to be powered

viz. Intrinsic safe relays only.

All wiring for power, control, lighting etc., (which is not

running in the IGUS cable drag chain) shall be carried

out with 1.1.K.V grade XLPE Armored copper

conductor cables.

All wiring for power, control, lighting etc., (which is

running in the IGUS cable drag chain) shall be carried

out with 1.1.K.V grade flexible copper conductor

cables.

Minimum size 4 mm sq. in power circuit and 2.5 mm

sq in control circuit.

All wiring to be done neatly through perforated trays

from the protective panel / VVVF panel to the top

junction boxes fixed in suitable places.

Wiring shall be neatly bunched, adequately supported

and properly routed to allow easy access and

maintenance.

Wires shall be identified by numbered ferrules at each

end.

The ferrules shall be of the ring type and of non-

deteriorating material.

Cable tags to be provided for cable connections as

per circuit diagram.

Schematic Plug-in Pendant locations in side building

are given in Annexure-2A. The pendant control cables

are to be routed properly in suitable cable trays along

the building structure.

9.40Power and Control

Cables

Indication lamps9.39

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ACCEPTANCE

9.41 Earthing

The crane rails, structures, motor/brake frames, metal

enclosures of all electrical equipment, conduit and

trays shall be effectively grounded with double

earthing and shall be connected to building earth

through gantry rails. The laying of Earth strip from

Gantry rail to Earth pit ( which is around 10m aways

from the crane bay) outside the building is in the

scope of party.

Labels of permanent nature to be specified.

All power and control cables, etc are to be tagged at

both the ends.

FLP junctions Boxes are to be planned for inter facing

the connections between field connections and panel

connections. Sufficient space to must be available for

the maintenance.

The probable locations of the JBs are

Crane LT Girder

Crane Platform

Crane Trolley / crab

Rotary Limit Switch – 1 No. To be linked with both the

hoist motors and linked to the control circuit according

to the operational requirement) (For hoist and lower

limit).

Gravity Limit Switch – 1 No.

Rotary Limit Switch – 1 No. (For hoist and lower limit)

Gravity Limit Switch – 1 No.

9.46Limit Switches for CT &

LTTwo Lever type - 2 Nos. for CT & 2 Nos. for LT

Over speed detection to be sensed by means of over

speed sensor switch of reliable make.

During over speed of drum (by ~20% of actual speed)

due to any reasons, the swich has to detect and

activate the emergency disc brake system and caliper

brakes shall be applied on ropedrum to stop the free

falling of the load.

9.42

9.45

9.43 Junction Boxes (FLP)

9.44

Drum Over speed

detector switch9.47

Identification of Circuit &

Cables

Limit Switches for Aux

Hoist

Limit Switches for Main

Hoist

SECTION – V

OTHER SPECIFICATIONS AND TERMS & CONDITIONS OF SUPPLY OF 250t/32t

FLAMEPROOF EOT CRANE

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ACCEPTANCE

10

10.1 Surface Cleaning

The entire surface of fabricated materials, girders,

frames, platforms, trolley, end carriage, wheels etc.,

are to be sand / grit / abrasive blasted to white metal

finish (SA 2½ quality) and cleaned properly off rust,

grease & dirt.

10.2

Painting with Epoxy

Primer (Total thickness

of 80 microns)

Two coat of epoxy primer (Apcodur CP 680 of M/s

Asian Paints or equivalent) shall be applied to a Dry

Film Thickness (DFT) of 80 microns.

10.3

Painting Epoxy Paint

(Total thickness of 120

microns)

Two coats of epoxy paint of Golden Yellow color

(Apcodur CF 693 of M/s Asian Paints or equivalent)

shall be applied to a Dry Film Thickness (DFT) of 80

micron and 40 micron for first and second coats with

proper drying in between coats. Final touching shall

be done after erection & commissioning at site.

Painting quality shall ensure austhetic looking of

crane.

10.4Total paint thickness

including primer

Not less than 200 microns. This will be tested during

stage inpsections and final inspection at supplier

works.

10.5

10.6

11

11.1

11.2

INFORMATION/DOCUMENTS TO BE SUBMITTED ALONG WITH

QUOTATION (offer will be rejected unless these information / documents

are submitted)

PAINTING OF CRANE : Total painting thickness, DFT, shall be 200

microns. (DFT shall be measured at the time of final inspection)

Bid Qualification Criteria shall be submitted, along with specifications, in the

format specified in the instructions to tenderer.

11.3

Questionnarie, attached with BQ Criteria, shall be duly filled by Vendor and

shall be submitted along with quotation.

In addition if any intermediate cleaning required between successive coats of

paint are to be carried out as per the recommendation of paint manufacturers

and as per the instruction of the Purchaser (SDSC SHAR).

Interior of all gear box housings shall be sand blasted and painted with two

coats of oil resisting durable paint.

Technical & Major component DATA of EOT crane shall be provided as per

Annexure - 4.

Technical Specifications with Point-wise Specifications to all points as given in

this "Specification cum Compliance Statement" (given in this FORMAT).

Deviations, if any shall be mentioned clearly in a separate sheet. (See. II in

page 1).

SDSC SHAR

SPP



Page:34


ACCEPTANCE

11.5

11.6

11.7

12.1

12.2

12.3

12.4

12.5

12

As mentioned, Bidder shall quote seprately for two options of Main Hoist drive

system as per clause nos. 1.10 of this specifications.

11.4

GA drawing of Crane shall be provided for Both the options ( Twin load path

and Single load path) indicating clearances, hook appraoches and general

arrangment of main Hoist Drive.

Bidder shall submit following list of Three sets (03 sets) of drawings/

calculations / documents (in 03 -three sets) for approval before manufacture of

crane within 4 weeks after placement of purchase order. (12.5 to 12.40).

Note: It is the responsibility of the supplier to get the drawings/ documents

approved from TPIA/ Purchaser (SDSC SHAR).

At the same time, Supplier shall be responsible for proper submisssion of

following drawings & calculations along with technical specifications to Third

party Inspection Agency (TPIA) and obtain design Approvals from them.

DESIGN APPROVALS:

If the drawings and other particulars are returned by the Purchaser (SDSC

SHAR), because they are incomplete or faulty, the Bidder shall make the

necessary correction / modifications and resubmit the drawings and

calculations within a reasonable time, but in any case, should not exceed two

weeks from the date of receipt of purchaser’s / third party inspection agency's

comments.

General Arrangement (GA) drawing of crane to scale with dimensions, Bill of

materails, Boughtout items, makes, weight breakups and wheel loads.

The bidder shall quote separately for erection and commissioning of Crane.

DRAWINGS /DOCUMENTS (EACH 3 COPIES) TO BE SUBMITTED AFTER

PLACEMENT OF ORDER FOR APPROVALS.

[ Note : It is the responsibility of the supplier to get the drawings /

documents approved from Third Party Inspection Agency (TPIA) ]

GA drawing showing full details of crane, with dimensions, span, height of lift,

end clearances, head room, overhead clearance, hook approach limits,

weights, wheel loads, major components etc..

Design of load bearing structures shall be as per IS 807 and drive mechanisms

as per IS 4137 and also as per technical specifications in to consideration.

Bidder shall quote separately for extra safety features that are to be provided in

crane i.e for emergency rope drum disc brake (Option-2) with model no.

and make.

SDSC SHAR

SPP



Page:35


ACCEPTANCE

12.6

12.7

12.8

12.9

12.10

12.11

12.12

12.13

12.14

12.15

12.16

12.17

12.18

12.19

12.20

12.21

12.22

12.23

12.24

12.25

12.26

12.27

12.28

12.29

Calculations for selection of wheels & wheel bearings.

All the componets of crane which are lifted for erection shall be design

checked for erection / lifting loads and necessary Calculations shall be

submitted.

GA drawings of Protective Panel and other panel and inside components

arrangements

Selection of keys, key ways & couplings

Calculation for selection of motors, brakes, drives, cables and switch gear with

manufacturer datasheets & Exproof certificates. All Motors' torque and speed

curves shall be submitted for approval.

Electrical circuit diagrams of EOT crane with individual drive circuits, control

circuit, and with interlocks' circuits.

Calculations for selection of wheel bogie connecting pins.

LT rail arrangement (on Ganrty Girders) drawing to scale with Bill of Materials

(BOM).

Quality Assurance Plan for total crane manufacture, erection & testing as

given in Annexure - 3.

Design & Constructional Drawings of Girder, end carriage, and trolley their

connections with bill of materials.

Sub-assembly drawings for rope drum assembly, wheel assemblies, hook

blocks etc.,

General Arrangement drwing of Dual wire rope reeving with dimensions and

rope equlizer assembly.

GA drawing, Hydraulic circuit, Electrical circuit, Calculations & selection of

Emergency disc brake system of M/s SIME STROMAG, France.

Selection of sheaves & sheave pin with calculations.

Calculations for drive shafts and plummer block bearings.

Calculations for selection of CT & LT rails.

GA drawings, details and selection criteria, design calculations for gear boxes

with manufaturer's data sheets

Selection of bearings for EOT Crane.

GA Assembly Drawing of Trolley with all components.

Calculation for bridge girder with deflection & camber, trolley frame, end

carriage, with weight breakup.

Delivery schedule of EOT crane in the form of Bar chart indicating different

stages.

Sizing calculations for selection of Machine elements like wire rope, hook

blocks, cross head, sheave pins, rope drum, couplings, wire rope pulleys,

shafts, bearings etc.,

GA Drawing of individual drive mechanisms for Main Hoist, Aux. Hoist, CT and

LT.GA drawing of both options of Main Hoist drive shall be submitted.

Bridge Girder CT rail arrangement drawing to scale with BOM.

SDSC SHAR

SPP



Page:36


ACCEPTANCE

12.30

12.31

12.32

12.33

12.34

12.35

12.36

12.37

12.38

12.39

12.40

13

13.1

13.2

13.3

13.4

13.5

13.6

13.7

13.8

13.9

13.10

13.11

Manufacturer installation & maintenance manuals, test certificates and

Warranty / Guarantee Cards for all Bought-Out-Items.

Lubrication schedule, diagram with details of lubrications.

Final test certificate of EOT crane from TPIA with inspection report

Trouble Shooting Chart for Main and all Sub-Systems.

4 sets of all as built Drawings of all systems of crane as mentioned above

aprroval drawings that have been finally approved by TPIA / Purchaser (SDSC

SHAR).

Total weight of trolley including electrical equipment.

Weight and name of individual heaviest mechanical components.

QAP/shop Inspection report document showing Third party design approvals,

manufacturer test certificates., all stage & final inspection reports, load test

reports as per QAP and TPIA report on final inspection at works & TPIA

clearance report.

Test certificates of all items like raw materials, hooks, wire ropes, motors etc

and for all crane parts certified by "Competent person of third party agency"

as per QAP & standards.

2 sets of Gearbox spare parts and service manuals shall be provided.

2nos. of Emergency disc brake spare parts and maintenance manuals shall be

provided.

4 sets of Crane operation & maintenance manuals

2 sets of spare parts manuals

Total weight of structural, mechanical and electrical components separately

Electrical ciruit, hydraulic circuit, and control circuit diagrams of Emergency

disc brake system.

List of Manuals / drawings/ documents/ certificates to be submitted at the

time of inspection of crane at supplier's works and also at the time of

commissioning at ISRO, SHAR

Lubrication arrangement of EOT crane with points indicated in drawing.

Bidder shall give the break-up weights of crane as mentioned below

during final design :

Weight of each bridge girder as assembled and ready for erection, with and

without mechanical and electrical components.

Total weight of crane including electrical equipment.

Weight of each end carriage as assembled and ready for erection.

Wire rope spooling monitoring G.A drawing and electrical circuit.

Weight of trolley structure ready for erection shall be provided.

SDSC SHAR

SPP



Page:37


ACCEPTANCE

13.12

14

14.1 Span over LT wheels + 4mm maximum

14.2 Diagonal on wheels ± 5mm maximum

14.3 Parallelism of Girders< 1/1000 of wheel gauge (measured at every 1m

interval)

14.4 Verticality of Girders < 2mm (measured at every 1m interval)

14.5Verticality of End

Carriages< 1mm (measured at every 1m interval)

14.6 Trolley wheel gauge ± 2mm (measured at every 1m interval)

14.7 LT wheel alignment ± 1mm (maximum)

14.8Difference in height

between trolley rails<1/1000 of wheel gauge maximum at 1m interval

14.9CT Rail alignment w.r.t

Girder centre±1 mm (measured at every 1m interval)

14.10Tilt of wheels ( both

horizontal & vertical)< D/ 1000mm where D = diameter Of wheels

14.11CT/LT wheel

displacement<2mm (measured at all wheels) Wheel alignment

14.12CT / LT wheel diameter

variationless than 0.1 mm in diameter of wheel

14.13Squareness of Girders

to End carriageswithin 1.60mm ( for wheel base of ~4000mm)

14.14 Hoisting speed +10% -5% of specified speed.

14.15 Lowering speed +20% -5% of specified speed

14.16 Travelling speed +10% -5% of specified speed.

Bidder shall ensure that the crane shall be manufactured as per the

tolerances specified below. Final inpection reports shall be submitted in

drawing format.

Final as built drawings of crane and machinery, Maintenance & spare part

Manuals, test certificates shall be supplied in soft form in the forms of DVDs

and Memory stick in the latest software format.

Tolerances on Crane dimensions and manufacturing :

SDSC SHAR

SPP



Page:38


ACCEPTANCE

15

15.1

DESIGN / DRAWINGS

APPROVALS &

CERTIFICATE from

TPIA before crane

manufacture.

Supplier shall obtain all design/ drawings approvals

from third party inspector (TPIA) before starting

crane's production. Crane & components shall be

manufactured & inspected as per the approved

drawings only. All inspection/test repots shall be

made with respect to approved drawing with ref. no.

15.2QAP & Third party

agency

Manufacturing stage INSPECTION and testing shall

be carried out as per QAP enclosed here with in

Annexure-3. Supplier shall hold the manufacturing at

specified "HOLD" places and call for inspection. The

Schedule of Inspections shall be strictly adhered to

and shall be witnessed by THRID PARTY and/or

ISRO. All the critical inspections and load testing

shall be done in the presence of Third Party and /or

ISRO.

15.3Raw materials

identification & stamping

Raw material identification for structures, wheels,

hoist mechanisms, Gears, load pins etc., shall be

done by Third party inspectorate and/or department.

Raw material test certificates, traceability of materials

with identification marks shall be made available

during identification.

15.4Welding inspection &

Testing

All Butt Welded Joints (both compression & tension

flanges / web joints) shall be subjected to 100% X-

Ray Testing and X-Ray Films to be produced for TPIA

and/or ISRO/SHAR for evaluation and shall form part

of the quality (QA) documentation submitted to

purchaser.

15.5Inspection major parts

and records

Inspection of Bridges, End Carriages, trolley, rails

gauge, Wheels and Measurement of Camber,

mechanical assemblies checking as per QAP.

Reports shall be made in drawing format.

15.6

Dimensional inspection

& alignment checking &

records

Inspection of Span & Diagonal Dimensions (Minimum

~10Kg pull should be applied while checking),

Checking bridge & end carriages' squareness,

Checking of Wheel Alignments, Mechanical drive

Assemblies alignment and Pulley blocks alignment.

Reports shall be made in drawing format.

15.7

15.8 Load testsNo load test, Full load tests and Deflection

measurement as per as per QAP and as per IS: 4137.

15.9 Load tests

Test at OVER-LOAD (125% SWL) capability Check

and Permanent Set Measurement as per QAP and as

per IS 4137.

The crane hook should be tested and certified by the dock labor board / govt.

Approved test house for twice its SWL and test certificate should be provided.

INSPECTION & TESTING DURING MANUFACTURE & SHOP TESTING OF

CRANE

SDSC SHAR

SPP



Page:39


ACCEPTANCE

15.10 Clearance for despatch

The equipment shall be despatched only after

satisfactory performance testing/ inspection at

supplier's works and on written clearance from ISRO

& TPIA.

15.11

15.12

16

16.1 At ISRO- SHAR worksPart of supplier's scope. Inspection and testing

during/after erection shall be as per QAP.

16.2Erection Plan &

Procedure

Before erection, supplier shall submit detailed

erection plan and procedure along with erection loads

on building & also on parts being lifted shall be

submitted for approval.

16.3 Erection Supervision

Supplier shall depute adequate qualified personnel

i.e., Two Engineers/supervisor/ foreman, (one for

mechanical and one for electrical), fitters, riggers,

and electricians and helpers for carrying out quality

erection work at our site within schedule.

16.4

Material (lifting

equipment, lifting

tackles, etc) required

during erection.

Part of supplier's scope. All lifting machines / tackles

used shall be tested & certified as per standards

before their usage for lifting crane.

16.5

16.6

16.7

Performance Proving &

Smooth running of EOT

crane

Proving out for the Crane’s Capacity and Smooth

Functioning of the Crane at Full load and Over load

shall be the responsibility of the supplier.

16.8Test/Clearance

certificates for crane

Part of supplier's scope. To be inspected and certified

by "Competent Person/ Third party Inspection Agency

" as per Industrial Laws and provide

certification/clearance from Third Party Inspection

Agency for fianl clearance & usage.

Initial filling of lubricants and spare parts required for commissioning at site

shall be provided by the supplier.

Testing the extra safety features in EOT crane.

Checking the Performance of Emergency disc brake system at supplier works.

Department shall provide suitable hooks on the roof in the facility for lifting of

crane components. The capacity & location of hooks shall be given by

manufacture during detail engineering. However the lifting machinery ( power

winch, pulley blocks, wire ropes, lifting gear, etc.,) and accessories are in the

scope of supplier.All lifting machines/tackles' Test certificates shall be

furnished.

ERECTION & COMMISSIONING OF EOT CRANE

SDSC SHAR

SPP



Page:40


ACCEPTANCE

17

17.1GEAR BOXES and

Geared Motors

Elecon /Shanti /GREAVES(Premium transmission)

/DB-Radicon/Renold/Sumitomo/Flender.

17.2

Structural Steel

Materials Plates, rolled

sections

All the structural raw materials (plates, angles,

beams) shall be NEW and of reputed make of M/s

SAIL / M/s JINDAL/ M/s ESSAR/ M/s TATA STEEL /

VIZAG-RINL

17.3

Forged steel materials

wheels, shafts, keys,

gears

SAIL / JINDAL / TATA STEEL / ESSAR / VIZAG-

RINL / SUNFLAG STEEL / TIMKEN / Mahindra Ugine

Steel (MUSCO) / BHARTH FORGE

17.4 Wire Ropes M/s. Usha Martin only.

17.5 Bearings SKF / FAG / TIMKEN / INA

17.6Imported flameproof

Thruster Brakes

Pintsch BUBENZER-BREMSEN / SIBRE / WITTON

KRAMER / GALVI/ Sime GKN Stromag

17.8Emergency Rope drum

Disc BrakesSIME-GKN- Stromag, France only.

17.9 Hooks EEK / Hercules/IRIZAR/ Shilpa Udyog

FENNER / Elecon / Shanti

Drum/Barrel coupling - Malmedie, Germany

17.11 RailsSAIL / IISCO / JINDAL / ACCELOR / TATA STEEL /

ESSAR

17.12 Paints Asian Paints / Berger

17.13All Electrical Switch

gearM/s Siemens

17.14 Flame Proof Motors M/s. Siemens / Bharat Bijilee / Crompton Greaves

17.15 VVVF Drives M/s. Siemens only.

17.16 Pushbutton switches M/s Siemens

17.17 Limit switches M/s. Sterling controls / Speed-O-Control / Electromag.

17.18LT power & control

cables

M/s. Lapp / Universal / Nicco / Finolex / RPG /

Uniflex.

17.19 Panels M/s. Rittal

17.20 Terminal Blocks M/s. Elmex / M/s. Connectwell

17.21 EncodersM/s. Hubner / P&F (Flame Proof / Intrinsic safe)

Hollow shaft type Encoder can be planned.

17.22 Junction Boxes (FLP) M/s. FCEG / BALIGA

17.23Junction Boxes (Non-

FLP)M/s. Rittal

MAKE OF THE BOUGHT-OUT ITEMS

17.9 Couplings

SDSC SHAR

SPP



Page:41


ACCEPTANCE

17.24 Intrinsic Safe realys M/s P&F only

17.25

18

18.1

18.2

18.3

18.4

18.5

18.6

18.7

18.8

18.9

18.10

General TERMS & CONDITIONS during Supply and Installation :

Defects in the material like fractures, cracks, blow holes, laminations, pitting,

etc., are not allowed.

In the design of Crane, all indian standards, all safety regulations as applicable

under provision of factory Act, Indian Electricity rules etc. as prevailing in the

country / State of Andhra Pradesh (site of installation) shall be taken into

consideration.

Delivery Schedule:The crane shall be supplied with in 10 months from date

of Order and shall be erected & commissioned with in two months from date

of supply.

Other reputed and reliable makes of bought out items will be conisdered during

detail engineering with submission of technical details, references and

credentials. However about other makes final decision is of SDSC SHAR.

Only assembling of equipments shall be done at our site (SDSC SHAR).

Fabrication of crane parts shall fully completed at supplier works.

Dimensions of all parts used on crane shall conform to metric standards.

The supplier should satisfy himself about the site condition before hand to

avoid any difficulty during erection and commissioning of the crane.

Supplier shall submit complete erection plan with details of erection loads &

pattern of wheel loads that will act on building civil structure, erection

procedure, material handling procedure etc, during design and detail

engineering.

Arrangements shall be made by the supplier for the inspection and testing of

the crane during different stages of its manufacture starting form the raw

materials till the completion of the crane by the SDSC,SHAR and/or Third Party

Inspection Agency (TPIA) at the suppliers site as per the QAP schedule.

SDSC, SHAR / Third Party Inspection Agency (TPIA) shall have the right of

inspection and supervision of the manufacturing process adopted by the

Supplier for the manufacture of equipment at various stages through their

authorized representatives. In case the manufacturing process adopted is not

found suitable and commensurate with the desired quality of the equipment, the

Supplier will be advised to adopt the correct manufacturing process which will

be binding on the Supplier. SDSC, SHAR’s decision regarding the quality of

work and its acceptability shall be final and binding on the Supplier.

The transfer of title of Crane to the Purchaser (SDSC SHAR / ISRO) will take

place only after satisfactory erection, testing and commissioning of the crane by

the supplier and fully acceptance by the Purchaser (SDSC SHAR / ISRO).

SDSC SHAR

SPP



Page:42


ACCEPTANCE

18.11

18.12

18.13

18.14

18.15

19

19.1

19.2

19.3

19.4

19.5

19.6

Supply Prices shall be F.O.R. Sriharikota.

Free electricity and water will be provided by the Purchaser (SDSC SHAR) for

the erection, testing and commissioning of the crane at the site.

During the erection, testing and commissioning of the crane at site in

Sriharikota, the supplier has to make his own arrangements for boarding,

lodging, transportation of his men and materials. However, hostel

accommodation may be provided by the Purchaser (SDSC SHAR) on

chargeable basis, if available.

Liquidates Damages (LD) : Department will levy a penalty for delayed delivery

at the rate of 0.5% per week and part thereof subject to a maximum of 10% of

the value of unexecuted portion of the order.

Excise duty (ED) exemption Certificate will be issued by the Purchaser (SDSC

SHAR / ISRO) for the crane. Hence ED shall be NIL.

Transportation & Transit Insurance are fully in the scope of supplier, NO

transit insurance will be paid by department.

A toolbox containing all necessary tools as given in attached list which are

required for the maintenance of the crane should be supplied along with the

Crane. List of minimum tools required are given here shall be complied by

supplier. Any additional tools required can be indicated in quotation at extra

cost.

Before starting the site work (at SDSC SHAR), the contractor shall provide

insurance to all his personnel working at site in Sriharikota against accidents.

Till commissioning of EOT crane, the safe storing and handling of crane parts is

in the scope of supplier with insurance of materials. Insurance for the same will

not be paid by the Purchaser (SDSC SHAR) i.e, SDSC SHAR.

COMMERCIAL TERMS & CONDITIONS :

Bidder should quote separately for optional spares as considered necessary

for two years trouble free operation of crane as given in Annexure-5.

However, purchaser reserves right to place order for spares at the stage of

ordering.

Delivery : 12 months for total work. The crane shall supply the crane within

10 months from date of Order and shall be erected & commissioned with in 2

months from date of supply.

All Taxes (like sales tax, VAT, service tax etc.,) and duties applicable shall be

indicated clearly in quotation.

SDSC SHAR

SPP



Page:43


ACCEPTANCE

19.7

19.8

19.9

19.10Advance along with

Order

Maximum 30% of supply value against Bank

gaurantee.

19.11Payment after crane

reciept at site

(90% - Minus value of 19.10.1) of Supply value

along with transportation charges, taxes & duties.

19.12

Balance Payment after

completion of erection &

commissioning &

acceptance.

10% of Supply value along with erection &

commissioning charges against submission of

Performance Bank Guarantee as per clause 19.9

19.13

Date : Signature & Office Seal of the bidder

Validity of Offer shall be minimum period of 4 (Four) months from the tender

due date.

Performance Bank guarantee (PBG) for 10% of total landed cost of the crane

(including taxes and duties) shall be provided by the Vendor for a period of 12

months from the date of commissioning and acceptance of the crane at

Purchaser (SDSC SHAR)’s site at Sriharikota.

Payment Terms in three stages. Bidder shall comply with.

Guarantee period shall be for a period of 12 calendar months, commencing

from the date of acceptance & taken over by the Purchaser (SDSC SHAR) at

our site. During this period any defect noticed on design, materials, poor

workmanship shall be replaced/rectified by the supplier at free of any cost.

44

List of Tools to be supplied along with the crane (Ref : 18.14)

S.No Description of Item Units Required Qty

1 Double end Spanners from 10-11 to 36-41 (set of 13nos.) Set 01

2 Ring Spanners from 10-11 to 36-41 (set of 13nos.) Set 01

3

Heavy duty socket spanner set with T-handle, Ratchet and Extension rod with ¾” drive or 1” drive from 20mm to 55mm. (1 set – 10 nos.)

Set 01

4 Torque wrench upto 55kg-m with ¾” drive or 1” drive.

No. 01

5

Screw driver set a) Flat - 300mm long b) Star – 300mm long

No No

01 01

6 Adjustable spanner of 12” or 300mm length No 01

7 Cutting plier ( Size ~10” length) No 01

8 Locking / Grip plier ( Size ~10” length) No 01

9 Circlip plier

a) External Circlip plier ( Size ~10”) b) Internal Circlip plier ( Size ~ 8”)

No No

02 02

45

CODES AND STANDARDS FOR 250t/32t FLAME PROOF EOT CRANE

The design, manufacture and testing of the crane shall conform to the latest editions of the following codes and standards wherever applicable:

IS:4137 Code of practice for Heavy duty electric overhead traveling cranes including special service machines for use in steel works

IS:807 Code of Practice for Design, Manufacture, Erection and Testing (Structural Portion) of Cranes and Hoists.

IS:3177 Code of Practice for Design of Overhead Traveling Cranes and Gantry Cranes other than Steel Works Cranes.

IS:2062 Steel for general structural purpose.

ANSI/AWS D14.1 Code of welding practice for Industrial cranes, Mill cranes and other material handling equipment

IS:800 Code of practice for use of structural steel in general building construction.

IS:3681 Gears tooth form and modules.

IS 7403 : 1974 Code of Practice for Selection of Standard Worm and Helical Gear Boxes

IS 4460 : Parts 1 to 3 : 1995

Gears - Spur and Helical Gears - Calculation of Load Capacity

IS:1835 Steel Wires for Ropes

IS:6594 Technical supply conditions for steel wire ropes and strands.

IS:2266 Steel Wire Ropes for General Engineering Purposes.

IS:2363 Glossary of terms relating to wire ropes.

IS:3973 Selection, installation, maintenance and technical supply conditions of wire ropes.

IS:3443 Crane Rail Sections

IS:5749 Forged Ramshorn Hooks

IS:3815 Point Hook with Shanks for General Engineering purpose

IS:816 Code of Practice for Use of Metal Arc Welding for general Construction in Mild Steel.

IS:823 Code of Practice for Use of Metal Arc Welding of Mild Steel.

IS:1181 Qualifying Tests for Metal Arc Welders (Engaged in Welding Structures other than pipes).

IS:1323 Code of Practice for Oxy-Acetylene Welding for Structural Work in Mild steel.

IS:325 Three Phase induction Motors.

IS:4029 Guide for Testing Three Phase induction Motor.

ANSI/ASME B30.2 Safety Codes for overhead and Gantry Cranes.

IS:2147 Degrees of protection provided by enclosures for low voltage switch gear and control gear.

IS:5571 Guide for selection of electrical equipment for hazardous areas

IS:5572 Classification of Hazardous Areas (Other than Mines) for electrical installations.

IS 2148 : 1981 Flameproof enclosures for electrical apparatus

IS 2206 : Specification for Flameproof Electric Lighting Fittings

IS 5780 : 1980 Specification for Intrinsically Safe Electrical Apparatus and Circuits.

IS:8239 Classification of maximum surface temperature of electrical equipments for use in explosive atmosphere.

IS:1554 PVC Insulated (Heavy Duty) electric cables.

IS:2208 HRC cartridge fuse links up to 650V.

IS:2959 Contactors for voltage not exceeding 1000V AC or 1200V DC

IS:4064 Air-break switches, Air-break dis-connector, Air-break switch dis-connector and fuse combination for voltages not exceeding 1000V AC. or 1200VDC.

IS:4237 General requirements of switch gears and control gears for voltages not exceeding 1000V AC.

IS 8623 : 1993 / IEC Pub 439-1 : 1985

Specification for Low-Voltage Switchgear and Controlgear Assemblies - Part 1 to Part 3

IS 13947 : Part 4 : Sec 1 : 1993 / IEC Pub 947-4-1 : 1990

Specification for Low-Voltage Switchgear and Controlgear - Part 1 to Part 5 : Suppliers and Motor-Starters - Section 1 : Electromechanical Contactors and Motor Starters

IS 10118 : 1982 Code of Practice for Selection, Installation and Maintenance of Switchgear and Controlgear

Part I : General

Part II : Selection

Part III : Installation

Part IV : Maintenance

IS 1024 : 1999 Use of Welding in Bridges and Structures Subject to Dynamic Loading - Code of Practice

46

SECTION – VI

ANNEXURES

51

EOT CRANE CLEARANCE DIMENSIONS – 250t / 32t FLAMEPR OOF EOT Crane

(Top running, Double Girder, Flameproof EOT crane)

Refer Annexure – 1C (Fig) for details All Dimensions are in meters

Sl.No Facility Name

Rated SWL

In tons

Span (S) A B C D F G H P N M X Y

01 Casting – II MH– 250t AH – 32t

23.0 m 6.5m 1.0m 3.0m 2.5m 0.3m 0.4m 0.3m 28.50m ~ 8.0 m Not more

than 10.0m

~ 4.0m ~ 4.0m

Sl.No Facility Name

Rated SWL

In tons

Span (S)

Height of Lift (m)

Main Hoist Auxiliary Hoist

I J K L

01 Casting – II MH– 250t AH – 32t

23.0 m 26m 10m 29m 15m

Note :

1. The above dimensions are indicative only. EOT crane supplier shall work out the exact dimensions by keeping the view to minimize the end hook approaches and head room and shall provide the same in Cranes GA, drawing along with quotation.

2. EOT Crane span & lift are subjected minor changes which shall be accommodated by supplier during detail engineering.

53

Selector Switch

No. of

push

button

Indication

lamps

1 & 2

1

2

Main UP 1

Main DOWN 1

Creep UP 1

Creep DOWN 1

Main UP 1

Main DOWN 1

Creep UP 1

Creep DOWN 1

Main Right 1

Main Left 1

Creep Right 1

Creep Left 1

Main Forward 1

Main Reverse 1

Creep Forward 1

Creep Reverse 1

- 1 -

- 1 -

- 1 -

- 1

- 1 -

1 - -

- -

Emergency Stop with Lockable Key

UB lights

Control ON

Control OFF

Control ON Indication lamp

Push Button for Bell

Long Travel

Aux. Hoist - -

Cross Travel - -

Annexure - 2 B

-

Hoist - -

Crane Motion / Requirement

Selection of Main Hoist

Motor3-way Selector switch -

SCHEMATIC OF PUSH BUTTON OPERATING STATION FOR OPTION 1 & 2

QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE

Legend 1 Third Party Inspection Agency 2 Vendor (Suppliers) 3 Sub Vendor / Item Supplier

(TPIA) Place: Date:

Signature of Crane Vendor with Designation

Annexure - 3

54

Sl. No

Components/ Operations

Characteristic to be checked

Category

Type / Method of

check

Extent of

check

Ref.

Document

Acceptance Norm

Format of record

Agency

Remarks

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A B C D E F G H I J K

i) H

Identification of Raw materials structural plates, forged steel material, Alloy steel etc.,

All raw materials shall be offered with test certificates for identification for Crane manufacture before start of fabrication. Stamping shall be done for verification at later date.

Component Specs./ IS 2062/ IS1570/ En steels

Stamping on parts & Identification record

1

-

_

All materials shall be Identified by Third

Party Agency . (HOLD)

1 STRUCTURAL WORKS : BRIDGE GIRDERS, END CARRIAGES, CRAB FRAME, DRIVE BASES & PLATFORMS ETC.

1.1

Materials - Plates/rolled sections

Chemical composition/ Mechanical Properties

Major T.C. Correlation (if not available then test)

One per heat

Approved drawings/ Specs./ IS 2062

Approved drawings / Tech. Specs./ IS 2062

Material T. C. / Supplier's Test Report

3,2

-

1

Reports / TC review by TPIA .

1.1.1 Lamination /Internal defects

Major Ultrasonic

Testing 100% ASTM A-435 ASTM A-435 Supplier IR

3,2

-

1

For a l l plates of thickness > 20mm, UT qualification ( volumetric test)

1.2 Welding Welding procedure & Welders qualification.

Critical Test piece visual

& physical test. One for each position

ASME Sec.IX ASME Sec.IX WPS/ PQR

format

2

-

1

1.2.1

Load Bearing Butt welds (both tensile and compression)

a) Welding quality & Surface defects

Critical Visual &

D.P. Test

100% IS:3658 &

AWS D14.1 IS:3658 & AWS D14.1

Supplier’s IR

2

-

1 Visual inspection & Use weld

gauges for measurement of weld size

b) Sub surface defects

Critical

Radiography

100 %

ASME Sec.VIII Div I

ASME Sec.VIII Div

I

Supplier’s IR

2

1

-

Review of radiography films by I.A.



(TPIA) Place: Date:


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Category

Type /

Method of check

Extent

of check

Ref. Document

Acceptance Norm

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Remarks

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1.2.2 Other than load Bearing Butt welds & fillet welds

Surface defects & Size Major Visual & DPT 100% Visual check & DP test

10% random

IS:3658

IS:3658

Supplier’s IR

2

-

1

Use weld gauges for measurement of weld size

1.2.3

H

Bridge Girder & End Carriage inspection before closing the box

Visual, & Welding

Measurement Major Visual &

welding quality Visual 100% DPT- random of 10%

Component drawing AWS D14.1

Component drawing/ AWS D14.1

Supplier’s IR

2

1

-

Use weld gauges for measurement of weld size (HOLD)

1.2.4 Final Welding Inspection

Visual Inspection Major Inspection of

Welding quality 100% Specification/

AWS D14.1 AWS D14.1 Supplier’s IR

2

-

1 Visual final welding inspection by TPIA

1.2.5 Final Inspection of fabricated components Girders, End carriages, Trolley, LT drive frame, etc..,

Dimensional , Camber , straightness, level, Parallelism, verticality, etc.,

Major Measurement tolerances as per specifications

100% Tech. Specification/ Component drawing/IS 807

Tech. Specification/ Component drawing/IS 807

Supplier’s IR

2

-

1

Measured Dimensions shall be marked on component drawing. Review of reports at next stage by TPIA. (HOLD)

2.0 ROPE DRUM Fabricated/ Heavy duty Seamless pipe

Material composition/ Mechanical Properties UTS, YS, % elongation


One per heat

Spec/drawing/ ASTSM A106/ IS 2062

Spec/drawing/ ASTSM A106/ IS 2062

Material T. C. / Supplier’s Test Report

3,2

-

2, 1

Reports / TC / pressure test reports review by TPIA

2.1 ROPE DRUM joint Welding / Seamless pipe

Welding Joint quality & Weldment defects

Critical Visual/DP Test/RT/ UT

100% Component drawing

ASME Sec.VIII Div I

Supplier’s IR

3/2

2`

1 Measured Dimensions shall be marked on component drawing. Examination of RT films by TPIA.

Stress relieving Major Verification 100% Mfg’s std. Stress relieving chart

Supplier’s IR

3/2

2

1



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Category

Type /

Method of check

Extent

of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

Per

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3.0

Gear box Housings Fabricated

Material composition/ Mechanical Properties UTS, YS, % elongation


One per heat

Spec/drawing/ IS 2062

Spec/drawing/ IS 2062

Material T. C. / Supplier’s Test Report

3,2

-

2, 1

Reports / TC to be

review by TPIA

3.1 Stress relieving Major Verification 100% Mfg's std. Stress relieving chart

Supplier's IR 2

-

1 SR chart will be reviewed by TPIA.

3.2 Surface defects & dimensional check

Major Visual/DP Test/ Measurement

DPT 10% random & 100%

visual

IS:3658/ Component drawing

IS:3658/AWS D14.1

Supplier's IR

2

-

1

Measured Dimensions shall be marked on component drawing

4.0 a) Platform b) LT Frame c) Hand Rails

d) chequered Plates

Dimensional Conformity/

Visual checking / Mfr’s TC

Minor Measurement 100% Critical dimension s / others at random

Component drawing/ Mfr’s TC/ Industrial standards

Component drawing/ Mfr’s TC/ Industrial standards

Supplier's IR

2

-

1

5 MECHANICAL COMPONENTS – GEAR BOXES

5.1 MH, AH , CT & LT Input shafts, Gears , Pinions, keys, spacers

Material composition/ Mechanical properties Hardness value / UT / MPT/ DPT of materials

Major Correlation with Mfr’s TC ( if not test materials)

100% Specification IS:1570 / BS 970 / IS:2048

Component drawing/ IS2048 Specification/ IS:1570 / BS 970

Mfr's TC/ Supplier's IR

3,2

-

1

1) UT volumetric test for wrought or forged materials as per ASTME 114 and A388.

2) DPT or MPT shall be performed as per ASTM A 275, E709

5.1.1 Machined components

for Gear boxes like input shafts, gears, pinions, keys, spacers etc.,

Dimensional conformity Hardness of gear teeth/ Bearing s/ Oil seals/ keys and key ways.

Major Measurement/ Visual examination for finishing

100% Component drawing/ IS4460/ AGMA/DIN IS:2048

Component drawing/ IS4460/ AGMA/DIN/ Heat treatment chart

Supplier's IR

2

-

1

Key ways shall be inspected by TPIA before assembly of gearboxes. Measured Dimensions shall be marked on component drawings.



(TPIA) Place: Date:


Annexure - 3

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Category

Type /

Method of check

Extent

of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

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5.1.2

H Gear box Assembly Dimensional

conformity/ Inspection of machined surfaces like gearbox base, bearing mounts etc.,.

Major Measurement/ Visual check of Internal painting

100% Gearbox GA

drawing Gearbox GA Drawing.

Supplier's IR

2

-

1

Measured Dimensions shall be marked on Gearbox GA drawings with allowed dimensional variations. (HOLD)

5.1.3

Gear box assembly testing (No load run test for minimum of 4 hours )

Contact ratio of surfaces/ Backlash/

Noise level & Bearing temperature/ Breather/ Oil level gauge

Major Measurement & no load running

100% Gearbox GA drawing / IS4460/ AGMA / Specification

Gearbox GA drawing / IS4460/ Specification / Noise level of gear box ≤ 75dBA

Supplier's IR

2

1

-

No Load Test shall be witnessed by TPIA. Noise level of gearboxes shall be ≤ 75dBA. Temperature rise

shall be less than 4 0C

5.2 MECHANICAL COMPONENTS – LT AND CT DRIVE SHAFTS

5.2.1 Materials of LT & CT Shafts, and Keyways & Keys

Material composition/ Mechanical properties Hardness of material / UT / DPT

Major Correlation with Mfr’s TC ( if not test materials)

100% Approved drawing/ IS2048/ Specification IS:1570/BS970/

Approved drawing/ IS2048

Specification/ IS:1570 / BS 970

Mfr's TC/ Test reports/ Supplier's IR

3, 2

-

1

UT of wrought and forged materials as per ASTM

5.2.2 Machining of LT & CT Shafts, and Keyways & Keys ( Dimensional measurement)

Straightness & Dimensional conformity Checks & Inspection of Key way milling

Major Dimensional Measurement/ Visual examination

100% Approved drawing/ Specification IS:1570 / BS 970/IS2048

Approved drawing/ IS2048 Specification/ IS:1570 / BS 970 /IS 2048

Supplier's IR

2

-

1

Keys & keyways shall be inspected by TPIA before assembly.

5.3 COUPLINGS a) Materials b) Torque capacity c) Key ways

Coupling s Size/ Material composition/ Mechanical properties / Hardness value / UT / DPT

Major Correlation with Mfr’s TC

100% Approved drawing/ Specification IS:1570 / BS 970

Approved drawing/ IS2048 Specification/ IS:1570 / BS 970


3, 2

-

1

Keys & keyways shall be inspected by TPIA before assembly. UT of wrought and forged materials as per ASTM



(TPIA) Place: Date:


Annexure - 3

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Category

Type /

Method of check

Extent

of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

Per

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5.4 Plummer blocks & bases

PB & bearing sizes/ Material composition/ Mechanical properties

Major Correlation with

Mfr’s TC 100% Approved

drawing/ Specification

Approved drawing/ Specification/


2

-

1

Review of Test certificates by TPIA and issue Compliance certificate.

Measured Dimensions shall be marked on Component drawings with allowed dimensional variations.

5.5 LT & CT Wheels

5.5.1

a) Material Forged steel C55Mn75

Material composition/ Mechanical properties Hardness of material /



drawing / Tech. Specification IS:1570/BS970

Approved drawing / Tech. Specification IS:1570/BS970


3, 2

-

1


UT of forged blanks Major UT checking 100% ASTM A-388 ASM A-388 Mfr's TC Supplier's IR

3, 2

-

1 Review of Test certificates by TPIA and

issue Compliance certificate.

5.5.2 b) Wheels after machining with Keys & key ways

Dimensional Conformity for Bore, wheel tread, taper of flange / Hardness/depth

Major Measurement 100% Approved Component drawing

Approved Component drawing

Supplier's IR

2

-

1

Measured Dimensions shall be marked on each Component drawings with allowed dimensional variations.

5.6 WHEEL AXLES with key ways & keys

Material composition/ Mechanical properties Dimensional inspection

UT & DPT /MPT

Major Correlation with Mfr’s TC / Measurement

100% Approved drawing / Tech. Specification IS:1570/BS970



3, 2

-

1


5.7 Pulleys with Roller Bearings

5.7.1 a) Material (Forged Steel ) Material composition/ Mechanical properties Hardness of material / UT & DPT / MPT



drawing / Tech. Specification IS:1570/BS970



3, 2

-

1




(TPIA) Place: Date:


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Category

Type /

Method of check

Extent

of check

Ref. Document

Acceptance Norm

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Remarks

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5.7.2 b) Visual Inspection

c) Dimensional Inspection Overall visual inspection / All dimensions as per drawing like bore, width, groove, etc.,/hardness of

Major Measurement with vernier / Micrometer

100% Component drawing / Specification

Component drawing / Specification Noise level of gear box < 80db

Mfr's TC

3

-

1,2


5.8 Snatch block Cross head

Material composition/ Mechanical properties Dimensional inspection, 100% UT & MPT


100% Approved drawing / Tech. Specification IS:1570/BS970



3, 2

-

1


5.9 Snatch block assembly Dimensional Conformity Major Measurement 100% Approved Assembly dwg .

Assembly Drawing

Supplier's IR 2

-

1 Review of reports by TPIA

5.10

Hook

Material composition/ Mechanical properties/ and 100% UT& DPT / MPT

Major Correlation with TC.

100% Component drawing / IS1875

Component drawing /IS 1875

Mfr's TC 3

-

2, 1

Proof load test from Govt. approved test house.

Proof Load Test Major Testing 100% IS3815 IS3815 Mfr's TC

3

-

2, 1

Stress relieving Major Verification 100% Component drawing/ IS3815

Component drawing /IS3815

Vendor TC 3

-

2,1

5.11

Brake Drums with key and Key ways

Material composition/ Mechanical properties

Major Correlation with Mfr’s TC /

100% Approved comp. drawing / Tech. Specification IS:1570/IS1030

Approved comp. drawing / Tech. Specification IS:1570/IS1030


3, 2

-

1


5.12

Dimensions/ Dynamic balancing/ Key way and key inspection.

Major Balancing test/ Measurement with

100% Component drawing / Specification

Component drawing / Specification

Mfr's TC

2

-

1

1. Dynamic balance report shall be reviewed by TPIA.

2. Measured Dimensions shall be marked on each Component drawings with allowed dimensional variations.



(TPIA) Place: Date:


Annexure - 3

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Category

Type /

Method of check

Extent

of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

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Ver

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6 BOUGHT-OUT & Other items

6.1

Wire Rope

Dimensional, Genuine of make, Lay, core and stands, Tensile grade

Major Mfr's TC 100% Component drawing/ BOOM

Component drawing / BOOM

Mfr's TC 3,2

-

1

Review of Mfr's TC by TPIA. Visual examination of wire rope for any defects by 2 & 1.

Breaking Load test Major Mfr's TC 100% IS2266 IS2266 Mfr's TC 3 - 1

6.2 Bearings Bearing No./ Genuine Major Mfr's TC/

Invoice 100% Approved make

and type SKF/FAG/TIMKEN Mfg TC/

Supplier IR

2

-

1

6.3 Machined Fit Bolts & Nuts

Material composition/ Mechanical properties / Measure dimensions


100% Approved comp. drawing / Tech. Specification /IS

Approved comp. drawing / Tech. Specification IS:1570/IS1030


3, 2

-

1


6.4 FASTENERS (Bolts, nuts, washers, lock nuts)

Type / Genuine make conformity Major Mfr's TC/

Invoice 100% Approved make

and type TVS/UNBRAKO Mfg TC/

Supplier IR

2

-

1

7 ELECTRICAL EQUIPMENT

7.1 Electrical Control Panels ( VVVF drive panels)

Dimensional, Visual Sequence / Functional and high voltage Test

Major Electrical test 100% Electrical Circuit diagram/ Approved drawing/ Specifications

Approved drawing/ Specification.

Supplier's IR

3

1

Review of test certificates of all bought out items by IA

7.2 Motor Visual/ Name Plate Major Name Plate 100% IS 325/ Spec IS 325/spec Mfr's TC

2

-

1

7.2.1 Routine / No load test Major Elec. test 100% IS 325 IS 325 Mfr's TC

3

-

2, 1 Review of TC & Flameproof certificates by TPIA

7.2.2 Flameproof test cert. Major Gap measure 100% IS2148/ CMRI IS2148/ CMRI Type test cert.

3

-

2,1

make conformity



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Category

Type /

Method of check

Extent

of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

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7.3 Brakes and

Thrusters,

Brake Coil

Visual/ Name plate/ Make Torque & Thrust / Material TC verify / Test certificate/ Ex proof certificate

Accessibility of parts.

Major Name plate details, make Verification of TC

Verification of Ex-proof TC

100% Approved Drawing/ Make/ BOM/Spec

Approved Drawing/ Make/ BOM/Spec/ ATEX- PTB/ IS2148 -CMRI

Mfr's TC/ Type test cert for Flameproof / Supplier IR

3

-

1

Review of TC & Ex-proof certificates by

TPIA

7.4 Resistance box Megger test, Resistance value

Major Electrical test 100% BOM/ drawing / Specifications.

BOM/ drawing / Specifications.

Mfr's TC 3

-

1 Review by TPIA.

7.5 Master controller / Limit switches / Switch Gear

Sequence, Number of cams, Idle operational test

Major Visual 100% BOM/ drawing / Specifications.

BOM/ drawing / Specifications.

Mfr's TC

3

-

1

Review of TC by I.A.

7.6 Cables Routine test Major Test One per BOM/spec. BOM/spec. Mfr's TC 3

-

1

Review of TC by I.A.

8 H ASSEMBLY OF CRANE (Before assembly of EOT crane all parts shall be inspected by TPIA/Purchaser. Supplier shall inform readiness of all parts) (HOLD)

8.1 Bridge Girder & End carriage assembly.

Overall Dimension s Structural Alignment & LT Wheel alignment. Span measurement Diagonal Checks

Major Measurement/ visual inspection

100% Approved General Arrangement drawing / Specifications

Approved General Arrangement drawing / Specifications

Supplier's IR

2

1

-

Measured Dimensions / alignment values shall be marked on GA

/component drawings with allowed dimensional variations.

8.2 Crab assembly with Main Hoist & CT machinery

Dimensional & CT Wheel alignment Couplings’ alignment

Major Measurement 100% Approved drawing / Specifications

Approved drawing / Specifications

Supplier's IR

2

1

-

Measured Dimensions / alignment values shall be marked on GA /component drawings with allowed dimensional variations.



(TPIA) Place: Date:


Annexure - 3

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Category

Type /

Method of check

Extent

of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

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9 H LOAD TESTING AT WORKS (HOLD)

9.1 NO LOAD TEST

(MH ,AH , CT & LT mechanisms)

NO Load test/ Performance & Safety systems verification speed, Current etc.,

Major NO Load test/ Measurement of parameters

100% Approved dwg / IS807/ IS 3177 /Specification

Approved dwg / IS807/ IS 3177 /Specification

Supplier's IR & Load test Format

2

1

-

Measure Gear Box Noise. (Noise Level should be <75dBA).

9.2 FULL LOAD (SWL) TEST AT WORKS FOR HOIST & CT MOTIONS

9.2.1 DEFLECTION TEST

With Safe Working Load Deflection Major Measurement

as per approved procedure.

100% Specifications/ IS807/ IS 3177

Specifications/ IS807/ IS 3177


2

1

-

Deflection < Span/1000 . Record procedure of test & measurement with sketch.

9.2.2 Main Hoist and Auxiliary Hoist With Safe Working

Load

Performance, duty cycle, Speeds, Current, , Safety systems etc.,

Major Full Load test/ Measurement of parameters



Load test report /Supplier's IR

2

1

-

Measure Gear Box Noise. (Noise Level should be <80dBA) .

9.2.3 CT Mechanism With Safe Working Load






2

1

-


9.2.4

OVER LOAD (125% SWL) TEST (MH, AH & CT)

Static test/ Capability of all motions/ Permanent set

Major Capability of CT

&Hoist motion/ Measurement



Supplier's IR & Load test report

2

1

-

Record procedure followed for test & measurement with sketch. After testing check for any damage, cracks/paint flaking in load bearing members.

10 PAINTING

10.1 Sand/ Grit Blasting & Surface Cleaning

Surface Cleanliness/

texture visual inspection Major Visual Random Specification /

SSPC SA2 1/2 Specification / SSPC SA2 1/2

Supplier's IR 2

-

1

10.2

Primer Coat Painting DFT Thickness/ visual inspection

Major Measurement in µm / Visual

Random Specification / DFT ≥75µm

Specification / DFT ≥75 µm

Supplier's IR 2

-

1 Paint thickness shall be measured

with paint thickness gauge/ elcometer.



(TPIA) Place: Date:


Annexure - 3

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Category

Type /

Method of check

Extent

of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

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10.3 Epoxy paint Painting (Two coats of 80 µm & 40 µm)

DFT Thickness/ visual inspection

Major Measurement/ Visual

Random Specification / DFT ≥195 µm

Specification / DFT ≥195 µm

Supplier's IR 2

-

1

Paint thickness shall be measured with paint thickness gauge/ elcometer . Final DFT measured in presence of TPIA.

11 ERECTION AT SITE

11.1 GANTRY GIRDER RAIL ALIGNMENT

Gantry rail Span, Level, straightness, rail Joints and Rail clamp distance.

Major Measurement of parameters

100% Approved drawing / IS 807

Specification / IS3177

Approved drawing / IS 807

Specification / IS3177

Supplier's IR

2

-

1

Tolerances: Rail span : ±5mm; Slope of rail : 1/1000 at 2m interval; Height diff : ±10mm between LH & RH rails; Rail Gap :2mm; Straightness of rails: ±5mm

12 LOAD TESTING AFTER ERECTION AT SITE.

12.1 NO LOAD TEST

(MH ,AH , CT & LT mechanisms)

NO Load test/ Performance & Safety systems verification speed, Current etc.,

Major NO Load test/ Measurement of parameters




2

1

-

Measure Gear Box Noise. (Noise Level should be <75dBA).

12.2 DEFLECTION TEST

With Safe Working Load Deflection Major Measurement

as per approved procedure.

100% Specifications/ IS807/ IS 3177

Specifications/ IS807/ IS 3177


2

1

-

Deflection < Span/1000 . Record procedure of test & measurement with sketch.

12.3 Main Hoist and Auxiliary Hoist With Safe Working Load






2

1

-


12.4 CT Mechanism With Safe Working Load






2

1

-




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12.5 LT Mechanism With Safe Working Load






2

1

-


12.6 Brake Path Test/ Brakes Effectiveness testing for all motions

Each Brake holding Brake path / Delay between two brakes

Major Measurement of path & Brake currents

100% Specifications/ Brake path ≤17mm for Hoist

Specifications/ Brake path ≤17mm for Hoist


2

1

-

12.7

OVER LOAD (125% SWL) TEST (MH, AH , CT and LT motions)

Static test/ Capability of all motions/ Permanent set

Major Capability of CT

&Hoist motion/ Measurement



Supplier's IR & Load test report

2

1

-

Record procedure followed for test & measurement with sketch. After testing check for any damage, cracks/paint flaking in load bearing members.

13.

Final Painting & touch up

Aesthetic look of crane/ DFT measurement

Major

Thickness measurement

Random

Tech . Specifications.

Tech . Specifications.

Supplier's IR

2

1

-

Final DFT measured in presence of TPIA.

14

Safety features like limit switches, overload relays, buffers, stoppers etc.,

Performance, interlocks

Minor

Performance

100%

Tech . Specifications./ IS3177

Tech . Specifications./ IS3177

Supplier’s IR

2

1

-

15

Emergency disc brake unit.

Performance checking, Interlock checking, Leak checking, Checking of manual lowering of load in case of failure in the system.

Major

Testing at no load condition and full load condition.

100%

Tech Specifications

Tech Specifications and Supplier recommendations

Supplier`s IR / SHAR report

2

1

-



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16 Spool limit switch

Performance

Major

No Load test

100%

As per Specifications

As per Specifications Load test

report /Supplier's IR

2

1

-

17 Decoupling of main hoist output shaft coupling to rope drum of option – 1

Ensuring the decoupling of drive system

Major Ensuring the removal and fixing of drive system

100% As per specifications

As per specifications Load test

report /Supplier's IR

2

1

-

66

DETAILS OF EOT CRANE’S MAJOR COMPONENTS CONSIDERED BY BIDDER (TO BE DULY FILLED AND SUBMITTED ALONG WITH QUOTATION)

EOT CRANE – SWL: ________________ , SPAN: ______m, Lift: ________m

Sl.No Specifications Specification quoted by Bidder

1.

EOT crane SWL : (in metric tons)

Span : (in meters)

Height of lift: a) Main Hoist : Above FFL / Below FFL (m) b) Auxiliary Hoist : Above FFL / Below FFL (m)

2. Duty class Class-II of IS 4137

3. Flame proof (FP)

4. Bay length / Travel of crane

5. Under slung HVMV lights - 4nos (400 Watts)

6. No. of rope falls: a) Main Hoist b) Auxiliary Hoist

Details to be furnished for both the options For Option 1 For Option 2

7. Main Hoist: a) Motor KW b) RPM of motor : ~ 750 c) IP55 / Flame proof d) No. of motors.

8. Main Hoist MOTOR Encoder for VVVF drive feedback

a) Make b) Type / Model

9. Main Hoisting coupling between motor and gearbox a) Type b) Size c) Torque rating @ r.p.m

10. Main Hoisting Brakes shall be Flame proof Electro hydraulic thruster brakes of imported make a) Model / Make b) Size c) Torque rating d) No. of brakes

11. Main Hoisting Brake drum a) Type b) Size c) No. of brake drums

12. Main Hoisting Gearbox a) Model / Make b) Size/Reduction ratio c) Torque rating of Gearbox d) No. of reductions

admin

Text Box

Annexure-4

67

13. Main Hoisting Rope drum a) Pitch Diameter of drum b ) Length of the drum (approx)

14. Main Hoist coupling between rope drum and gearbox a) Type b) Size c) Make d ) Torque Rating

15. Emergency Disc brake details (For Option – 2) a) Model of brake calipers b) No. of calipers. c) Hydraulic power pack model d) Make of tube fittings

16. Over speed switch (for option – 2) a) Type b) Make & Model

Details to be furnished for both the Hoists

For Main Hoist

For Aux Hoist

17. Hoist wire rope (Galvanized) a) Diameter b) Construction c) Grade Breaking strength

18. Sheaves & pulleys a) Size / diameter b) Material: Forged steel

19. Fleet angle for hoist wire rope shall be less than 2.5 deg.

20. Hoist limit switches a) Rotary limit switch : Make & Model b) Gravity limit switch : Make & Model c) Enclosure type (IP55/ISC)

21. Type of hook a) Ramshorn hook b) Single point “C” hook

22. Bearing size in bottom hook block and hook

23. Auxiliary Hoist: a) Motor KW b) RPM of motor : ~ 750 c) IP55 / Flame proof

24. Auxiliary Hoist MOTOR Encoder for VVVF drive feedback

a) Make b) Type / Model

25. Auxiliary Hoisting coupling between motor and gear box

a) Type b) Size c) Torque rating @ r.p.m

68

26. Auxiliary Hoisting Brake drum a) Type b) Size c) Rating d) No. of brake drums

27. Auxiliary Hoisting Brakes (Imported flame proof Electro-hydraulic thruster brakes) a) Model / Make b) Size c ) Torque Rating d ) No. of brakes

28. Auxiliary Hoisting Gearbox a) Make & Model b) Size / Reduction ratio c) Torque rating of Gearbox d) No. of reductions

29. Auxiliary Hoisting Rope drum a) Pitch Diameter of drum b) Length of the drum (~approx.)

30. Auxiliary Hoist coupling between rope drum and gearbox a) Type b) Size c ) Make d ) Torque Rating

31. Trolley a) Wheel base b) Wheel span

32. CT wheel a) No. of wheels. b) Diameter of wheel. c) Rail Size. d) Wheel bearing size

33. Trolley drive a) Central /Corner drive b) No. of driven wheels c) KW of motor d) No. of motors e) RPM of motor

34. Trolley drive coupling between Motor & gearbox a) Model /Type / Make b) Rating and RPM

35. Trolley drive brake (Imported Flame proof thruster brakes) a) Model / Make b) Size c) Rating d) No. of brakes

36. Trolley drive coupling a) Make / Model b) Torque Rating c) Rating and RPM

69

37. Trolley drive gearbox a) Type of gearbox Vertical / Horizontal b) Make c) Size/reduction ratio d) Torque rating e) No. of reductions

38. Trolley drive floating shaft a) Diameter b) No. of plummer block supports c) Make of shaft plummer blocks

39. Trolley drive couplings between Wheel & gearbox output a) Model & Make b) Rating

40. Trolley limit switches a) Type b) Qty c) Make

41. Bridge: a) Main girder size (Section: Height x Width) b) End carriage size c) No. of LT wheels d) Wheel base e) Wheel span

42. LT wheel a ) No. of wheels b ) Diameter of wheel c ) Rail Size d ) Wheel bearing size

43. Rail Clamps : a) Double bolt type b) Make : GANTREX c ) Model of rail clamps

44. Bridge drive a) No. of corner drives (4 nos.) b) No. of driven wheels c) KW of motor d) RPM of motor e ) No. of motors

45. Bridge drive gear box a) Type of gearbox - Horizontal b) Make c) Size/ reduction ratio d) Torque rating e) No. of reductions

46. Bridge drive coupling between motor & gear box a) Make & Model b ) Torque Rating

47. Bridge drive brake (Imported flame proof brakes) a) Model & Make b) Size c) Torque Rating

d) No. of brakes (each 1No. per motor)

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48. Bridge drive coupling a) Make & Model b) Torque rating

49. Bridge drive shaft a) Diameter b) Distance between bearing supports c) Plummer block make

50. Bridge drive coupling between wheel & gearbox output a) Make and Model b) Torque rating

51. Bridge limit switches a) Make & Model b) Qty

52. Overall end carriage length

53. Overall Width of Crane

54. Torque rating of all motors 20% more than the calculated torque as per specifications.

55. The pull out torque of all motors shall be 2.75 times nominal torque.

56. VVVF Drive rating

55.1 Main Hoist (KW/ Current)

55.2 Aux. Hoist (KW/ Current)

55.3 CT (KW/ Current)

55.4 LT (KW/ Current)

57. Contractor ratings

58. Control voltage

59. Intrinsic safe circuit for push button station

60. Intrinsic safe Circuit for limit switches

61. IGUS Cable drag Chain for both bridge travel and trolley travel

62. Earthing as specified in tender document.

63. VVVF control positioning in separate identified room at ground level.

64. Laying of control cables from VVVF control room to the panels mounted on the crane.

65. Confirm that Basic price of crane quoted in price bid for Option – 1 i.e Main Hoist with Twin load path along with GA drawing.

66. Confirm that Basic price of crane quoted in price bid for Option – 2 i.e Single drive load path for Main Hoist along with GA drawing.

67. Confirm that Spare parts for two years trouble free operation is furnished with quantity and price (quoted separately)

71

S.No Item Description Unit Qty

I Electrical

1 Main Hoist - CUVC card No 1

2 Contact Kits for each power contactor above 63A Set 2

3 Auxiliary contactors No. 5

4 Semi conductor fuse (for each type) Nos. 3

5Lever type limit Switch (Two way lever / One way lever as

provided in the EOT crane)No. 1

6 Indication lamps Red, Yellow, Blue (Each) Nos. 2

7 Push buttons Nos. 6

8 Emergency push button with lock and key Nos. 2

9 Encoder for main hoist No. 1

10 Encoder for Auxiliary hoist No. 1

11 Intrinsic safety relay No 4

12 Brake MPCB w.r.t each rating (Each) No. 1

II Mechanical

13 Main hoist gearbox input shaft oil seals. Nos. 4

14 Aux. hoist gearbox input shaft oil seals. Nos. 4

15 CT gearbox input shaft oil seals Nos. 4

16 LT gearbox input shaft oil seals Nos. 4

17 Sealing rings for geared coupling (each type - 1no.) Set 2

18 Main hoist thruster brake springs Nos. 2

19 Aux. Hoist thruster brake springs Nos. 2

20 Main Hoist thruster brake shoes (1Set = 2 Nos.) Set 2

21 Aux. Hoist thruster brake shoes (1Set = 2 Nos.) Set 1

22 LT rail clamps Sets 10

23 CT rail clamps Sets 10

Annexure - 5

LIST OF SPARES PARTS TO BE SUPPLIED

Date post:	22-Jun-2018
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BID QUALIFICATION CRITERIA FOR SUPPLY OF 250t/32t EOT CRANE · BID QUALIFICATION CRITERIA FOR...

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