SATISH DHAWAN SPACE CENTRE SHAR SOLID PROPELLANT PLANT
Indent Ref: SHAR/ SPP/2018007951
TECHNICAL SPECIFICATIONS OF DOUBLE GIRDER FLAMEPROOF EOT CRANES
Sl.
No
Type of
crane
Capacity
of crane
(ton)
Span
(m)
Height of
Lift (m)
Crane
Travel
(m)
Duty
class of
crane
Quantity
( No) Facility
1
Double
Girder
Flameproof
EOT Crane.
60t 19.60m 12.0m ~37m
Class - II
of
IS 3177
01 New S200
NDT, SPP
2
Double
Girder
Flameproof
EOT Crane.
60t 19.10m 12.0m ~25m 01 New S139
NDT, SPP
The above EOT cranes shall be supplied, transported, erected and commissioned as per the Technical Specifications, Terms & Conditions given in following pages of this document.
Ref : SHAR/SPP/2018007951
CONTENTS OF BOOKLET
Sl. No
Contents
Page No.
1 Bid Qualification Criteria for supply of 60t Double Girder
Flameproof EOT Cranes A to B
2 Full Technical Specifications cum Compliance statement, Terms
& conditions of supply including codes and standards. 1 to 34
3 Annexure – 1A to 1B :
EOT Crane Clearance diagram and dimensions. 35 to 36
4
Annexure – 2A, 2B & 2C :
Layout of VVVF Room & Crane bay 37 to 39
Annexure – 2D :
Schematic of Push Button operating station 40
5 Annexure – 3 :
Quality Assurance, Inspection and Testing plan for EOT Crane 41 to 51
6
Annexure – 4 :
Commercial Terms & Conditions of the contract. 52 to 55
Page A
BID QUALIFICATION CRITERIA FOR SUPPLY OF 60t DOUBLE GIRDER FLAMEPROOF EOT CRANES
Bidders who are qualifying /meeting following Technical and Financial capabilities are eligible to
participate in the bid for supply of 2 nos. of 60t EOT Cranes. Bidder shall furnish all the requirements asked in
this criterion 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 without seeking any
further clarifications.
Bidder shall print, sign and stamp each page of proposal as token of acceptance & submit scan copy of
the same along with the offer.
I. Bid Qualification Requirements (Techno commercial):
The bidder should meet the following all technical qualifying requirements and shall submit relevant
certificates to establish his credentials.
Sl.
No Description of Requirements Bidders confirmation
1 The Bidder should be an organization with experience in having executed
contracts for design, engineering, manufacture, supply, erection, testing
and commissioning of Double girder EOT cranes for last 5 Years in India.
2 The Annual turnover of Rs. 5.5 crores per year on an average for last 3
financial years.
3
The firm should have successfully completed Design, Manufacture,
Installation, Testing and Commissioning of following EOT cranes / works :
3a At least 1no. of double girder EOT crane of capacity 50t or above and
Span equal to 16m or above during last 05 years.
3b At least 1no. of flame proof EOT Crane of 40t or above for last 05 years.
3c At least 1no. of 40t EOT crane or above used for critical lifts/handlings
like propellants (or) nuclear materials (or) hot metal handling ladles for
reputed organizations like ISRO, DRDO, NPCL, SAIL, TATA steel, IOCL, IEL,
BHEL, etc.,..
3d At least 1 no. of EOT crane with VVVF (VFD) drive control systems not
less than 40t in the last 5 years.
3e At least 1no. of EOT crane by using Drum/Barrel coupling of reputed
make in the hoist mechanism.
Bidders should provide relevant documentary proof for the above cases
“3a to 3e” with copies of orders along with the submission of bid.
4 The firm should have facility to full load test and over load testing of 60t
EOT crane (hoist and cross travel) at their factory.
5 The firm should have successfully completed Design, manufacture and
establishment of EOT cranes (40t and above) to the satisfaction of
reputed third party inspection agencies such as MECON, M.N.Dhastur,
Loyds register, BVQI and DNV.
6 Bidder shall furnish the details of their factory like manpower,
machinery, quality system etc, for department to access their capability.
II. The following documents shall be submitted along with the application for prequalification of Bid:
S.No Description of Requirements Bidders confirmation
1 Firm establishment certificate and nature of work (for S.No.1)
2 Details of work of similar type completed (for S.No.3a to 3e, 4, 5)
3 Satisfactory work Completion certificates from the clients with the work
order copies (for S. No. 3a to 3e, 4, 5)
Page B
4 Performance Report of EOT cranes established (with years of service
from End users with addresses and contact person with phone numbers).
5 Documentary evidence (Technical details & drawings) for fulfilling special
technical conditions (S.No. 3a to 3e, 4, 5).
6 Copy of audited Balance sheets for last three financial years
7 IT/TDS certificates for last three financial years.
8 Current Solvency Certificate for a value around Rs.1.8 crore.
9 List of EOT crane projects (for capacity 40t and above & Span 10mt and
above completed for last 5 years with PO copies).
10 List, value and purchase order copies of total projects under Execution
with Purchaser name and address.
11 Structure and organization Chart and company.
12 List of personnel with qualification & experience in the firm in the areas
of design production, quality safety administration etc.
13 List of Machinery & Equipment in factory suitable for the EOT Crane
works.
14 Any other relevant information which is related to above.
Date: Signature of competent person
with company seal.
III. IMPORTANT NOTES:
1. Bidder shall furnish all the above details/information/ documents 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.
IV. Bid Selection Procedure and Process of BID Qualification
Step-1 : Short listing based on documents submitted, satisfying all the 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. Feedback from Bidder’s clients will be verified.
Step-3 : If required, visits will be made to sites where bidder has established EOT Cranes by technical
team (ISRO or Third party).
Step-4 : If required to visit will be made to their factory/ firm by technical team (ISRO or third party) for
accessing the capacity of manufacturer.
Step-5 : Mean while technical Bids will be opened and scrutinized for meeting all technical specification
and supply conditions.
• ISRO – SDSC SHAR reserves right to verify the information/data furnished by Bidder. If the same is
found as false or with any deviation the bid will be summarily rejected.
• Only those Bidders who are found suitable & meeting all the above qualification Criteria/
requirements will be finally qualifying for opening of the price Bids for evaluation.
Page :1 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
SDSC SHAR
I
Bidder shall completely fill the following format of technical specifications and terms & conditions with mentioning required details. Bidder can add more information and details, if required, by attaching separate 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 cranes 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.
II
Bidder shall submit complete information asked in Qualification Criteria for qualifying for bid with all information’s, 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.
III THE FOLLOWING INFORMATION/ DOCUMENTS SHALL BE
SUBMITTED ALONG WITH QUOTATION.
Confirm whether
attached & up loaded
in e-portal
III.a
Acceptance of Technical Specifications with Point-wise Specifications to all points as given in this "Specification cum Compliance Statement" (given in the following FORMAT). Bidder shall agree / accept for all technical specifications / terms & conditions by filling acceptance colums and signing with company seal in all the pages of this tender specifications.
III.b Bidder Qualification Criteria with duly furnished information, as given along with this specifications.
III.c Schematic GA Diagram/ Clearance drawing of EOT Cranes showing major dimensions & clearances as per following specifications.
III.d Deviations with respect to specifications given below are not acceptable. However Bidder can submit / suggest improvements, if any, separately by indicating the clause no. in this specifications.
III.e Bids/Quotations without above documents/Information, will be not be considered for evaluation and will be rejected.
SL.NO. DESCRIPTION ISRO-SHAR SPECIFICATION Bidder’s
Confirmation 1 Scope of Work
1.1 A Detailed scope
of work
1. Design, Manufacture, Inspection, Shop testing,
Supply, Erection, Commissioning and Performance
proving of 2nos. of 60t Flame proof, Top
running, Double girder heavy duty EOT
cranes, along with LT gantry rails, power cable
system as per the following specifications, terms &
conditions and in accordance with latest editions of
IS:3177, IS:807 & relevant codes and standards.
2. 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, third party inspection services,
painting, load testing at supplier works.
3. Packing, marking, loading on Trucks/ Trailers and
safe transportation of EOT cranes & other parts /
items / accessories from supplier site to SHAR site.
4. Erection of EOT cranes, Bridge rails, and LT Drag
chain power cable system at our site.
5. Testing & commissioning of EOT cranes shall be
done as per the Technical Specifications, QAP, &
conditions and also in accordance with latest
editions of IS: 3177, IS: 807 & relevant codes
and standards.
Page :2 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
SDSC SHAR
1.1B
Third party
inspection is
in the scope
of supplier
Arranging the third party inspection is in the scope of
supplier for the entire scope of work (Design
approvals, Stage inspections, & testing) as given
above and as per QAP enclosed. Supplier shall engage
third party inspection agencies like M/s. Mecons, M/s
M.N.Dhastur, M/s Lloyds register, M/s DNV. The
finalization of third party agency shall be done on
mutual agreement between ISRO and Supplier.
1.1 B General
EOT cranes shall meet requirements of these tender
specifications which contain different sections, and as
per relevant standards. In case of any difference /
conflict between various sections of specifications and
to that of standards, the stringent of all as per
department (purchaser’s) view shall be applicable.
1.1 C VVVF Drive
Panels
Location
VVVF panels shall be erected in a separate room at
ground level and cabling shall be done from this room
to the EOT cranes at gantry girder height.
1.2 Quantity of
Cranes
Cranes – 1 (For NDT, SPP : S200 bay)
• SWL : 60t • Span : 19.6m • Height of Lift : 12m • Top of LT Gantry girder : 12.70m • Cranes Travel : ~37m • Qty : 1no
Cranes – 2 (For NDT, SPP : S139 bay)
• SWL : 60t • Span : 19.10m • Height of Lift : 12m • Top of LT Gantry girder : 12.70m • Cranes Travel – ~ 25m • Qty : 1no
1.3 Hazardous
area
conditions
EOT cranes shall be equipped with flame proof electrical systems suitable for operating in hazardous area classified as Zone1, Gas group IIA/IIB,T4 as per relevant IS/IEC standards.
1.4 Application
These heavy duty EOT cranes are used for handling of
dangerous/ hazardous materials like rocket motors,
propellant containers, fuel/oxidizer powder tanks etc.,
for positioning and assembly during processing of
space vehicles. In case of any failure of crane, there
will be heavy loss to property and life. Hence Supplier
shall design, manufacture and erect the cranes with
emphasis on quality, reliability and safety and shall
ensure smooth & reliable operation of cranes with long
service life.
1.5
Usage period &
Desired life of cranes
These heavy duty EOT cranes will be put to use for
365 Days, intermittent duty with Hoist CT, and LT
movements. EOT Cranes shall be designed for long
service life with trouble free operation.
1.6
Operating
Environment of
Cranes
Indoor, near to sea (i.e., saline atmosphere), with
ambient temperature 50ºC and with relative humidity
95%. Weather conditions are tropical. Bidder shall
consider above while design of EOT cranes, electrical
systems, enclosures, painting of cranes and related
parts.
Page :3 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
SDSC SHAR
2.0 MAIN PARAMETERS OF 60T DG FLP EOT CRANES (02Nos.)
2.1 Type of Cranes Top running, Double girder, Flame proof EOT Cranes
for Indoor use.
2.2 Class & Duty Structure Class-II (M5) duty as per IS: 807.
Mechanisms: Class – II (M5) as per IS:3177.
2.2 A
Duty Factor
(Cdf) for flame
proof Cranes
As cranes is used for handling dangerous materials,
the Duty factor (Cdf) of 1.7 shall be taken in design of
components in hoist motion.
Crane 1 Crane 2
2.3 EOT Crane
capacity 60t (60,000kg) 60t (60,000kg)
2.4 Span 19.6m 19.1m
2.5 Lift of height
(above FFL) 12.0m 12.0m
2.6 Distance from
Floor to top of
rail
~ 12.7m ~ 12.7m
2.7 Crane travel
in metre (LT) ~ 37.0m ~ 25.0m
2.8 Operation Speeds (maximum) in m/min for both the cranes
i) Hoist in m/min Main-2.5/ Creep-0.25 (Through VVVF Drives).
ii) Long travel in
m/min
Main-6.0/ Creep-0.8 (Through VVVF Drives).
iii)
Cross travel in
m/min
Main-6.0/ Creep-0.8 (Through VVVF Drives).
iv)
Creep speed VVVF drives
Creep speed shall be provided through VVVF drives & controls of make : M/s SIEMENS / M/s ABB
2.9 Side clearance (Distance from centre of gantry rail to nearest
obstruction) ~ 400 mm
2.10 Head Room available
(Maximum) (Vertical distance from top of gantry rail
to lowest overhead obstruction) ~ 4.0meters
2.11 Hook Approaches for 60t EOT Cranes
CT: DSL side / Non DSL side:~2.5m / ~2.0m
LT: Drive side / LT Non-Drive side: ~3.0m / ~3.0m
2.12 CT Wheel diameter
Not less than 400mm
2.13 LT Wheel Diameter
Not less than 500mm
2.14 Location of
VVVF Panels
VVVF drive panels, DBR units, other electrical panels
shall be kept in separate room in ground level. Refer
clause no. 5.4.8
2.15 Size of Cross Travel Bridge Girder Rail
Cranes CT Rails not less than CR-80 as per IS:3443.
Only CR rails shall be used.
2.16
Size of Cranes
gantry rails for
Long Travel
Cranes LT Rails not less than CR-100 as per IS:
3443. Only CR rails shall be used. LT Rails are in the
Cranes vendor's scope.
Page :4 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
SDSC SHAR
2.17 COMMON PARAMETERS FOR FLP EOT CRANES
2.18
Number of wheels for LT drive
4
2.19 LT Drive
Horizontal type, Foot mounted, standard make
gearboxes as ment ioned in the “Make of
bought out i tems” shal l be used. Central drive
shall be used.
2.20 Number of wheels for
CT drive
4
2.21 CT Drive
Central drive with Vertical type gearboxes of standard
make shall be used with proper lubr icat ion
arrangement for gearbox.
2.22
Platform for
approach for
maintenance
of CT drive
Maintenance platform covered with chequered plate shall be provided for maintenance of CT drive.
2.23 Type of bearings for LT/CT wheels
Anti-friction, heavy duty double row Spherical Roller Bearings.
2.24
Type of mounting of
LT/CT wheels
"L" type brackets, fastened with fit bolts with nut and lock nuts.
2.25
Operations
required
through
Floor operated pendant with down shop leads.
3 MECHANICAL ELEMENTS DESIGN & DETAILS
3.1
EOT cranes mechanisms components shall be designed for strength
under case I, II, III and IV loading conditions and load combinations as
per clause no. 7.3.2 of IS:3177.
3.1a
Factor of safety and permissible stress shall be calculated as per clause
no. 7.4.3 & 7.4.4 of IS: 3177 and technical specifications given and on
the basis of minimum ultimate tensile strength. However for all load
bearing mechanical components’ factor of safety shall not less than 5
for case-I loading.
3.1b
Supplier shall consider above loading conditions & permissible stresses
in design of EOT Cranes and accordingly shall submit calculations for
mechanism components.
3.1c
The stresses in all components of hoist mechanism and gearboxes should not exceed 66% of yield stress/proof stress of the material for the component under break down conditions of motor i.e. pullout
torque of motor.
3.1d
All mechanical components in Hoist (vertical load path), shall be designed for infinite fatigue life. Fatigue analysis shall be based on the cranes maximum rated load. Necessary calculations shall be submitted during detail engineering as per code IS 3177.
3.1e
No cast iron part should be used /considered in mechanical load bearing member on the cranes, except for electrical equipment. Similarly wood or combustible material and Bush bearing should not be used in any part of the cranes.
3.2 Hoist hook type Forged, Single Shank Point hook with safety latch and Thrust Bearing as per IS:3815 / IS:15560.
Page :5 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
SDSC SHAR
3.2a Lubrication of hook
Provision shall be made for lubrication of hook thrust
bearing and provide with dust cover.
3.3 Number of falls for Hoist
08 (Eight).
3.4 Rope Drum Rope Drum shall be of fabricated type made from
steel of IS: 2062 Grade ‘B’ and shall be duly stress
relieved and shall be made as per IS 3177.
3.5 Rope drum diameter shall be minimum 28 times the
diameter of wire rope.
3.5.1
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.
3.6 Rope Drum
Rope drum shall be provided with not less than three
dead turns at each anchored end and at least one
spare groove at the other end. Grooves shall be
finished smooth.
3.7
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.
3.7.1
In the event of failure of drum shaft or bearing, the
drum must be retained on the trolley without falling.
3.8 Hoist wire rope
M/s USHA MARTIN make, Galvanized, 6x36, RHO lay, core IWRC, Grade 1960MPa. Genuine wire rope shall be used. No joints shall be used for wire ropes under this specification.
3.8.1 Factor of Safety on wire rope
Minimum Factor of safety on wire rope shall be 8 (eight) on minimum breaking strength of wire rope.
3.9 Rope Sheaves
All sheaves shall be of forged steel only. Sheave
diameters shall be minimum 24 times rope diameter.
In the event of hook over travel, where the lower
block contacts the cranes trolley structure, the ropes
shall not be cut or crushed.
All the sheaves shall be mounted above the trolley
platform with ease access to maintenance/repair and
inspection.
All the top sheaves shall be positioned such that it
can be removed individually without removing other
components like equalizer pulley, rope drum etc.
3.9.1
Bearings for Sheaves
/Pulleys
All the sheaves & pulleys shall be provided with
standard roller bearings of genuine make of SKF,
FAG, INA, TIMKEN.
3.9.2
Lubrication of Pulleys
Arrangement shall be provided for periodical
lubrication/ greasing of bearings.
Guards/covers shall be provided for all sheaves.
3.9.3 Equalizer
Pulley
Equalizer pulley shall be 18 to 20 times the wire rope
diameter and shall be mounted on swiveling
arrangement.
Page :6 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
SDSC SHAR
3.9.4 Sheaves
1. Sheave grooves shall be machined smooth and
support wire rope uniformly at least 1360 angle of
contact over its circumference.
2. Wire rope fleet angle shall be not more than 2.50
for sheaves.
3.10 Gear Boxes for
HOIST
Standard reputed make, Crane duty, Helical type,
parallel shaft, spilt type housing gearboxes,
horizontal foot mounted shall be used for hoist motion.
3.11 Gear Boxes for
CT & LT
Helical /Bevel helical, parallel shaft gearboxes of
Crane duty shall be used for CT & LT drives.
Vertical Gearboxes shall have an oil pump lubrication
system when vertical gearing exceeding three stages.
Tubing/ Piping for gearbox lubrication shall be
provided with SS316/SS304 and must be properly
clamped. No hoses shall be used. Visual indicator/
gauge for oil flow shall be provided in line.
3.12
Standard make of Gearboxes for all motions of EOT Cranes.
Makes shall be M/s. Elecon / Shanti Gears/
Premium- GREAVES /Flender-Siemens only. Other makes & Own make gearboxes are not
acceptable.
3.12a
Material of
gears &
Pinions, Shafts
All are Forged Alloy Steel / Case hardening steels, as
per standard manufacturer of gearboxes.
3.12b Torque rating of Gearboxes/ Pinions/ Gears
1) Gearboxes selection shall consider starting torque of motor (i.e., 2 times the full load torque) of selected motors.
2) Due consideration shall be given for braking torque in input shaft of Gearbox.
3) Service factor shall be 1.6 for hoist on the electrical KW of selected motor.
4) Service factor shall be 1.5 for LT & CT on the electrical KW of selected motor.
5) The stresses in all components of hoisting machinery & gearboxes should not exceed 66% of yield point (proof stress) of the material for the components under break down conditions of motor i.e., pull-out torque of motor.
6) All the pinions shall be integral with the shafts.
7) Input shaft design calculations and torque rating shall be considered with 2nos. of brakes for Hoist Motion.
8) The noise level shall not be more than 80dBA during the gearbox in operation measured at a distance of 1m from gearbox.
3.12c
Details/
Drawings of
gearboxes
Drawings and Details of gear boxes, selection criteria,
Power rating & torque rating, materials,
stresses calculations, service factor, bearing details,
data sheets etc., shall be submitted for TPIA/
Purchaser for approvals during design phase.
Page :7 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
SDSC SHAR
3.13 Gearboxes
construction
Gearboxes shall have fill and drain connections,
Breathers, lubricant level indicator, and shall have
good accessesibility for checking, maintenance and oil
filling.
The casings of gearboxes shall be made from
structural steel (IS:2062) and duly stress relieved.
No oil leakage is allowed from gearboxes. Oil drip
pans shall be provided around the gearbox.
Sufficient clearance need to be maintained between
gear of one stage to pinion of next stage of non
meshing sets to avoid interference.
For hoist mechanism, the brake drum (02nos.) shall
be provided on each side of the input shaft of the
gearbox.
Reliable oil seal arrangement i.e., double stage oil
sealing arrangement shall be provided for shafts of
gearboxes.
3.14 Brakes
3.15 Hoist Brakes
Two nos. of imported electro hydraulic flameproof
thruster brakes with Manual release. Makes shall be
M/s Witton Kramer /M/s Bubenzer /M/s SIBRE /M/s
GALVI. Thrusters for brakes shall be Explosive Proof
(Ex d), ATEX/ PTB Certified. Make of thrusters: EMG,
Germany or Brook Crompton, UK, or Galvi. Explosion
proof certificates shall be submitted for Approvals
during design phase.
3.16 Brake performance certificate, test certificate and Ex-Proof certificates
shall be provided from original manufacturer of brakes.
3.17 Hoist Brake Rating
Torque rating of Each thruster brake shall be
minimum 2 times motor full load torque. One of the
hoist brake shall be provided with operating delay in
brake application from brake to brake.
Minimum diameter of the brake drum shall be
Ø315mm for the hoist mechanism.
3.18
Braking
distance/ brake
path
Hoist components and brake shall be selected such
that the braking distance for lowering motion as per
IS 3177 with one brake at full rated speed.
Necessary calculations shall be submitted in this
regard during design phase.
3.19 Brakes for CT & LT
For each motor, flame proof EHT brakes of M/s
Electromag/ M/s Kateel/ M/s Sterling Controls
shall be provided. Brakes shall be minimum 1.5
times full load torque of selected motor.
Minimum brake drum diameter shall not be less than
Ø160mm.
3.20
Brake rating/
adjustment
for CT and LT
motions
In travel motion retardation with brakes shall not
exceed 7cm/sec2. Necessary calculations shall be
submitted in this regard during design phase.
3.21 Brakes shall be mounted on the input pinion shaft of the gearboxes.
Page :8 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
SDSC SHAR
3.22 Brake Drum
Brake drum shall be forged/cast steel/ SG iron.
Drums shall be completely machined and Static &
dynamically balanced. Hardness of surface of
finished drum shall be 38-43 Rc Width of the brake
drum shall be 5 to 10mm more than the width of the
brake shoes.
3.23 Mounting of
equipment
All the gearboxes, motors, brakes, Wheel L brackets,
bearing pedestals, etc. shall be mounted on
machined and leveled surfaces. If shims are needed,
only Stainless steel shims shall be used.
3.24
Couplings
between
motor, brake
drum
Flexible Full geared couplings shall be used. Make of Couplings shall be M/s Fenner only.
3.25
Couplings
between
gearbox and
rope drum for
hoist
Drum/ Barrel coupling of adequate rating shall be provided between output shaft of hoist gearbox and rope drum
Make of drum/barrel coupling shall be M/s Malmedie
/ M/s Jaure only.
Service factor of minimum 2.0 on the rated KW/Full Load torque of selected motor.
Selection criteria, calculations, service factor, Torque rating, drawings shall be submitted for approval during design phase.
3.26 Travel Wheels All cranes wheels shall be made from forged steel
like C55Mn75 and minimum hardness shall be 300-350BHN for a case depth of 10mm.
3.27 Travel Wheels
Wheels shall be double flanged with straight tread
with 12 deg taper flanges with adequate flange
thickness. Wheels shall be accurately precision
machined and shall be matched in pairs with minimum
deviations.
3.28 Drive shafts
Shafts shall be of forged steel C45. Angular
deflection of the shaft at torque corresponding to
1.33 motor rated torque during acceleration
shall not exceed 0.10deg./m of shaft length.
3.29 Fasteners
Galvanized, high tensile fasteners of tensile quality
8.8 or more shall be used in cranes parts, except for
Fit bolts of Girder.
Make of all fasteners shall be M/s TVS/ UNBRAKO/
LPS only. Test certificates shall be provided.
Galvanizing shall be done by original manufacturer
of bolts.
3.29a Fasteners for
Couplings
High tensile Fit bolts (as per IS:3640) of Property
class min 8.8 shall be used for Couplings, and other
power transmission components as required.
3.30 Lubrication of Cranes
Localized/ semi centralized lubrication system with
easy approach for all pedestal & pulley bearings,
couplings, wheel bearings etc., shall be used.
Page :9 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
SDSC SHAR
3.31
Maintenance
accessibility &
Safety
Safe access for maintenance and removal of all
mechanical and electrical parts must be ensured
without any additional scaffolding. All parts requiring
replacement or inspection or lubrication shall be easily
accessible.
3.32 Keys & Keyways
All keys where ever used should be of parallel keys as
per IS:2048 (couplings / gearboxes / motor shafts).
Material of keys shall be 45C8 or alloy steel.
Proper fits and tolerances shall be used between key
and keyways; such that key should not get loosened
in service life. Key end arrestors shall be provided.
3.33 Bearings
Ball and roller antifriction bearings of approved make SKF / TIMKEN / FAG 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 20,000hrs).
Special consideration shall be given to bearings which
operate at low speeds. Certified confirmation of the
bearings capacity at low speeds must be obtained
from the manufacturer during design phase.
All bearings shall be provided with proper lubrication
and means of lubrication. Mounting fits, tolerances
and clearances shall be as recommended by the
bearing manufacturer.
3.32 Bearing
Housings
All bearings housings shall be of STANDARD MAKE
(SKF / FAG / TIMKEN) and made of cast steel or
forged steel or fabricated steel bolted to a rigid
portion of cranes structure by minimum 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.
4.0 STRUCTURAL DETAILS OF EOT CRANES
4.1 Design of
structural work
The cranes should be rigid, robust and of sturdy
construction. The design of all structures shall be done as per IS: 807 - Class –II (M5) and as per this technical specifications.
4.2
Material of
structural
items.
All the structural plates used in fabrication of Girders, Trolleys and End carriages, etc., shall be of minimum
8mm thick of IS:2062. .TPIA stamping, heat no., lot no. and standard makes mentioned in the annexure shall be made available.
4.2.1 Platform cover
plates M.S Chequered plates for trolley and platforms’ covering shall be minimum of 6mm.
4.3 Girders Bridge Girders shall be of double Girder, Box Type construction having maximum rigidity.
4.4 Deflection of Girders
The bridge girders shall not deflect more than
1/1000 of span with safe working load on the
trolley, with trolley stationed at mid span and
excluding deflection due to dead load.
4.5 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.
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4.6
Ratio of
span to
depth
For Box Girders Span to Depth ratio shall not exceed
18. Accordingly other ratios as per heavy duty cranes
shall be selected as per standards.
4.7 Local Buckling
of top flange
Local buckling of top flange and compression
members shall be considered. Adequate top flange
thickness shall be considered for heavy duty
structures and necessary calculation shall be
submitted for approval.
4.8 End Carriages End carriage shall be fabricated as solid box section
made from rolled steel plates IS2062, except for
essential openings which shall be reinforced.
4.9 Structural bolted
Joints
Fit Bolts (as per IS3640 ) 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.,
4.10 Trolley
The trolley frame shall be built up of rolled sections
and box sections to form a rigid structure and shall be
arranged to afford maximum accessibility to
mechanical and electrical parts placed on it.
The trolley frame shall be of rigid construction
such that lifted loads do not cause deflections
that impair the proper operation of machinery.
No parts shall be mounted under the trolley except for
the gravity limit switch weight. Top pulley block and
all other pulleys, equalizer pulley, fitments shall be
mounted on the top of trolley platform only.
4.11 Top chequered
plate of trolley
The top of the trolley frame shall be fully covered with
6mm chequered plate all over except for openings
required for the ropes for bottom block etc., to pass.
4.12
Safe distance
Between trolley
& top pulley
block
Trolley and top pulley block 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.
Safe access for maintenance and removal of all
mechanical and electrical parts must be ensured
without any additional scaffolding.
All parts requiring replacement or inspection or
lubrication shall be easily accessible without the need
for dismantling of other equipments or structures.
4.13
CT
maintenance
platform
Maintenance platform covered with chequered plate
shall be provided under the CT mechanism (i.e below
CT gearbox). Access shall be there for draining of oil.
4.14 Hand rails for trolley
Handrails of 1000mm height shall be provided on all
the four sides of the trolley.
4.15 CT rail wear plate
Full length wearing plate of minimum 8mm should be
provided under the trolley rails and should be 10 to
12mm lesser in width than the rail base as per
IS807.
4.16 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
/ purchaser.
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4.17 CT & LT rail
clamping
CT & LT Cranes rails shall be clamped to the girders
with double bolt clamping plates of M/s GANTREX /
M/s GANTRAIL make. The rail clamps shall be spaced
not more than 450mm apart.
4.18 Rail Clamps for
CT & LT rails
All the rail clamps & fasteners shall be of standard
make of M/s GANTREX/ M/s GANTRAIL.
4.19 Rail stoppers
/Wheel ramps
CT & LT Rails shall be prevented from creeping in the
longitudinal direction by welded rail stops and Wheel
ramps.
4.20 Jacking pads
Suitable jacking pads should be provided on end
carriages and trolley for jacking up the cranes for
changing track wheels
4.21 Safety Pads
Safety pads shall be provided under the end carriages
and trolley to prevent the cranes from falling more
than 25mm in the event of breakage of a track
wheel/axle.
4.22 End buffers Spring buffers of rated capacity shall be provided for
long travel and cross travel.
4.23 Metric
Component
Systems
All components including fasteners should be in metric
system only.
4.24 Locking of fasteners
Bolts in rotating parts shall be locked with spring
washers and lock nuts.
All couplings and brake drums shall be provided with
“Fit” type bolts.
4.25
Make of
steel raw
materials
All the structural raw materials (plates, angles, beams)
shall be of NEW and fresh lot and of reputed make of
M/s SAIL/ M/s JINDAL/ M/s ESSAR/ M/s TATA STEEL
only.
4.26 Welded joints
All butt joints shall be 100% radiographed for both
compression and tension joints and in flanges / Webs.
All other welds shall be DP tested.
4.27 Platforms
Full length chequered platform of width
750mm shall be provided on both bridge Girders
with hand rails of height 1000mm. The platforms
shall be bolt jointed.
4.28 Toe guards
Toe guards shall be provided for all openings, on
trolley and on bridge platforms with minimum height
of 100mm.
4.29
Machine
bases on
trolley/ LT
platform
Parts of steel frames carrying machinery should be
provided with doubling plates (including stiffeners) of
adequate thickness welded and machined to true
surface.
All the drive system bases shall be made rigid to take
all the loads.
4.30
Protection
Guards for
rotating
equipment
Guards: All the moving parts 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.
4.31 Welded snugs shall be fitted against the feet of all pedestals,
gearboxes, brakes etc., except motors. Motors shall be provided with
alignment screws for side alignment.
4.32 Ladders
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4.32.1 Approach Ladders shall be provided from catwalk to end carriage and
to LT platforms in all four corners.
4.32.2 Approach ladders to be provided for reaching the trolley at two
locations along the span of the girder.
4.33
Protection Guards for rotating equipment
Guards: All the moving parts couplings, shafts shall 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.
4.34 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.
ELECTRICAL & CONTROL SYSTEMS
5.1 Electrical Equipment Environment
5.1.1 Items supplied should be suitable for Hazardous Area: Zone1, Gas Group IIA/IIB, T4 as per IS 5572, IS 5571, IS 2148 and IS 5780 or equivalent IEC standards.
5.1.2 Item supplied should be suitable for tropical and humid climate: Temperature of 50°C & RH not less than 95%.
5.1.3 De-rating: All the drive motors, power cables etc., shall be done for ambient temperature of 50°C.
5.2 Power supply conditions :
5.2.1 Item supplied should be suitable for the following power supply variation: Voltage ±10 % and Frequency ±3 %.
5.2.2 Power supply to motors: 3 Ph, 4 Wire, 415 V AC ± 10%, 50 Hz ± 3%.
5.2.3
Control Voltage inside the Electrical Panel: 1 Ph, 2 Wire, 110 V AC for all contactors, relay, indication lamps, etc. 1 Ph, 3 Wire, 230 V AC for all lights, power sockets, etc. 24 V, DC supply for Drive auxiliary supply (if required).
5.2.4 Control Voltage in the Pendant push button: 8.9 V, Intrinsic safe supply (interfaced to hazardous to safe area).
5.3 Electric Motors :
5.3.1 Should accept the input from VVVF drive, 60% CDF, min of with 300 starts per hours, IP55, Inverter Duty, Class ‘F’ insulation, suited to hazardous area mentioned above.
5.3.2 All the motors shall have a provision to connect encoder in its shaft.
5.3.3 Thermistors
1. All the motors shall be housed with inbuilt THERMISTOR.
2. Independent thermistor relay need to be used. 3. Alarm and Trip input to be wired separately as a
input to VVVF control unit. 4. Protection like switch OFF / TRIP the motor in case
of increase in surface temperature more than T4 classification.
5. Qty: 2 sets per motor.
5.3.4 Bearings
1. Preferably sealed ‘ZZ’ bearing. 2. If not suitable lubrication provision to be provided. 3. Insulated bearings shall be provided for motors
rating more than 55 kW.
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5.3.5 Torque rating of Motors
1. Pull out torque of motors shall be not less than 2.75 times of full load torque.
2. Motor full load torque rating shall be minimum 120% of calculated mechanical torque as per IS:3177.
5.3.6 Speed rating of Motors
Shall be of 8 pole motors with speed ~ 750 RPM.
5.3.7 Current drawn by the Motors
Maximum Current drawn by all motors (rating more than 2 HP) with SWL should not exceed 80 % of the full load rated current.
5.3.8 Over load capability
150% of full load current for 2 minutes without damage or permanent deformation from zero to base speed.
5.4 VVVF Drives
The power (kW) rating of VVVF drive shall be higher than the selected or finalized electrical power (kW) rating of the motor.
5.4.1 Hoist Drive
1. Shall be provided with 2 Nos. (1 Working; 1 Standby).
2. Three positions selector switch shall be provided for selecting the drive and shall be indicated by means of indication lamp.
3. It shall have a provision for communicating to the automation system via. Ethernet protocol.
5.4.2 CT & LT Drives 1. Shall be supplied with 1 No. (1 Working). 2. It shall have a provision for communicating to the
automation system via. Ethernet protocol.
5.4.3 Drive Control Unit
1. Shall be supplied with 2 Nos. (1 Working; 1 Standby).
2. Three positions selector switch shall be provided for the above selection.
3. The selected control unit shall be indicated by means of indication lamp.
5.4.4 DI & DOs 20% additional DI / DOs with respect to the used/assigned terminals for future usage.
5.4.5 Operator Panel
1. Combined advanced operator panel capable of commissioning the individual drive need to be provided.
2. Operator panel shall be capable of provided with fault history read and logging facility.
3. It needs to be mounted on the panel door. 4. Qty: 2 Nos. (1 Working; 1 Standby)
5.4.6 Drive Software
1. Suitable software with valid license need to be supplied along with drive.
2. This software to be loaded on the laptop (which is the scope of department).
3. Drive communication cable suitable for support either USB or RJ45 of the laptop need to be supplied.
5.4.7 Make & Model of VVVF Drives
Model:S120 of M/s SIEMENS (or) Model:ACS880 of M/s ABB
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5.4.8
Location of
VVVF Panels for
the
Flameproof
EOT cranes
All VVVF & electrical panels shall be kept in separate
room in ground level as mentioned below :
At Entrance of the bay and apx. centre of the bay. All
the power and control cables towards the EOT
cranes shall be routed from this rooms to the top
with fo r EOT cranes. Approx. cable length
(Armoured) from VVVF room to EOT cranes junction
box at 2m from FFL at centre of the LT girder is as
mentioned below :
Crane 1 : ~110m.
Crane 2 : ~100m.
5.4.9 Panel door limit
switch
Door Limit switch: Should control the panel lighting of
the VVVF Drive panel. Qty: As per panel design.
5.5 Input and Output Chokes
Suitable input choke for controlling harmonics and output choke for reducing dv/dt and terminal peak voltages at Motor.
5.6 Dynamic Braking Resistors
1. DBR of suitable capacity/rating shall be provided to all VVVF drives (in feed re-generative model shall not be selected).
2. 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.
3. Necessary forced cooling needs to be planned. Controlling of the cooling fans needs to be linked with control supply ON.
5.7 Dynamic Braking Unit
Suitable rated Dynamic Braking Unit (DBU) need to be provided for individual drives.
5.8 Encoder for Motor
Intrinsic safe / flame proof hollow shaft incremental encoder to be used to achieve vector control mode of operation for Hoist application.
All Encoder signals shall be suitable for VVVF drive input.
Encoder signal shall be of intrinsic safe / flame proof signal only. Screened cable /fiber optic cable as per manufacturer recommendations and as decided by purchaser shall be used for encoder.
Encoder shall have a provision to send two signals from the single encoder.
Encoder shall have a terminal strip termination for connecting the cables.
5.9 Flameproof Thruster Brakes
All the brakes need to be powered with suitable rated Motor Protection Circuit Breaker (MPCB)
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5.10 Scheme to be followed for powering the Brakes :
5.10.1 All Hoist Brakes
1. Logic for operation: a. Opening: Monitoring min. of 20% of current
built in the motor. b. Closing: Monitoring min. of 0% speed of the
motor. 2. No. of power contactor: 2 Nos. per brake set. 3. Controlling of power contactor:
a. One no. of digital output/contactor from the control unit.
b. One no. of intrinsic safe relay/contactor. 4. All the brake contactor status needs to be
monitored. 5. In case of any one power contactor got welded/
fused, the system has to operate with flashing indication.
6. If both the power contactors got welded/fused, main (line) contactor need to be switched OFF.
7. Similarly MPCB trip status needs to be wired as one digital input to control unit for logic evaluation.
5.10.2 All CT & LT brakes
1. Logic for operation: a. Opening: Monitoring min. of 20% of current
built in the motor. b. Closing: Monitoring min. of 0% speed of the
motor. 2. All the brake contactor status needs to be
monitored. 3. MPCB trip status needs to be wired as one digital
input to control unit for logic evaluation.
5.11 Limit Switches
1. Gravity Limit switch: Should control the Entire power supply of the cranes. Qty: 1 No.
2. Rotary Limit switch: Should control the Hoist motion of the cranes. It shall have a 4 NC points. Qty: 1 No.
3. 2-Way Lever Limit switch: Should control the Cross Travel and Long Travel of the cranes. Qty: 4 Nos.
5.12 Junction Boxes
5.12.1 Flame Proof Junction Boxes
1. FLP junction boxes shall be provided for inter facing of all the equipment which are powered not
through intrinsic safe supply (i.e., > 8.9 V) 2. All the terminal inside this box shall have a
provision for connecting ring type lugs only. 3. Make: M/s FEPL / M/s BALIGA/FCG / STAHL
5.12.2 Non-Flame Proof Junction Boxes
1. Non-FLP junction boxes shall be provided for inter facing of all the equipment which are powered through intrinsic safe supply (i.e., pendant control, limit switches, etc)
2. Make: M/s Rittal / M/s President.
5.12.3 Probable location of Junction boxes
The probable locations of the JBs are a. Cranes LT Gantry Girder. b. Cranes LT Platform. c. Cranes Trolley / LT platform.
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5.13 Power Socket
1. On the Cranes: Each side of the LT platform 1 No. of 1 phase, 230 Volts AC FLP switch cum socket with plug top with necessary isolating switch / MCB inside the panel.
2. Inside the Panel: 1 No. of 230 V AC power sockets with ON / OFF switch for all the panels.
5.14 Light Fittings & Bell
1. On the Cranes: a. Under slung FLP, 150watts LED light fitting
shall be provided. Qty: 4 Nos. b. FLP bell need to be planned. Qty: 1 No.
2. Inside the Panel: 1 No. of 230 V AC LED light fittings shall be provided for all the panels.
5.15 Pendant Push Button Station
1. Shall be provided with Key way switch with Mush room head Emergency OFF.
2. Control ON & OFF indication lamp powered through Intrinsic Safe circuit.
3. Shall be provided with push buttons for controlling main and creep of all motions. i.e., Hoist: UP/down; CT: right/left; LT: forward/reverse and bell
4. Push buttons shall have 1NO+3NC add-on blocks.
5. 2-way Switch for Under Bridge Lights. 6. Minimum 30% Spare Core shall be provided in
PBS with respect to the used cores. 7. All push buttons are to be powered through
intrinsic safe module only apart from other control elements like limit switch, etc..,
8. Enclosure and Chain for the pendant shall be Stainless steel.
9. Trailing cable supported on wheeled trolleys with anti-friction sealed (ZZ) bearings.
10. Stainless steel chain shall be provided for DSL arrangement and also for pendant hanging.
11. Pendant track shall be provided above LT platform for ease of maintenance.
5.16 Cables All the cables need to laid and end-terminated as per the site requirement.
5.16.1 Encoder Cable for Hoist motor
The following cables need to be supplied: 1. The Encoder cables shall be minimum of 8 core. 2. The cable shall be of screened cables and the
shield to be connected to earth. 3. Flexible single cable without any joints shall be
used for encoder from panel to encoder. 4. Qty of cable with full length: 2 Nos. To be
connected to both the signals of the proposed encoder.
5. Make: M/s LAPP or M/s IGUS
5.16.2 Power Cables
The following cables need to be supplied: 1. All the power cables shall be of 4 core only. 2. Minimum size shall be of 4 sqmm. 3. The cable running between panel to field
equipment, other than the cable running in Drag Chain are of 1.1 kV Grade, XLPE insulated, copper conductor, G.I. armoured cables only.
4. From power supply source at SDSC SHAR to Protective Panel Incomer. Qty: ≈50 mtrs.
5. From Protective panel to all the other panels, field equipments like motor, brakes, lights, bell, etc.
Page :17 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
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Power cables towards the motors are to be selected as follows:
1. Selected / approved motor electrical kW and rated current to be selected for the voltage drop calculation.
2. Maximum 3% of Voltage drop only will be accepted in the selected cables.
3. Incomer cables rating to be considered for maximum of three different motions along with EOT Cranes lights and other transformers loads.
4. Out of used cores, 30% of core shall be kept as spare with respect to each size of the cables from panel to junction boxes.
5.16.3 Control Cables
The following cables need to be supplied: 1. All the control cables shall be minimum of 12 core
only. 2. The cable running between panel to field
equipment, other than the cable running in Drag Chain are of 1.1 kV Grade, XLPE insulated, copper conductor, G.I. armoured cables only.
3. From Protective panel to all the other panels, field equipment like brake limit switches, various limit switches, pendant, etc.
5.16.4 Cable Identification
1. Cable tags indicating the source and destination to be provided for all the cables.
2. The ferrules shall be of ring type and of non-deteriorating material.
5.16.5 Cable identification Inside the panel
The following cable management to the planned: 1. Power circuit – Minimum size: 4 Sq.mm 2. Control circuit – Minimum size: 2.5 Sq.mm 3. Signal wire (for Control Unit and Encoder module) -
Maximum size: 0.5 Sq.mm 4. Colour coding should be followed as:
a. 110 V AC Phase – Grey without sleeve. b. 240 V AC Phase – Grey with RED sleeve. c. 110 V &240 V AC Neutral– Grey with BLACK
sleeve. d. 415 V AC – Black with RED, YELLOW, BLUE
and / BLACK. e. 24 V DC Positive– Red. f. 24 V DC Negative– Blue. g. 8.9 V DC – Orange. h. Signal cable – As per the standard of
LAPP/IGUS cable. i. Earth cable – Green & Yellow.
3. All the limit switch terminals (Hoist, CT, LT and Brakes, etc) need to be wired up to the terminal block of the VVVF panel.
4. Interconnecting / looping of above terminals need to be carried out in the VVVF panel terminals only.
5. Interconnecting of above terminals in the equipment’s and bringing the common terminals to the VVVF panel is not acceptable.
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5.16.6 Earthing
The following area cables/strips need to be supplied: 1. G.I. Earth strip (min. 25 x 6 mm) shall be
provided 2. LT Rail at both the sides of the cranes needs to be
earthed. 3. All the equipment including the mechanical
structure needs to be grounded effectively with double earthing.
4. Suitable bridge clamp need to be positioned on the cranes for tapping of earth points.
5. Panel shall be provided with earthing provision at both the ends.
6. All earthing shall be connected with plant earth (which is 20 mtr. away from the panel location).
5.16.7 Drag Chain
1. Drag chain shall be provided for LT and CT motions.
2. Necessary supports (like beam / angles, guided cable tray, etc) for running the drag chain along the LT and CT motions shall be provided. Drawings shall be submitted for approval during design phase.
3. Maintenance cage shall be provided for attending the LT drag chain maintenance.
4. All the cables running inside the drag chain are of same make as that of the drag chain.
5. Make: M/s IGUS / M/s LAPP
5.17 Cable Tray
1. Perforated G.I. cable trays need to be planned for routing the cables from the panel to top of the cranes.
2. Necessary supports (like beam / angles, etc) for running the cable tray inside the trench (bottom of the panel), on the wall, on the cranes, etc need to be supplied.
3. Entire length of the cable trays need to be
covered with G.I. sheet cover. Fasteners shall be as per the manufacturers recommendations.
4. No cables are routed without cable trays and covers.
5. The cable trays are also to be earthed with respect to the common ground.
6. Cable Layout and tray mounting drawings shall be provided along with number and sizes of cable trays during design phase.
5.18 MCCB
1. Protective Panel - MCCB with adjustable overload, adjustable short circuit protection, adjustable ground fault and Instantaneous protection to be provided.
2. Protective Panel - MCCB handle (door operated) shall have a illumination kit for indicating ON / OFF / TRIP.
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5.19 Switch Dis-connector Fuse (SDF) unit
1. All motion Panel - Switch Dis-connector Fuse unit. 2. All SDF to be provided with semi-conductor fuse
with fuse indication cum monitoring device. 3. All SDF to be provided with auxiliary switch to
ensure the ON / OFF status of SDF Unit. Same to be wired up to drive input to enable the drive for operation.
4. All the semi-conductor fusing indication to be wired as the drive input in series with the above point to enable the drive for operation.
5. All the isolating switches are to be provided with door interlocking and defeating provision.
6. All the isolating switches (either MCCB / SDF) are to be located uniformly in the height of 1600mm from FFL.
5.20 Fuses
Hoist, CT and LT power supply to VVVF drives to be routed through Semiconductor fast acting Fuses of adequate rating as per drive manufacturers recommendation. Semiconductor fuses shall have an indicator for fusing.
5.21 MCB
1. Voltage input to the Multifunction meter shall be routed through 3-pole MCB
2. Individual components control shall be planned by a dedicated MCB control.
3. All the MCBs shall have the provision for ON, OFF and Alarm contact provisions. The same shall be wired for the control logics (wherever required).
5.22 Contactors
5.22.1 Power Contactor
1. Duty: AC-3 2. The contactors shall be able to withstand their
rated current for one second without welding / fusing of the contacts
3. Individual Power Contactors are to be provided for each motion for controlling.
4. All the power contactors needs to be powered viz. auxiliary or interposing contactors / relays with suitable rating along with surge suppressor.
5. Any multiplication of NO, NC points – auxiliary contactor need to utilized.
6. NO add-on blocks will be allowed for power contactors.
5.22.2 Auxiliary Contactor
1. Shall be used as intermediate contactors to the power contactors.
2. All the field interlocks need to be wired to the auxiliary contactor level.
3. Suitable surge suppressor need to be supplied along with auxiliary contactor.
4. It shall be utilized for contact multiplication instead of add-on NO, NC contacts for power and auxiliary contactor.
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5.23
Motor Protection Circuit Breakers (MPCB)
1. Rating shall be selected as per the type-2 co-ordination chart with respect to fuse-less feeder.
2. All the brakes need to be powered with suitable rated motor protection circuit breaker.
3. To be provided for the each motor where the output of single VVVF drive is driving two or more nos. of motors.
4. Trip status to be wired as one no. of Digital Input to control unit to create logic as per the user requirement.
5. ON/OFF status also to be wired as one no. of Digital Input to control unit to create logic as per the user requirement.
5.24 Intrinsic Safe Relays
Input Relay: 1. All the field signals like pendant push button, limit
switches (motion & status) to be wired to this relay.
2. This relay shall be located in safe area (inside the panel) only. Make: M/s P&F
3. All this relay shall be selected to suitable for operating with 110V AC supply.
Output Relay: 1. These relay shall be used for powering indication
lamps in the hazardous location. 2. This relay shall be located in safe area (inside the
panel) only.Make: M/s P&F 3. All this relay shall be selected to suitable for
operating with 110V AC supply. Interlock: 1. All the output commands from control unit shall be
directly given to the digital input of this relay. 2. All the interlock wiring (if required) as per the logic
need to be carried out in this relay itself. 3. No relay board shall be used for creating any
interlock inside the panel. Make: P&F only (both input and output relays)
5.25 Panels
5.25.1
Individual panel (without patrician between panel) to be planned towards effective utilization of panel AC. Make: M/s Rittal/ M/s President (both panel and AC) Protective Panel (1 No.), Hoist Panel (2 Nos.), CT Panel (1 No.), LT Panel (1 No.), Control Panel (1 No.), Control & Lighting Transformer Panel (1 No.) & DBR Panel (As reqd.)
5.25.2 Protective panel shall be provided with mushroom head emergency switch to disable power supply during maintenance
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SDSC SHAR
5.25.3 Design & Construction
Enclosure – Indoor, Floor mounting, Front operated free standing Frame, Mounting plates, Doors & Covers – 2.0 mm Thickness CRCA Lifting arrangements - Suitable Lifting Arrangement shall be provided for each panel on the Top on all four sides Base frame – ISMC 100 x 50 with Matt black Glass door – will be provided in the overall control panel (where control unit, communicating systems, IS barriers, contactors, etc is arranged) Degree of protection – IP 54. Shrouding – As per standard (to be provided inside the panel, in front of power components and power terminals). Cable entry (power and control) – bottom. The panels to be provided with panel A/C along with water drain hose of sufficient length (min. 2 mtrs) The panels need to be provided with panel lamps (LED) along with door limit switches All the panels are to be maintained the uniform height and width. Height of the panel not less than 2000 mm excluding the base frame of 100 mm. Overall height of the panel not less than 2100 mm. All the panel line up to be taken care like a bureau opening type. Enamel Danger plates shall be provided on the Panel inscribed in Hindi, Telugu and English languages as directed by department. Drawing pocket needs to be considered. Comfort handles with key to be considered.
5.25.4 Painting 1. Paint shade – RAL 7032 / 7035. 2. Base frame – Matt black. 3. Mounting plate – Orange.
5.25.5 Wiring
1. Power circuit – Minimum size: 4 Sq.mm. 2. Control circuit – Minimum size: 2.5 Sq.mm. 3. Signal wire (for Control Unit and Encoder
module) - Maximum size: 0.5 Sq.mm.
5.25.6 Indication Lamps
1. It shall be of cluster LED provided with translucent lamp covers
2. Cluster LED module shall be suitable for direct operation on 230 V / 110 V, 50 Hz AC or 24 V DC.
3. Panel shall have the 3-phase indication lamps in the metering cubicle controlled by 3-pole MCB.
5.25.7 Name Plate 1. Material – Transparent acrylic. 2. Colour of letter – white letter in black
background.
5.25.8 Earth bus bar
1. Size – Minimum '30 X 10 Cu' with nuts, bolts & washers at each end is to be provided per panel
2. Necessary earth strip need to be supplied for the following
a. To link panel to rail at the gantry girder. b. To link rail and all the electrical elements on the
EOT Cranes. c. To link the panel to the earth strip.
Page :22 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
SDSC SHAR
5.25.9 Terminal blocks
1. Terminal blocks shall be of 750 Volts grade of
the stud type and shrouded.
2. Insulating barriers shall be provided between
adjacent terminals.
3. All the terminal blocks are grouped with respect
to the following:
a. 24 V Power distribution (separately for positive
and negative).
b. 110 V Power distribution (separately for phase
and neutral).
c. 230 V Power distribution (separately for phase
and neutral).
d. 415 V Power distribution if any
e. Motor and brake power distribution
4. Short linked Terminal blocks are to be used for
terminal multiplication. More than one wires
need to be avoided in one terminal block.
5. All future interlocks to be provided with
permanent shorting link.
6. Interlocking between the panels is to be routed
through respective panel terminal blocks only.
Direct wiring between the components of two
different panels to be avoided.
7. Power & Control circuit –Ring type end
termination of suitable size
8. All the terminals needs to be provided with group
markers
9. 25% Spare Terminals Shall be provided for both
Power and Control in each Panel
10. Make: Connectwell / Wago / Elmex
5.25.10 Multifunction meter
1. Panel shall be provided with Multifunction meter
2. Along with Add-on DI / DO modules
3. Communication: PROFINET modules
4. Make: M/s SIEMENS; Model: PAC 4200
5.25.11 SMPS (If required)
1. 24 V DC power supply to be provided (2 Nos.)
2. Shall be used as common supply to all the
motion including protective panel.
3. ORingdiode needs to be supplied.
4. The DC power supply failure shall be noticed via.
Digital inputs.
5. If either the SMPS or ORing diode fails a 24 V DC
missing indication lamp need to be provided.
6. Qty: 2 Nos.
5.25.12 Panel Space Heater
1. Panel Space heater is to be mounted in such a
way that, Power & Control Cables must not run
in close vicinity of it.
2. All the Panels shall be provided with space
heaters to avoid moisture condensation.
3. Necessary thermostat need to be supplied along
with the space heaters.
4. ON / OFF Control of space heaters shall be
interlocked with main contactor. i.e., whenever
main contactor is in OFF condition, power shall
be available at space heater terminals.
Page :23 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
SDSC SHAR
5.25.13 Rubber mats
1. Rubber mats to be supplied and provided in-front
of all the panels as per the designed length of
panels including Transformer and DBR panels.
2. The length to be supplied is 30 mtrs.
3. Class ‘A’, 3.3 kV ac (rms), 2.0mm ± 10%
thickness as per IS 15652/2006
4. Width: 1 mtrs. (maximum)
5.25.14 Layout details
1. 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
2. Selector switches, indication lamps and operator
panel needs to be provided on the panel door
3. Routing of Signal & Power/Control cables is to be
done separately wherever possible
4. All Communication cables shall be routed
through wire channel
5. Shield of all Signal Cables is to be properly
clamped to Body of the Device/structure.
5.26 INTERLOCKS scheme
5.26.1 At Pendant level
1. Pendant level:
a. Hard wired interlocks are to be provided at
push button station.
b. 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.
2. Auxiliary Contactor level:
a. Hard wired interlocks are to be provided at
push button station.
b. When Aux. contactor operates with respect to
the motion selected, remaining Aux. contactors
with respect to other motions should not be
operated. Aux. contactor shall be operated only
when main power contactor is in ON condition.
3. In VVVF Drive Logic control:
a. It is to be programmed such a way only one
motion has to be selected for operation at a time
in the VVVF drive.
5.26.2 ON Interlock for Hoist motion
1. Rotary limit switches i.e hoist and lower, Gravity limit switch.
2. Thruster Brakes' MPCB condition. 3. Brake Close limit switch condition. 4. Provision shall be made for two extra interlocks
for future usage.
5.26.3 ON Interlock for Cross Travel motion
1. Right and Left limit switches for respective motion of the drive.
2. Thruster Brakes' MPCB condition. 3. Brake Close limit switch condition. 4. Provision shall be made for two extra interlocks
for future usage.
Page :24 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
SDSC SHAR
5.26.4 ON Interlock for Long Travel motion
1. Forward / Reverse limit switches for respective motion of the drive.
2. Thruster Brakes' MPCB condition. 3. Brake Close limit switch condition. 4. Provision shall be made for two extra interlocks
for future usage.
6.0 PAINTING OF CRANES(DFT shall be measured at the time of
final inspection)
6.1 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.
6.2
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.
6.3
Painting Epoxy Paint
( Total thickness
120 microns)
Two coats of epoxy paint Golden Yellow colour
(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
aesthetic looking of cranes.
6.4
Total Paint Thickness
Including Primer
Not less than 200 microns, This will be tested during
final inspection at supplier works/ at the time of
dispatch. Necessary paint thickness measuring
instrument shall be provided by supplier at the time of
inspection.
7.0
DESIGN APPROVALS : DRAWINGS /DOCUMENTS TO BE
SUBMITTED AFTER PLACEMENT OF ORDER
1. Supplier shall submit following list of drawings/calculations/
documents for approval before manufacture of cranes within
one month after placement of purchase order. (7.1to7.16)
2. It is the responsibility of the supplier to get the drawings/
documents approved from TPIA/Purchaser.
3. Design of load bearing structures shall be as per IS:807 and
drive mechanisms as per IS:3177 and also as per technical
specifications in to consideration.
4. All the load bearing structure & drive mechanisms shall be
designed by taking dead loads, operational loads, transportation
loads, erection loads, loads due to sudden actuation of brakes
and acceptance testing loads.
5. All the drawings and calculations, and data sheets, and
flameproof approvals shall be submitted as a whole set, at a
time, within one month from Order date for verification &
approvals.
6. Three sets of following drawings/calculations shall be submitted
in HARD COPIES to Department/Purchaser (ISRO) for
review.
7. At the same time, Supplier shall be responsible for proper
submission of following drawings & calculations along with
technical specifications to Third party inspection agency and get
Design Approvals from them.
7.1 General Arrangement (GA) drawing of cranes to scale with dimensions,
Bill of materials & makes.
Page :25 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
SDSC SHAR
7.2 GA Assembly Drawing of Trolley with all components.
7.3 GA Drawing of individual drive mechanisms for Hoist, CT and LT.
7.4 Constructional Drawings of Girder, end carriage, and trolley their connections
7.5 Sub-assembly drawings for rope drum assembly, wheel assemblies, hook blocks, pulley system etc.,
7.6 GA drawings, details and selection criteria, power & torque calculations for gear boxes with manufacturer data sheets
7.7 Calculations for selection of Machine elements like wire rope, rope drum, couplings, wire ropes, pulleys etc.,
7.8 Calculation for bridge girder with deflection & camber, trolley frame, end carriage, with weight breakup and wheel loads.
7.9 Calculations for selection of wheels, bearings and Calculations for selection of CT & LT rails.
7.10 Calculations for drive shafts and Plummer block bearings.
7.11 Calculations for Selection & sizing of bearings for EOT cranes.
7.12 Selection of keys, key ways couplings.
7.13 Selection of sheaves and sheave pin with calculations.
7.14 Bridge Girder CT rail arrangement drawing to scale with BOM.
7.15 LT rail arrangement (on Gantry Girders) drawing to scale with Bill of Materials (BOM).
7.16
Calculation for selection of motors, brakes etc., along with manufacturer datasheets & Exproof certificates (wherever applicable), etc. For Motors necessary torque and speed curves, efficiency and power factor with respect to loading of the motor, speed and time with respect to current and complete G.A of motor, terminal box / boxes by mentioning the approved drawing reference and nos. shall be submitted for approval
7.17 Calculation for selection of motors and brakes with manufacturer motor /brake datasheets & Exproof certificates.
7.18 Electrical/electronic circuit diagrams for total cranes containing details of components with rating, make, type and settings
7.19 GA drawing of electrical, VVVF panels, Pendant, DBR Panels and layout of components within the panels. Heat losses / load calculation inside the drive panels.
7.20 Flameproof approval certificates for motors, all electrical components and brake thrusters.
7.21 Selection criteria/calculations for VVVF drives, DBRs and related
components. Heat loss calculation towards panel AC selection.
7.22 Sizing calculations for Control Transformer (with considering closed VA),
Lighting Transformer, SMPS with and without loading.
7.23 Selection of Cable sizes selection and ratings.
7.24 Drawings for Mounting and panels layout in the panel room with cable routing layout.
7.25 Drawing of Cable route from panel room to cranes equipment with location of junction boxes & cable trays with support lugs on cranes
7.26 Earthing layout of all the equipments connected in the EOT Cranes to be submitted for approval.
7.27 Necessary under / over current devices to be planned for tripping the lubrication pump.
Page :26 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
SDSC SHAR
7.28
TEST REPORTS shall be submitted for flame proof electrical fittings /
equipment (along with approved drawings (Either by CIMFR / ERTL (E))
with respect to all the annexure and amendments need to be submitted
for review and acceptance of all FLP items.
7.29
TEST REPORTS shall be submitted for Space heaters and its
thermostat, Transformers, Dynamic Braking Resistors, VVVF Drives and
its components.
7.30
TECHNICAL DATASHEETS shall be submitted for Motors, Brakes, VVVF Drives, Switchgear components, Power and Control Cables, Encoders, Cable Drag chain and its cables, Limit switches, Intrinsic safe relays and panels.
7.31 Quality Assurance Plan (QAP) for total cranes manufacture, erection & testing as given in Annexure - 3.
Supplier shall submit following along with supply of EOT Cranes: List of
Manuals/ drawings/ documents/ certificates to be submitted at the
time of inspection of cranes at supplier's works and at the time of
commissioning at ISRO,SHAR (clause 8.1 to 8.10)
8.1
QAP/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
&clearance report.
8.2
Test certificates of all items like raw materials, hooks, wire ropes,
motors etc and for all cranes parts certified by "Competent person of
third party agency" as per QAP & standards.
8.3 4 sets of Cranes operation & maintenance manuals
8.4 2Nos. of spare parts manuals.
8.5 4sets of as built Drawings of all systems of cranes as mentioned
above approval drawings.
8.6 Manufacturer maintenance manuals, test certificates and Warranty/
Guarantee Cards for all Bought-Out-Items.
8.7 Trouble Shooting Chart for Main and all Sub-Systems.
8.8 VVVF drive drives manuals soft copy
8.9 VVVF drive parameters list soft copy
8.10 Final test certificate of EOT cranes from TPIA with inspection report
8.11 Final as built drawings of cranes 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.
8.12 Final as built drawings of cranes control circuit, cable schedule with length of each cable in mtrs. along with source and destination, shall be supplied in hard form.
9 Tolerances: Supplier shall ensure that the cranes shall be
manufactured as per the tolerances specified below.
9.1 Span over LT wheels
+4mm maximum
9.2 Diagonal on wheels
±5mm maximum
9.3 Parallelism of
Girders <1/1000 of wheel gauge (measured at every 1m interval)
9.4 Verticality of Girders
<2mm (measured at every 1m interval)
Page :27 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
SDSC SHAR
9.5 Verticality of End
Carriages <1mm (measured at every 1m interval)
9.6 Trolley wheel gauge
± 2mm (measured at every1m interval)
9.7
Difference in
height between
trolley rails
<1/1000 of wheel gauge maximum at 1m
interval
9.8 CT Rail alignment
w.r.t Girder centre ±1 mm(measured at every 1m interval)
9.9
Tilt of wheels(both
horizontal &
vertical)
<D/1000mm where D=diameter Of wheels
9.10
CT/LT wheel
displacement <2mm (measured at all wheels) Wheel alignment
9.11
Squareness
of Girders
to End
carriages
Within 1.60mm(for wheel base of~4000mm)
9.12 Travelling speed +10% -5% of specified speed.
9.13 Hoisting speed +10% -5% of specified speed.
9.14 Lowering speed +20% -5% of specified speed
10. INSPECTION & TESTING DURING MANUFACTURE OF CRANES
10.1
DESIGN/
DRAWINGS
APPROVALS&
CERTIFICATE
from TPIA
before cranes
manufacture.
Supplier shall obtain APPROVALS for all design
calculations & drawings from third party inspector
(TPIA) and/or ISRO before starting cranes's
production. Cranes & 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.
10.2 QAP & Third
party agency
INSPECTION and testing shall be carried out as per
QAP enclosed here with in Annexure – 3. Supplier
shall hold the manufacturing at specified "HOLD
(H)" 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 TPIA and /or ISRO.
10.3
Raw materials
identification &
stamping
Raw material identification for structures, wheels,
hoist members, 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 and during
inspection of cranes.
10.4 All load bearing members shall be provided with heat no. & lot no along
with TPIA stamping on them which shall be visible after fabrication also.
10.5
Welding
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 documentation.
Page :28 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
SDSC SHAR
10.6
Inspection
major parts and
records
Inspection of Bridges, End–Carriages, trolley, rails
gauge, Wheels and Measurement of Camber,
mechanical assemblies checking as per QAP.
10.6.1
Inspection of Electrical motors & other electrical parts
Test certificate with approvals shall be provided for all motors such they are suitable for inverter duty, flame proof. Test certificate for thermisters heating/tripping temperature shall be provided. Test certificate for all other electrical components shall be provided as per QAP. ,
10.7
Dimensional
inspection&
alignment checking
& records
Inspection of Span & Diagonal Dimensions (10Kg pull should be applied while checking), Checking bridge & end carriages' squareness, Checking of Wheel Alignments, Mechanical drive Assemblies alignment and Pulley blocks alignment.
10.8 Record of inspection
All the inspections made shall be made with
drawing representation like span, diagonal, wheel
straightness, rail alignment, with dimensions &
tolerances mentioned.
10.9 The cranes 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.
10.10
Load tests
No load test, Dynamic tests at Rated Load and
Deflection measurement as per as per QAP and as
per IS 3177
10.11
Testing of Cranes at OVER-LOAD (125%SWL) capability Check and Permanent Set Measurement. All motions of the cranes shall be tested with 25% overload in which case the specified speeds need not be attained but the cranes shall show itself capable of dealing with the over load without difficulty.
10.12
Clearance
for
dispatch
The equipment shall be dispatched only after
satisfactory testing/inspection at supplier's works
and on written clearance from ISRO/SHAR.
11 ERECTION & COMMISSIONING OF EOT CRANES
11.1 Erection, testing and commissioning at ISRO-SHAR works is in the part of supplier's scope as per QAP.
11.2
Initial unloading of EOT cranes parts shall be done by supplier’s manpower & supervision. Equipment support with available equipments like Mobile cranes / Forklift / Hydra etc., will be spared for unloading of cranes parts by department at free of cost based on
11.3
If the cranes components are unloaded outside/any other facility of SHAR, the same will be transported to the site of erection by the departments equipment at free of cost. However work shall be carried out by supplier with their manpower & supervision.
11.2 Erection Supervision
Supplier shall depute required qualified personnel along with Engineers/ supervisor and qualified team for carrying out quality erection work at our site.
Page :29 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
SDSC SHAR
11.3
Material required during erection (lifting equipment like winch, lifting tackles, etc inside the facility).
Lifting machinery, tools and accessories are in the scope of supplier. All lifting machinery, tools and tackles of standard make only shall be used during erection inside the facility. Test certificate for all the lifting/handling equipments shall be submitted to the SHAR before handling. If required by supplier department can provide erection hooks on the roof in the facility for lifting of cranes components. However capacity & location of hooks shall be given by manufacture during detail engineering.
11.4 Initial lubricants and commissioning spares
Initial filling of lubricants/grease and spare parts required for commissioning at site shall be provided by the supplier.
11.5
Performance Proving & Smooth running of EOT cranes at purchaser site.
No Load test, Full load test and overload test (for
125%SWL) shall be done as per QAP and as per
IS3177. Proving out for the Cranes’s Capacity and
Smooth Functioning of the Cranes at Full load
(SWL) and Overload (125%SWL) shall be the
responsibility of the supplier.
11.6 Test/Clearance certificates for cranes
Part of supplier's scope. To be inspected and
certified by "Competent Person of Third party
Inspection Agency " as per Industrial Laws and
shall provide Certification from Third Party
Inspection Agency for final clearance & regular
usage of EOT cranes .
12 General TERMS & CONDITIONS during supply and installation:
12.1
In the design of Cranes, 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.
12.2
Arrangements shall be made by the supplier for the inspection and
testing of the cranes during different stages of its manufacture starting
from the raw material still the completion of the cranes by the
SDSC,SHAR and/or Third Party Agency at the suppliers site as per the
QAP schedule.
12.3
Assembly at site is to be kept as minimum as possible to enable early
commissioning of the cranes. Welding at site is to be avoided as far as
possible.
12.4
Any modifications carried out during erection like welding, gas cutting
etc., the same shall be finished properly by cleaning, application of
primer and painting as per standard mentioned above in these
specifications.
12.5 Supplier should satisfy himself about the site condition before hand to
avoid any difficulty during erection and commissioning of the cranes
12.6
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.
12.7
During the erection, testing and commissioning of the cranes 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 on chargeable
basis, if available.
12.8 Free electricity and water will be provided by the purchaser for the
erection, testing and commissioning of the cranes at the site.
Page :30 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
SDSC SHAR
12.9
Before starting the site work, the contractor shall provide insurance to
cranes parts and to all his personnel working at site in Sriharikota
against accidents/ or loss of material.
12.10
A toolbox containing all necessary tools as given in Page no. 31 are
required for the maintenance of the cranes should be from part of supply
along with the Cranes.
12.11
The transfer of title of Cranes to the purchaser/ISRO will take place only
after satisfactory erection, testing and commissioning of the cranes by
the supplier and fully acceptance by the purchaser/ISRO.
12.12
Guarantee period shall be for a period of 12 Calendar months,
commencing from the date of acceptance & taken over by the purchaser
at our site. During this period any defect noticed on design, materials,
workmanship shall be replaced/rectified by the supplier at free of any
cost.
12.13
Delivery Schedule :
12 months from the date of Purchase order.
Commissioning of EOT cranes :
For each crane 2 months from the date supply / clearance of site
readiness.
12.14
All commercial terms are mentioned in the annexure 4 of this booklet
and additional commercial terms attached by the purchase department
shall also be considered by the bidder during submission of bid.
Date : Signature of the competent Authority of Bidder with seal
Name of the company :
Address of the company :
Name of the contact person :
Contact no/ Phone / Mobile :
Fax No :
Email id :
Page :31 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
SDSC SHAR
List of Tools to be supplied along with the cranes (Ref : 12.10)
All tools shall be of standard make like M/s Snap-On/ Gedore/ AM tools/ FACOM
Sl. 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 Heavy duty single end spanners of size 55 Nos. 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
12 Calibrated steel tape of 30m length of reputed make Nos. 02
13 Suitable hydraulic jack capacity 20t., Make: VANKOS/ Holmatro : Nos. 02
10 Special tool driver kit suitable for SIEMENS Drives Nos. 01
11 Nut driver kit suitable for selected terminal blocks inside the panel Nos. 01
Page :32 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
SDSC SHAR
Annexure
LIST OF MANUFACTURERS / SPECIFIC BRANDS FOR BOUGHTOUT ITEMS
FOR FLAME PROOF EOT CRANES
1 Gear boxes : Elecon / Shanti Gears / Premium-GREAVE / Flender-Siemens/ only.
2 Wire ropes (All galvanised) : Usha Martin/ CASAR Germany/ BRIDON USA
3 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
4 Forged steel materials wheels, shafts, keys, gears
: SAIL / JINDAL / TATA STEEL / ESSAR / VIZAG-RINL / TIMKEN / Mahindra Ugine Steel (MUSCO) / BHARTH FORGE/ VIKRANTH FORGING/ KALYANI FORGING
5 Bearings : SKF, FAG, TIMKEN, INA
6 Hooks : Hercules/ IRZAR- FORJAS/ CROSBY / Shilpa Udyog/ STEEL FORGINGS
7 Couplings : FENNER
: Drum/Barrel coupling – M/s. Malmedie, Germany / M/s JAURE, Spain
8 Rails : SAIL / IISCO / JINDAL / ARCCELOR / TATA STEEL / ESSAR
9 Flame proof Panels, Light fittings, Glands, Junction Boxes etc.,
: Baliga/FCG/FEPL
10 Power & control cables : IGUS / LAPP make for cables used in cable drag chain system. Incab/ cable corpn of India, Universal/ Asian/ Finolex/ Polycab/ Lapp RPG/ HAVELLS – Pendent/ fixed power & control cables.
11 Flame proof electric motors : Kirloskar, Crompton Greaves, Bharat Bijilee , Alstom.
12 Thrusters brakes for hoist : M/S WittonKramer, M/S Pintch Bubenzer, M/S SIBRE, M/s GALVI
13 Thrusters brakes for CT & LT : M/S Electromag methods (EMM)/Kateel/Sterling Control
14 Power supply unit , Switch gears : M/S SIEMENS only
15 Limit switches : Speed-o-Control, Electromag, Sterling control
16 Contactors, Over load Relays : M/S SIEMENS only
17 Intrinsic Safe relays : P & F
18 VVVF Drive : Siemens/ABB
19 Cable chain drag system : M/S IGUS/LAPP
20 Electrical Drive Panel& Non FLP JBs
: M/S Rittal /Siemens
21 Encoder : P&F, Hengstler, Hubner, Kubler, Schnider. Hollow shaft encoder shall be planned.
22 LT Power & Control Cables : M/s. Lapp / Universal / CCI / Finolex / RPG / Uniflex.
23 Terminal Blocks : M/s. Elmex / M/s. Connectwell / M/s. Wago
24 Pushbutton switches : M/s Siemens
25 UB lights : M/s Baliga
26 Paints : Berger, Asian paints, Jenson & Nicholson, Nerolac, Dulex, Poly coat
Page :33 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
SDSC SHAR
CODES AND STANDARDS FOR FLAMEPROOF EOT CRANES
The design, manufacture and testing of the cranes shall conform to the latest editions of the following codes and standards wherever applicable:
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 Cranes Rail Sections
IS:5749 Forged Ramshorn Hooks
IS 3815/ IS 15560 Specification for point hooks with shank for general engineering purposes
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.
Page :34 TECHNICAL SPECIFICATIONS OF FLAMEPROOF 60t EOT CRANES
SDSC SHAR
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 Control gear 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 Control gear - 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 Control gear
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
IS: 325 Three Phase induction Motors.
ANSI/AWS D14.1 Structural Welding code : Code of welding practice for Mill cranes and
other material handling equipment.
36
EOT CRANES CLEARANCE DIMENSIONS
(Top running, Double Girder, Flameproof 60t EOT cranes)
Refer Annexure – 1A (Fig) for details
All Dimensions are in metre
Sl.No Facility
Name
Rated
SWL
In
tons
Span
(S) A B C F
E
(Max) G H K N M X Y
01
S200 NDT
facility,
SPP
60t 19.6 4.0m 2.0m 2.5m 0.1m 0.25m 0.15m 12.70m 12m ~ 5m ~ 6m ~2.5m ~2.5m
02
S139 NDT
facility,
SPP
60t 19.1 4.0m 2.0m 2.5m 0.1m 0.25m 0.15m 12.70m 12m ~ 5m ~ 6m ~2.5m ~2.5m
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.
2. EOT Crane span & lift are subjected minor changes which shall be accommodated by supplier during detail engineering.
3. E max : Shall be including the jacking pads.
WAY TO HIGH BAY
VVV
F R
OO
M/
EO
T C
RA
NE
DR
IVE
(AC
)
60T CRANE
PAS
SAG
E
D1
LD1
W1
W1
1700
1730
RC
D
BLO
WE
R D
UC
T (1
M X
1.6
M)
AT
4.8M
HE
IGH
T FR
OM
FFL
6000
5000
5700
2700
9050
2000
* VVVF ROOM LOCATION (S200 BAY)
Annexure - 2A
37
JUNCTION BOX(2m Above FFL)
Cable Routing from VVVF Room(Approx: FFL Level)
HIGH BAY (S200)
WAY TO HIGH BAY
D1
VV
VF R
OO
M/
EO
T CR
AN
ED
RIVE
(AC) W
1
60T CRANE
PA
SS
AGE
SD
3
LD117
30
HIGH BAY (S139)
RC
D
1200
6000
5000
3700
* VVVF ROOM LOCATION (S139 BAY)
Annexure - 2B
38
8600
2000
5650
JUNCTION BOX(2m Above FFL)
Cable Routing from VVVF Room(Approx: FFL Level)
Sche
mat
ic L
ayou
t of
VVV
F R
oom
, Ju
nctio
n Bo
x &
Cab
le R
outin
g to
Top
of
EOT
Cran
e
Elev
atio
n
Mai
nten
ance
cag
efo
r LT
Dra
gcha
in S
yste
m
Supp
ort
for
LT C
able
s dr
ag c
hain
(IG
US)
FFL
60t
EOT
Cran
e
ANN
EXU
RE
- 2C
Junc
tion
Box
(2m
abo
ve F
FL)
Cabl
e Tr
ay R
outin
g to
Top
of t
he C
rane
VVVF
RO
OM
Not
e:
1. C
able
Len
gths
sha
ll be
con
side
red
from
VVV
F Pa
nel R
oom
to
Junc
tion
box
and
Junc
tion
Box
to t
op o
f EO
T Cr
ane
as m
entio
ned
in
the
Spe
cific
atio
ns B
ookl
et
2. A
ll th
e ca
bles
rou
ting
from
pan
el r
oom
to
plug
-in p
enda
nts
and
supp
ly t
o th
e to
p of
the
EO
T cr
ane
mus
t be
don
e th
roug
h th
e pe
rfor
ated
cabl
e tr
ays
with
G.I
. coa
ted.
3. A
ll th
e ca
ble
tray
s sh
all b
e co
vere
d pr
oper
ly w
ith G
.I s
heet
s.
4. T
he c
able
tra
y sh
all h
ave
the
wid
th o
f 300
mm
.
5.Le
ngth
of
all t
he c
able
tra
ys s
hall
mee
t ab
ove
spec
ified
cab
le le
ngth
s.
6.Al
l the
cab
le le
ngth
s m
entio
ned
in t
he S
peci
ficat
ion
Book
let
are
as p
er t
he r
outin
g pr
ovis
ion
prov
ided
as
per
the
site
req
uire
men
t.
39
40
Annexure – 2 D
SCHEMATIC OF PUSH BUTTON OPERATING STATION FOR 60T EOT CRANES
Crane Motion / Requirement Selector
Switch
No. of
push
button
Indication
lamps
Hoist
Main UP
-
1
- Main DOWN 1
Creep UP 1
Creep DOWN 1
Cross Travel
Main Right
-
1
- Main Left 1
Creep Right 1
Creep Left 1
Long Travel
Main Forward
-
1
- Main Reverse 1
Creep Forward 1
Creep Reverse 1
Emergency Stop with Lockable Key - 1 -
Control ON - 1 -
Control OFF - 1 -
Control ON Indication lamp (red) - - 1
Push Button for Bell/ Hooter - 1 -
UB lights 1 - -
Note :
• Pendant hanging from crane (DSL type) with Stainless steel chain. • Pendant enclosure shall be with stainless steel only.
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANES
Annexure - 3
41
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
P
erf
orm
ed
W
itn
ess
ed
Ve
rifi
ed
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 on plates with heat number & lot number
such that it is visible after crane assembly for verification.
Component Gr.
B Specs./ IS
2062/ IS1570/ BS
970
Stamping on
parts &
Identification
record 1 - -
All materials shall be Identified by
Third
Party Agency / ISRO (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
(with lot no. &
heat no.)
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 / ISRO
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, MPT
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.
Legend 1 Third Party Inspection Agency Place Signature of Crane Vendor
2 Vendor (Crane Supplier) Date: with Designation
3 Sub Vendor / Item Supplier
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANES
Annexure - 3
42
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
Pe
rfo
rme
d
Wit
ne
sse
d
Ve
rifi
ed
A B C D E F G H I J K 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 Material composition/
Mechanical Properties
UTS, YS, % elongation
Major T.C. Correlation One per
heat Spec/drawing/
ASTSM A106/
IS 2062
Spec/drawing/
ASTSM A106/
IS 2062
Material T. C. /
Supplier’s Test
Report
3
-
2, 1
Reports / TC / pressure test
reports review by TPIA
2.1 ROPE DRUM joint
Welding 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
Legend 1 Third Party Inspection Agency Place Signature of Crane Vendor
2 Vendor (Crane Supplier) Date: with Designation
3 Sub Vendor / Item Supplier
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANES
Annexure - 3
43
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
Pe
rfo
rme
d
Wit
ne
sse
d
Ve
rifi
ed
A B C D E F G H I J K 3.0
Gear box Housings
Fabricated
Material composition/
Mechanical Properties
UTS, YS, % elongation
Major T.C. Correlation One per
heat Spec/drawing/
IS 2062 Spec/drawing/
IS 2062 Material T. C.
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
Measured dimensions shall be
marked on drawings.
5 MECHANICAL COMPONENTS – GEAR BOXES 5.1 Hoist, CT & LT Input
shafts, Gears , Pinions,
keys, spacers (for all
gearboxes)
Material composition/
Mechanical properties
Hardness value / UT /
MPT/ DPT of materials
Major Correlation with
Mfr’s TC 100% Specification
IS:1570 / BS 970
/ IS:2048
Component
drawing/ IS2048
Specification/
IS:1570 / BS 970
Mfr's TC/
Supplier's IR
2
-
1
1) 100% UT volumetric test for
wrought or forged materials as
per ASTME 114 and A388.
2) 100% 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.
Legend 1 Third Party Inspection Agency Place Signature of Crane Vendor
2 Vendor (Crane Supplier) Date: with Designation
3 Sub Vendor / Item Supplier
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANES
Annexure - 3
44
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
Pe
rfo
rme
d
Wit
ne
sse
d
Ve
rifi
ed
A B C D E F G H I J K 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
3, 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
3,2
1
-
No Load Test shall be witnessed
by TPIA. Noise level of gearboxes
shall be ≤ 75dBA. Temperature rise
shall be as per gearbox manufacturer
standard.
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
100% UT of wrought and forged
materials as per ASTM
100% DPT or MPT
5.2.2 Machining of LT & CT
Shafts, and Keyways &
Keys ( Dimensional
measurement)
Straightness &
Dimensional conformity
Checks & Inspection of
Key ways.
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
Mfr's TC/
Supplier's IR
3, 2
-
1
Keys & keyways shall be inspected by
TPIA before assembly.
UT of wrought and forged materials
as per ASTM
Legend 1 Third Party Inspection Agency Place Signature of Crane Vendor
2 Vendor (Crane Supplier) Date: with Designation
3 Sub Vendor / Item Supplier
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANES
Annexure - 3
45
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
Pe
rfo
rme
d
Wit
ne
sse
d
Ve
rifi
ed
A B C D E F G H I J K 5.4 Plummer blocks &
bases PB & bearing sizes/
Material composition/
Mechanical properties
dimensional
inspection
Major Correlation with
Mfr’s TC 100% Approved
drawing/
Specification
Approved
drawing/
Specification/
Mfr's TC/
Supplier's IR
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 /
Major Correlation with
Mfr’s TC 100% Approved
drawing / Tech.
Specification
IS:1570/BS970
Approved
drawing / Tech.
Specification
IS:1570/BS970
Mfr's TC/ Test
reports/
Supplier's IR
3, 2
-
1
Review of Test certificates by TPIA and
issue Compliance certificate.
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
Approved
drawing / Tech.
Specification
IS:1570/BS970
Mfr's TC/ Test
reports/
Supplier's IR
3,2
-
1
Measured Dimensions shall be marked
on each Component drawings with
allowed dimensional variations.
5.7 Pulleys with Roller Bearings
5.7.1 a) Material (Forged Steel ) Material composition/
Mechanical properties
Hardness of material /
UT & DPT / MPT
Major Correlation with
Mfr’s TC 100% Approved
drawing / Tech.
Specification
IS:1570/BS970
Approved
drawing / Tech.
Specification
IS:1570/BS970
Mfr's TC/ Test
reports/
Supplier's IR
3, 2
-
1
Review of Test certificates by TPIA and
issue Compliance certificate.
Legend 1 Third Party Inspection Agency Place Signature of Crane Vendor
2 Vendor (Crane Supplier) Date: with Designation
3 Sub Vendor / Item Supplier
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANES
Annexure - 3
46
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
Pe
rfo
rme
d
Wit
ne
sse
d
Ve
rifi
ed
A B C D E F G H I J K 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
Measured Dimensions shall be marked
on each Component drawings with
allowed dimensional variations.
5.8 Snatch block Cross
head Material composition/
Mechanical properties
Dimensional
inspection/ 100% UT &
MPT
Major Correlation with
Mfr’s TC /
Measurement
100% Approved
drawing / Tech.
Specification
IS:1570/BS970
Approved
drawing / Tech.
Specification
IS:1570/BS970
ASTM
Mfr's TC/ Test
reports/
Supplier's IR
UT reports 3,2 - 1
Measured Dimensions shall be marked
on each Component drawings with
allowed dimensional variations.
5.9 Snatch block assembly Dimensional Conformity
Bill of materials 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 as per specifications.
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
Mfr's TC/ Test
reports/
Supplier's IR 3,2
-
1
Measured Dimensions shall be marked
on each Component drawings with
allowed dimensional variations.
5.12
Dimensions/ static and
Dynamic balancing/ Key
way and key inspection.
Major Balancing test/
Measurement
with vernier /
micrometer
100% Component
drawing /
Specification
Component
drawing /
Specification
Mfr's TC
3,2 - 1
1. Dynamic balance report shall be
reviewed by TPIA.
2. Measured Dimensions shall be
marked on each Component drawings
with allowed dimensional variations.
Legend 1 Third Party Inspection Agency Place Signature of Crane Vendor
2 Vendor (Crane Supplier) Date: with Designation
3 Sub Vendor / Item Supplier
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANES
Annexure - 3
47
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No
Components/
Operations
Characteristic
to be checked
Category
Type /
Method of
check
Extent
of
check
Ref. Document
Acceptance
Norm
Format of
record
Agency
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A B C D E F G H I J K 6 BOUGHT-OUT & Other items
6.1
Wire Rope
Dimensional, Genuine
of make, Lay, core and
stands, Tensile grade
Major Mfr's TC /
measurement 100% Component
drawing/ BOM/
IS 2266
Component
drawing / BOM /
IS 2266
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
Major Correlation with
Mfr’s TC /
Measurement
100% Approved comp.
drawing / Tech.
Specification /IS
Approved comp.
drawing / Tech.
Specification
IS:1570/IS3640
Mfr's TC/ Test
reports/
Supplier's IR
3,2
-
1
Measured Dimensions shall be marked
on each Component drawings with
allowed dimensional variations.
6.4 FASTENERS (Bolts, nuts,
washers, lock nuts) Type / Genuine make
conformity /
measurement Major Mfr's TC/
Invoice 100% Approved make
and type TVS/UNBRAKO Mfg TC/
Supplier IR
2
-
1 Consolidated list of size fasteners
with (strength class and make shall
be submitted)
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
Legend 1 Third Party Inspection Agency Place Signature of Crane Vendor
2 Vendor (Crane Supplier) Date: with Designation
3 Sub Vendor / Item Supplier
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANES
Annexure - 3
48
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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 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 Assembly
/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/
Alignment values. Legend 1 Third Party Inspection Agency Place Signature of Crane Vendor
2 Vendor (Crane Supplier) Date: with Designation
3 Sub Vendor / Item Supplier
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANES
Annexure - 3
49
Sl.
No
Components/
Operations
Characteristic
to be checked
Category
Type /
Method of
check
Extent
of
check
Ref. Document
Acceptance
Norm
Format of
record
Agency
Remark
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A B C D E F G H I J K
9 H LOAD TESTING AT WORKS (HOLD)
9.1 NO LOAD TEST
(MH , 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 Supplier's IR &
Load test
Format
2
1
-
Deflection < Span/1000 . Record
procedure of test & measurement
with sketch.
9.2.2 Hoist With Safe Working
Load Performance, duty cycle,
Speeds, Current, , Safety
systems etc.,
Major Full Load test/
Measurement
of parameters
100% Approved dwg /
IS807/ IS 3177
/Specification
Approved dwg /
IS807/ IS 3177
/Specification
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 Performance, duty cycle,
Speeds, Current, , Safety
systems etc.,
Major Full Load test/
Measurement
of parameters
100% Approved dwg /
IS807/ IS 3177
/Specification
Approved dwg /
IS807/ IS 3177
/Specification
Load test
report
/Supplier's IR
2
1
-
Measure Gear Box Noise. (Noise
Level should be <80dBA) .
9.2.4 OVER LOAD (125% SWL)
TEST
(Hoist & CT)
Static test/ Capability of
all motions/ Permanent
set
Major Capability of CT
&Hoist motion/
Measurement
100% Approved dwg /
IS807/ IS 3177
/Specification
Approved dwg /
IS807/ IS 3177
/Specification
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 Photographs of finished metal shall
form part of inspection report.
10.2
Primer Coat Painting DFT Thickness/ visual
inspection Major Measurement
in µm / Visual Random Specification /
DFT ≥80µm Specification /
DFT ≥80 µm Supplier's IR
2
-
1 Paint thickness shall be measured
with paint thickness gauge/
elcometer.
Legend 1 Third Party Inspection Agency Place Signature of Crane Vendor
2 Vendor (Crane Supplier) Date: with Designation
3 Sub Vendor / Item Supplier
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANES
Annexure - 3
50
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 10.3 Epoxy paint Painting
(Two coats of 80 µm &
40 µm)
DFT Thickness/ visual
inspection Major Measurement/
Visual Random Specification /
DFT ≥200 µm Specification /
DFT ≥200 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, 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).
12.2 DEFLECTION TEST
With Safe Working Load Deflection Major Measurement
as per approved
procedure.
100% Specifications/
IS807/ IS 3177 Specifications/
IS807/ IS 3177 Supplier's IR &
Load test
Format
2
1
-
Deflection < Span/1000 . Record
procedure of test & measurement with
sketch.
12.3 Main Hoist With Safe
Working
Load Performance, duty cycle,
Speeds, Current, , Safety
systems etc.,
Major Full Load test/
Measurement
of parameters
100% Approved dwg /
IS807/ IS 3177
/Specification
Approved dwg /
IS807/ IS 3177
/Specification
Load test
report
/Supplier's IR
2
1
-
Measure Gear Box Noise. (Noise Level
should be <80dBA) .
12.4 CT Mechanism With Safe
Working Load Performance, duty cycle,
Speeds, Current, , Safety
systems etc.,
Major Full Load test/
Measurement
of parameters
100% Approved dwg /
IS807/ IS 3177
/Specification
Approved dwg /
IS807/ IS 3177
/Specification
Load test
report
/Supplier's IR
2
1
-
Measure Gear Box Noise. (Noise Level
should be <80dBA) .
Legend 1 Third Party Inspection Agency Place Signature of Crane Vendor
2 Vendor (Crane Supplier) Date: with Designation
3 Sub Vendor / Item Supplier
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANES
Annexure - 3
51
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 12.5 LT Mechanism With
Safe Working Load Performance, duty cycle,
Speeds, Current, , Safety
systems etc.,
Major Full Load test/
Measurement
of parameters
100% Approved dwg /
IS807/ IS 3177
/Specification
Approved dwg /
IS807/ IS 3177
/Specification
Load test
report
/Supplier's IR
2
1
- Measure Gear Box Noise. (Noise Level
should be <80dBA) .
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
Load test
report
/Supplier's IR
2
1
-
12.7 OVER LOAD (125%
SWL)
TEST (MH, CT and
LT motions)
Static test/ Capability of
all motions/ Permanent
set
Major Capability of CT
&Hoist motion/
Measurement
100% Approved dwg /
IS807/ IS 3177
/Specification
Approved dwg /
IS807/ IS 3177
/Specification
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 / ISRO
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
-
Legend 1 Third Party Inspection Agency Place Signature of Crane Vendor
2 Vendor (Crane Supplier) Date: with Designation
3 Sub Vendor / Item Supplier
Page 52
ANNEXURE – 4
COMMERCIAL TERMS AND CONDITIONS OF THE CONTRACT
Proposals are invited from the interested Bidders for the enclosed scope of work in
Two part bid.
• Part-1 Technical and Unpriced part of the work and
• Part-2 Priced Commercial bid.
1. TECHNICAL SPECIFICATIONS CUM COMPLIANCE STATEMENT
1.1 Overall technical specifications and functional requirements are detailed in
Specifications document. Bidder shall fill all the confirmations, print, sign and
stamp each page of document as token of acceptance & submit scan copy of the
same along with the offer.
1.2 The specifications document shall be completely filled in all respects and submitted
together with requisite information and Annexure. Any offer incomplete in any
particulars is liable to be rejected.
1.3 The tender shall be opened on the date and at the time, specified in the Letter
Inviting Bid. Quotations not received in time shall not be considered.
1.4 Bidder shall set their quotations in firm figures and without deviations or variations
or additions in the terms of the specifications cum compliance document. Proposal
containing qualifying expressions such as "subject to minimum acceptance” or
"subject to prior sale" or any other qualifying expressions or incorporating terms
and conditions at variance with the terms and conditions incorporated in the
quotations are liable to be rejected.
2. PREPARATION OF BIDS
2.1 VALIDITY OF OFFER: Bid shall remain valid for a period of 4 (four) months for
60t cranes (02nos.) from the due date of submission of the Bid. The Bidder shall
not be entitled during the said period to revoke or cancel his Bid or to vary the Bid
except and to the extent required by Purchaser and communicated in writing. Bid
shall be revalidated for extended period as required by Purchaser in writing. In
such cases, unless otherwise specified, it is understood that validity is sought and
provided without varying either the quoted price or any other terms and conditions
of Bid finalized till that time.
2.2 COST OF BIDDING: All direct and indirect costs associated with the preparation
and submission of Bid (including clarification meetings and site visit, if any), shall
be to Bidder's account and the Purchaser will in no case be responsible or liable for
those costs, regardless of the conduct or outcome of the Bid process.
2.3 SCHEDULE OF PRICES:
• Prices quoted should be on the basis of FOR Sriharikota.
• The schedule of prices shall be read in conjunction with all the sections of
proposal document. The prices quoted by the Bidder shall be firm and
fixed till the completion of the work. The price shall be filled in the
price format available in e-procurement portal only.
2.4 DOCUMENTS COMPRISING THE BID
2.4.1 PART – I: TECHNICAL AND UNPRICED COMMERCIAL PART
Technical and un-priced commercial part comprising the following
information shall be uploaded in e-procurement portal.
a. Copy of Bid Qualification Criteria document along with set of documents
& certificates as per bid qualification document duly filled, signed &
stamped on each page of document.
Page 53
b. Copy of duly filled, signed & stamped on each page of the document
“Technical Specifications cum Compliance Statement”.
c. Copy of Company’s registration certificate.
d. Scan copy of Power of attorney in favour of authorized signatory of the
bid / proposal documents.
e. All annexures of the bid shall be duly filled and signed & stamped on
each page.
f. Clearance diagram for EOT Cranes mentioning overall dimensions and
approaches.
2.4.2 PART – II: PRICE BID
Priced commercial bid shall contain schedule of prices, percentage of
GST and other taxes, if any, shall be filled in ISRO e-procurement portal
only. No deviations to terms and conditions, assumptions, discounts etc.
shall be stipulated in price bid. Purchaser will not take cognizance of any
such statement and may at their discretion reject such bids.
2.5 BID SUBMISSION
2.5.1 Bid shall be submitted in two parts
Part 1: Techno-commercial part of the bid
Part 2: Priced part of the bid
2.5.2 Offer should be submitted online using standard digital signature of
class -3 with encryption/decryption options.
2.5.3 The tenders authorized online on or before the open authorization date
and time will only be considered as valid tenders.
2.5.4 Prices shall be mentioned in the space/column provided in the ISRO
e-procurement portal only.
2.5.5 Prices shall not be uploaded along with technical specifications in any
form. If so, such bids will not be considered.
2.5.6 Prices quoted should be on the basis of FOR Sriharikota.
2.5.7 The Purchaser will not pay separately for transit insurance and same shall
be included in the cost quoted by the Bidder.
2.5.8 All risks in transit shall be exclusively borne the contractor and the
Purchaser shall pay only for such items that are actually received in good
condition in accordance with the purchase order.
2.5.9 Bids duly filled in by the Bidder should be submitted as stipulated in the
e-procurement portal.
2.5.10 Purchaser will open Part – I of the bid on the due date of opening. Price
Bid (Part-II) of the bids which are technically and commercially
acceptable shall be opened at a later date with prior intimation to all
qualified bidders.
2.5.11 Purchaser reserves the right to reject any or all the Bids without assigning
any reasons thereof.
3. MODE OF PAYMENT
All the payments due to Bidder shall be made through RTGS/ NEFT. Bidder
shall submit the banker details and payments can also be made through Electronic
Clearance System (ECS).
4. TERMS OF PAYMENTS
The Payment terms are proposed as follows: As the EOT Cranes are
involved with site erection & commissioning also along with supply.
Page 54
• Our standard payment terms is 90% of supply value plus taxes applicable including
transportation charges and packing & forwarding within 30 days after receipt,
acceptance of systems and after CLIP inspection at our site
SDSC SHAR on pro-rata basis against supply of each EOT Crane / Hoist.
• And remaining 10% of supply value and 100% erection and commissioning
charges along with taxes as applicable, TPIA charges etc will be paid within 30 days
after successful commissioning and handing over of the EOT Crane and sub systems
at SDSC SHAR on submission of Performance Bank Guarantee (PBG) (Valid upto
warranty period) on pro-rata basis against supply of each EOT Crane / Hoist.
• However advance payment 20% of supply value can be paid against submission of
equivalent bank guarantee.
5. DELIVERY SCHEDULE :
6. Bidder shall follow the following schedule for executing the contract
S.No Mile Stone
Expected date of
completion
60t cranes (02nos.)
1 Purchase order date T - (A)
2 Submission GA drawings, sizing and structural
calculations for approval. T+1month– (B)
3 Supply of EOT all Cranes T+12months-(C)
4 Erection and Commission and Testing for each EOT
Crane
C+2month from the
site clearance
Note: Readiness of the site shall be obtained from the indenter before
commencement of the erection work.
7. PROJECT EXECUTION AND MONITORING
Upon placement of purchase order, bidder shall prepare a detailed programme
schedule for review/approval by Purchaser. Bidder shall identify a project team with
one senior official as a project leader. Bidder shall submit the project status report
every 15 days giving the status of various activities w.r.t. planned schedule for
realization of EOT cranes. Bidder shall depute their Project team/ engineers for
monthly meeting to review the status and discuss/ resolve minor issues related to
project execution at SDSC SHAR/ bidder’s site based on mutual agreement on mutually
agreeable dates.
8. LIQUIDATED DAMAGES AND EARNEST MONEY DEPOSIT
7.1 LIQUIDATED DAMAGES:
In the event of the Bidder failing to complete the work within the delivery
period specified in the contract agreement or any extension agreed thereto, the
Purchaser shall reserve the right to recover from the Bidder as liquidated damages,
a sum of 0.5 percentage per week or part thereof of the undelivered portion of the
total contract price of equipment or work. The Total liquidated damages shall not
exceed 10.0 percentage of the total Contract price.
9. PERFORMANCE BANK GUARANTEE
The bidder shall guarantee for the performance of the contract by providing bank
guarantee in favour of the Purchaser for an amount equivalent to 10 %( ten percent)
of the total value of this contract valid till the warranty period of the contract with a
claim period of 60days. The performance bank guarantee shall be submitted by the
Page 55
bidder with in fifteen days from the date of accepting the equipment by the Purchaser
as per the CONTRACT. The format for the performance bank guarantee shall be
obtained from Purchaser.
10. CUSTOMS DUTY As per Notification No.5/2018-Customs dated 25.01.2018, S.No: 539(A) ISRO will
provide Customs duty exemption certificate for import items. Accordingly minimum 5%
customs duty and 5% IGST will be applicable on import items. To avail the above, the
bidder shall provide the list of imported items with quantity if any along with technical
bid without indicating prices, as this being a two part bid.
11. PACKING AND FORWARDING
• The Bidder shall arrange to have all the material suitably packed as per the
standards & statutes and as specified in the contract. Unless otherwise provided
for in the contract, all containers (including packing cases, boxes, tins, drums,
and wrappings) used by the Bidder shall be non-returnable.
• All packing and transport charges, transit handling costs, transit risk coverage
and transportation charges of agents employed at the place of delivery or
elsewhere, shall be deemed included in the price to be paid to the Bidder.
12. WARRANTY
The bidder shall provide twelve months warranty for the entire EOT Crane
system from the date of commissioning & fully acceptance of EOT Crane against design
& manufacturing defects, poor quality, poor workman ship, etc. During this period
bidder has to provide and adhere to the following:
• Goods covered by the contract shall be free from defects in design, materials or
workmanship for a period of twelve months from the date of successful
commissioning & acceptance by Purchaser.
• This period shall include maintenance, replacement of defective/ failed parts at
free of cost.
• Bidder has to attend unlimited breakdown calls at free of cost.
13. SAFETY Bidder shall follow the safety regulations / codes or safety instructions issued by
PURCHASER and shall take necessary measures at his own cost.
14. POWER SUPPLY
Electrical power provided by the Purchaser during installation of EOT cranes is NOT
chargeable. Reasonable quality of normal power will be made available at one point
(415V, 3 phase, 50 Hz). However, onward distribution shall be done by the bidder. All
electrical installation by the bidder shall be as per safety regulation & standard and will
be subjected to Purchaser inspection & approval.
15. WORK RULES
Generally, No work shall be carried out during night or public holidays unless a
written permission is obtained from Purchaser.
16. ACCOMMODATION • Very limited accommodation may be provided by Purchaser to senior supervisory
staff of the Bidder on chargeable basis subject to availability.
• Bidder shall make his own arrangement for accommodation & canteen facility for
all its staff, technicians, labour & workers. Transportation shall be arranged by
Bidder at his own expenses for his entire staff till the completion of the project.