technical specification for 30/5 te e.o.t. crane · testing of the crane at supplier’s works as...

Document No. NRB/E&P/EOT-1/6/2017 of 40

TECHNICAL SPECIFICATION

FOR

30/5 Te E.O.T. CRANE


INDEX

Sr. No. Description Page No.

1.0 Introduction 3

2.0 Scope of work 3

3.0 Technical Requirements 3

4.0 Quantity 3

5.0 Commercial bid & validity of the offers 3

6.0 Qualification criteria for the bidders 3

7.0 Documents to be submitted along with technical bid 3

8.0 General note to the supplier 4

9.0 Shipment and consignee 4

10.0 Delivery schedule 4

Annexure

Annexure I Technical Specifications for EOT Crane 5

Annexure II Design, Drawing, Documentation & Guarantee 16

Annexure III Fabrication, Inspection, & Testing 18

Annexure IV Installation & Commissioning 21

Annexure V Information Regarding Construction of the Crane 22

Annexure VI Bidder Evaluation Form 32

Annexure VII Preferred makes 36

Annexure-VIII “Quality Assurance Plan” to be followed 37

Diagram Clearance Diagram for 30/5 Te EOT Crane 41


1.0 Introduction:

Double girder type 30/5 Te capacity E.O.T. crane conforming to IS-3177 & other applicable standards as

mentioned in ‘Annexure–I’ and meeting technical specifications of this tender is required for handling

heavy equipment, RCC plugs, different components etc. in various areas of a project/plant at Tarapur.

2.0 Scope of work:

The scope of work include design, preparation of detail manufacturing drawings, procurement of materials,

manufacturing, assembly, inspection & testing at supplier’s works, packing and safe door delivery, erection

& commissioning at purchaser’s site of 30/5 Te EOT crane as detailed in clause no. 2 of Annexure-I,

annexed with this document.

3.0 Technical requirement:

Please refer Annexure-I to Annexure-III, annexed with this document.

4.0 Quantity: One No.

5.0 Validity of the offers:

Techno-commercial bid shall be submitted as per instructions of Directorate of Purchase & Stores. The

offer shall be valid for minimum 90 days from opening of the tender.

6.0 Qualification criteria for the bidders:

6.1 The offers from manufacturers will only be accepted.

6.2 The manufacturer should have experience in manufacturing, supply, installation and commissioning of

EOT crane of min. 20 Tonne capacity in last five years.

6.3 The bidder shall have supplied minimum three (3) nos. of EOT cranes in last five (5) years

(supporting documents to be submitted along with bid).

6.4 The manufacturer shall have in-house testing facilities to carry out all inspection & testing mentioned in

Annexure-III (Fabrication, Inspection & Testing) of this document.

6.5 The bidder shall have organizational structure with respect to design, drafting, engineering

planning, procurement, manufacturing/production and quality assurance.

6.6 The annual turner over of the bidder for last three financial years shall not be less than 1.85 Crores.

6.7 All documents/certificates mentioned below in clause no. 7.0 shall be submitted along with the bid.

7.0 Documents to be submitted/uploaded along with tender:

Following documents shall be uploaded along with bid:

7.1 Annexure-VI: “Information regarding construction of the crane” duly filled and certified.

7.2 Annexure-VII: “Bidder Evaluation Form” duly filled and certified.


7.3 Copies of purchase/work orders and completion certificate of supplying at least 3 nos. of cranes

(including one of them of 20 Tonne capacity) in last five years.

7.4 Details of major orders executed by the firm for similar supplies in past five years including orders of DAE/

PSU or other reputed firms. Details of order should contain name of purchaser, type & rating of cranes

supplied, P.O. no. & date, stipulated delivery period, actual delivery period, date of completion including

installation & commissioning. and purchaser’s contact details for reference,

7.5 List of manufacturing facilities available in-house with the manufacturer.

7.6 List of testing facilities available in-house with the manufacturer.

7.7 An organisation chart.

7.8 Copy of QA Plan duly approved by the purchaser/TPI for similar orders executed in recent past.

7.9 Copy of audited balance sheet and profit & loss account for previous three (3) years

7.10 List of deviations from this specification, if any, stating the clause of Specification & Deviation.

In case, there is no deviation, a statement to that effect shall be submitted/uploaded with the offer.

In the absence of above documents/certificates, it will be presumed that offers does not meet the

“qualification criteria for the bidders” as mentioned in technical specifications and liable for

rejection without further correspondence.

8.0 General notes to the supplier:

8.1 Material shall be offered strictly conforming to the technical specification of this tender. Deviations, if any,

should be clearly indicated by the supplier in their quotation.

8.2 Any technical and commercial questions, information, clarifications, etc. that may be required pertaining to

this tender may be obtained from the Purchaser before submitting the tender or during pre-bid meeting.

8.3 Evaluation of bidders will be carried out, if required.

9.0 Shipment & Consignee:

9.1 All the material shall be delivered to Assistant Stores Officer, TWMP, BARC Facility, Tarapur,

P.O. Ghivali, Boisar, Dist.-Palghar, Maharashtra, PIN 401502 only after obtaining a shipping

release from the purchaser or his authorized representative.

9.2 The supplier shall be fully responsible for protective measures to ensure the safe delivery of the materials.

9.3 Material received with any short of physical damage, distortion etc. will be summarily rejected.

10.0 Delivery, Installation & Commissioning Schedule:

All the material shall be delivered within 12 months from date of placement of purchase order. Installation

and commissioning of the complete crane shall be completed at site within 4 months from the delivery date

or site clearance from the purchaser, whichever is later.


ANNEXURE-I

TECHNICAL SPECIFICATION FOR EOT CRANE

1 . I N TR O D U C T I ON:

EOT crane is required for handling heavy plugs, equipment/components in various area of the project/plant during construction, operation and maintenance. The crane shall be reliable, trouble free and maintainable.

2 . S C O P E O F T H E W O R K

2.1. The scope of work for supplier includes design, manufacture, testing, supply, and installation and commissioning of 30/5 Te capacity EOT crane (01 No.) in Cell Top area of the project at Tarapur.

2.2. Design of LT, CT, Hoisting drive assemblies and its components; bridge and trolley structure; cable take up for LT and CT; Lifting tackles for engagement and lifting of CT (crab) & LT drive, control panel, wiring system including connectors, assemblies.

2.3. Preparation / submission of detailed manufacturing drawings along with design calculations for purchaser's approval.

2.4. Preparation / submission of detailed Q.A. program for purchaser’s approval.

2.5. Procurement of all materials in accordance with the material specifications as given in the approved drawings and in tender specification.

2.6. Submission of test certificates from govt. approved agency/NABL accredited laboratories for all raw materials and standard bought out components procured for manufacturing the crane as and when required.

2.7. Obtaining approval of the purchaser for any materials used or intended to be used as alternative to the specified materials.

2.8. Manufacture of the components as per approved drawings.

2.9. Preparation of inspection reports of all components and subassemblies at the appropriate stage during fabrication as per approved QAP. Submission of these reports to the purchaser as and when required during the execution of the contract for verification and records.

2.10. Obtaining approval of any deviations in design with necessary reasons for the same from purchaser.

2.11. Offering the components, subassemblies and assembly of full equipment for inspection to purchaser’s representative as and when required by him to do so during the execution of the contract.


2.12. Carrying out any necessary modifications or improvements until satisfactory performance of the crane for which it is intended. Such modifications shall be carried out by the contractor at free of cost if they are required for reasons arising from poor designs, bad-workmanship or non-conformity to the specifications.

2.13. Testing of the crane at supplier’s works as per approved procedure.

2.14. Packing and safe crating of the equipment so as to avoid any damage during handling, transportation and storage before installation.

2.15. Delivery of the equipment to site.

2.16. Erection / installation, load Testing and Commissioning of the crane at site as per approved procedure.

2.17. Incorporating the as built changes in the manufacturing drawings and submission of as built drawings (reproducible prints) in soft as well as hard copy.

2.18. Submission of bound copies of the documents (3 sets) consists of Q.A. documents, all test reports, operation and maintenance manual, design report, catalogues of bought out items and as built drawings.

3 . TEC HN I C A L DATA F OR EO T C R A N E

3.1 GENERAL:

3.1.1 Type of Crane Double girder EOT crane

3.1.2 Duty of the crane Class M5 as per latest IS: 3177

3.1.3 Type of service In-door

3.1.4 Safe working hoisting load in addition to dead weight for a) Main Hoist

b) Aux. Hoist

30 Te

5 Te

3.1.5 Atmospheric condition Normal atmosphere with high humidity

3.1.6 Weight Details: a) Crane weight b) Crab weight

To be furnished by Supplier

To be furnished by Supplier

3.2 OPERATING SPEEDS (at rated load)

3.2.1 Long travel motion (L.T.) 10 meters/min

3.2.2 Cross travel motion (C.T.) 6 meters/min

3.2.3 Hoisting motion for a) Main Hoist

b) Auxiliary Hoist

3 meters/min

8 meters/min

3.2.4 All motions namely Main & Aux. Hoist, L.T. & C.T. shall be achieved with three speeds 10%, 50% and main speed i.e. 100% speed using VVVF (Variable Voltage Variable Frequency) controlled drives.


3.3 CRANE PERFORMANCE AND STRUCTURAL DETAILS:

3.3.1 Crane clearance diagram Refer Drg. No.

AVS-A/10012222/DWG/001/R0

3.3.2 Span 18010 mm **

Total lift required for Main and Aux. hoist.

a) Above floor (L)

b) Below floor (if any)

19750 mm

Nil

3.3.3 Distance between the bottom of the LT crane gantry beam to the bottom of top RCC slab (Head room available) (A)

To be finalized during detailed design.

3.3.4 Minimum clearance required from topmost point of crane to lowest obstruction of roof / civil structure. (T1)

Min. 200 mm

3.3.5. Minimum clearance required from working platform (LT) above the crane to lowest obstruction of roof / civil structure. (T2)

Min. 2000 mm

3.3.6 Distance between the centerline of the crane rail to the adjoining wall (H+100 Min.)

275 mm (on both the sides)

3.3.7 Distance of transverse approach for Main Hoist from L.T. rail (C)

2000 mm ( Minimum possible is desired)

3.3.8 Distance of transverse approach for Main Hoist from L.T. rail (D)

1500 mm ( Minimum possible is desired)

3.3.9 Distance of transverse approach for Aux. Hoist from L.T. rail (C+N1)

2000 + N1 mm

3.3.10 Distance of transverse approach for Aux. Hoist from L.T. rail (D-N1)

1500 - N1 mm

3.3.11 Distance of L.T. approach for Main Hoist from wall (X)

2000 mm (Minimum possible is desired)

3.3.12 Distance of L.T. approach for Main Hoist from wall. (Y)

1500 mm (Minimum possible is desired)

3.3.13 Distance between main and aux. hooks in Vertical direction (E)

(To be furnished by supplier)

3.3.14 Height of Lift

a. MH (L)

b. AH (L+E)

19750 mm

To be furnished by supplier

3.3.15 Distance between civil bracket to lowest obstruction of roof / civil structure (B)

3700 mm

3.3.16 Distance between LT rail top to lowest obstruction of roof / civil structure (R)

To be finalized during detailed design.

3.3.17 Distance between main girder to lowest obstruction of roof / civil structure (G)



3.3.18 Distance between main and aux. hooks in transverse direction (N1)


3.3.19 Distance between main and aux. hooks in longitudinal direction (N2)


3.3.20 LT wheel base (J) To be furnished by supplier

3.3.21 CT wheel base (Q) To be furnished by supplier

3.3.22 Clear distance between electrical panel to main girder on LT platform

500 (min.)

3.3.23 Fixing arrangement for down shop leads (for long travel)

They shall be at a spacing of about 2 meters.

3.3.24 Fixing of crane rails to the runway girder (structural steel beam)

The crane rails shall be suitably fixed at a spacing of about 500 mm (Maximum) staggered.

3.3.25 Bay length 35300 mm (Approx.) **

3.3.26 Operation of crane Through push button pendent operating from floor / cabin operated /

Additionally, through radio remote pendent as per facility requirement.

** The supplier shall measure as built dimensions of building prior to starting the fabrication of crane.

4 . MA T ER I A L O F C ON S TRUC T I ON :

All materials used shall be of industrially proven and sound quality. It shall conform to latest relevant standards as given below:

a) Steel Plates : IS-2062 Grade E250 quality ‘BR’ b) High Tensile Bolts : BS-970 (EN-24) or IS equivalent c) Hooks and Clevises : 20Mn2 & IPSS or IS-1875 Class 3A d) Steel Pinions : BS-970 (EN-24) or IS equivalent e) Steel Shafts and Axles : BS-970 (EN-8 or 9) or IS equivalent f) Pins and Screws : BS-970 (EN-8) or IS equivalent g) Steel Castings : IS-1030 (Gr-II) h) Steel Forgings : IS-2004, Class III i) Hoisting rope : IS-2266 j) Rails for L.T. & C.T. : IS-3443, 50C12 k) Wheels : BS-970 (En-9) forged l) Seamless pipe : ASTM A-106 Gr. A/B

5 . D E S I G N R EQ U I R E M E N T S :

The crane shall be designed as per latest standards IS-807 & IS-3177. The crane shall be designed for Class-M5 duty (In-door service) double / single girder type. The crane structure / components shall be rigid and have adequate margins to give excellent performance, safety arrangements for preventing overloading, over stressing on motors and shafts. The crane shall be provided with easy maintenance facilities like platform with chequered plates and with suitable walk ways and hand railings for easy approach of the crane components. All efforts shall be made to make the


crane as compact as possible. The compactness of the crane and availability of various crane reaches is the most important criteria for design of the crane.

5.1. MECHANICAL DESIGN REQUIREMENTS:

5.1.1. CRANE BRIDGES AND TROLLEYS: The end carriages of the bridge and trolley shall be provided with suitable jacking pads for easy maintenance of the wheel bearings, axles etc. Wheel mountings shall include safety lugs to prevent a drop of more than 2.5 cm. in case of broken axles. The end carriage shall be designed so as to ensure that the crane remains square and prevent skewness. Bridge & Trolley shall be provided with suitable service platforms. The minimum clearance above service platform shall be 1800mm. The platforms shall be surrounded by suitable hand railings to facilitate easy access and maintenance of equipment placed on the trolley and bridge. Mechanical end stoppers shall be provided for effectively arresting the motion of bridge and trolley. They should be fitted rigidly on the gantry beams for the Crane Bridge and on the bridge girder for the trolley at all the Four Corners. Mechanical wheel stoppers are also desired for LT & CT for additional safety.

5.1.2. GEAR BOX, GEARS, SHAFTS AND AXLES: In order to ensure smooth operation and long life of gear train, all gear transmission shall be achieved from accurately formed machine-cut helical gears at each stage. The HP rating of gear box for individual motion shall be greater than mechanical KW of the motor selected for that motion. The gear boxes for all motions (MH, AH, CT & LT) shall be of standard gearboxes of SEW, ELECON make or equivalent. The supplier shall furnish necessary catalogue for gear box selection with all technical details. The design calculation for hp rating of gear box shall be checked as per IS-4460. Gears shall be of forged steel with teeth cut from the solid blanks. Gears train with ground teeth will be preferred. Pinions shall be of steel forging. All gear boxes shall be suitably oil lubricated. All shafts and axles shall be turned from forged steel bars. All axles shall be held rigidly in position by arresting plates and shall be designed for easy removal. Open gear transmission shall not be allowed. All gear, pinions, shaft, couplings etc. for individual drive mechanism shall be designed to withstand motor pull out torque with adequate factor of safety. For selection of gearbox, shaft, axles and other components of hoisting machinery duty factor shall be considered as minimum 1.7. All shafts and axles shall be manufactured from forged steel bars and shall be Ultrasonic tested. Material of construction of shafts and axles shall conform to BS: 970 (EN-8 / EN9).

5.1.3. WHEELS AND RAILS: Driving / driven wheels of C.T. and L.T. shall be of double flange cylindrical or tapered (conical) treads type and machined from En-9 forged steel. The wheels shall be ultrasonic tested. The wheels shall be mounted in such a manner as to facilitate ease in removal and replacement. The rails for L.T and C.T shall conform to I.S. 3443. The rails shall be fixed on the runway and bridge (for L.T. and C.T. respectively) at a spacing of about 500 mm (maximum) staggered. Wheel shall be harder and 50 BHN hardness difference shall be maintained between wheel and rail.

5.1.4. HOOKS AND HOOK BLOCKS: The hook shall be compact in nature and shall be of long shank and trapezoidal C shank hook type. Hooks shall be ultrasonic, chemical, physical, proof load tested. The heat treatment procedure shall also be provided for hook. The hook shall be capable of swiveling and designed to turn easily on roller thrust bearings. The hook shall be capable of being readily removed and replaced and fixed rigidly. Hook geometry shall comply with the requirements of IS-15560 or IPSS. The material of construction of hook shall conform to IS-1875 Class 3A (high tensile forged steel) or 20Mn2 for IPSS. Hook shall be of B.R. HERMAN & MOHATA / E.E KARACHIWALA / Smriti Forging / Hurculus Forging make or equivalent. The hook block shall be designed to lift the rated load without twisting. The block sheaves shall have turned grooves and shall be provided with suitable roller bearings. The hook shall be capable of swiveling and designed to turn easily on thrust bearings. The hook shall be provided with spring loaded locking arrangement for locking the swiveling action at each 90 degree of rotation as and when required.


5.1.5. HOIST ROPE: Hoist rope shall be flexible and with steel core. The rope shall be fastened to the drum with an attachment having strength at least equal to that of the rope. Rope shall be of sufficient length so that minimum two full pass shall remain on drum at extreme low position of the hook. Reverse bends, cross bends and kinks shall be avoided. The size of wire rope shall be selected considering minimum Factor of Safety of 6.0 with rated load, weight of the lower pulley block and weight of the wire rope for each hoisting load path. Hoisting rope shall be of USHA MARTIN make or equivalent and shall comply with IS-2266.

5.1.6. ROPE DRUM: The rope drum shall be preferably machined from seamless pipe (ASTM A-106 Grade A/B) to the extent possible. Drum rolled from the IS-2062 Gr-B plate will also be considered in case of non-availability of seamless pipe. Ultrasonic (both straight and angle beam technique), chemical and physical testing shall be carried out for rope drum. Drum shall have flanges on both sides. The selection of the rope drum shall be on the basis of wire rope selection. If the rope drum is fabricated from plate, the plate shall be ultrasonic tested and welded butt joint shall 100% radiographed. The wire rope shall be fastened securely on rope drum ends. The length of rope drum shall be selected such that two & half turns at ends and one turn at center shall be available for rope reeving. The rope drum design calculation shall include design verification for bending, torsion and crushing.

5.1.7. Additional safety means for mechanically locking the drum shaft to avoid the sudden fall of lifting material in the event of brake failure shall be provided.

5.1.8. BEARINGS: All the bearings used shall be of suitable heavy-duty adequate antifriction type. For wheel assemblies and rope drums, self-aligned roller bearings shall be used. All the bearings shall have adequate load carrying capacity and shall be so arranged that they might be removed for their maintenance without disturbing, to the extent possible, the shafts with their gears and pinions. All the bearings shall be of genuine SKF/FAG make or equivalent.

5.1.9. GUARDS: All gear wheels, pinions shall be completely encased. Effective guards shall be provided for rotating shafts, couplings, chain drives, all moving parts on the bridge and cross trolley and sheaves of hook blocks.

5.1.10. CENTRALISED GREASING AND LUBRICATION SYSTEM: The crane shall be provided with the centralized greasing and lubrication system.

5.1.11. CAPACITY PLATE: A plate mentioning rated capacity of hoist, year of manufacture etc. shall be placed so as to be easily legible to read from the grounds.

5.2. ELECTRICAL DESIGN REQUIREMENTS:

5.2.1. MOTORS: All motors shall conform to latest revision of IS-325 & IS-12615. Drives for long and cross travel of the crane as well as hoist shall comprise of totally enclosed, fan cooled (IP-55) squirrel cage induction motors suitable for VVVF drives and operating on a 415V, 3 phase, 50 Hz AC electrical supply. The motors shall be suitable for reversing and frequent acceleration and mechanical braking. All motors shall be rated for intermittent periodic with starting (S4 duty) and Class F insulation. Motors insulation shall be suitable for its operation in hot, humid and tropical climate. The motors above 25 KW rating shall be complete with space heater and 6 Nos. thermistors. Accordingly required thermistor relay shall be provided and wired in control panel. Selection of VVVF drive & motor shall be such that only required accelerating torque shall be produced. Duty of motor shall be S4 duty with minimum CDF of 40%. At room temperature under hot condition, the motors shall be suitable for 150 starts per hour. Motors shall start at 80% minimum of rated voltage. It shall be capable of operating at full load for 15 minute at 80% of rated voltage. Motors also shall be capable of withstanding 120% over speed for 2 minutes without mechanical damage. The motors shall be capable of withstanding for 15 seconds without stalling or abrupt change in speed an excess torque of 60% of their rated torque. The motors shall have cast iron cooling fan and the terminal box shall be suitable for terminating Al conductor XLPE insulated armoured cables. The motor shall be of inverter duty and in order to take care of thermal de-rating,


one frame size higher motor shall be selected. The motor selected shall be able to deliver rated torque at rated speed and at 110% of rated speed. Ambient temperature and humidity shall be considered 45 degree C and 95% RH respectively. HP rating of all motors shall be based on latest IS-3177. The pull out torque of motor shall be minimum 250% of rated torque. The motor shall be of industrially proven BHARAT BIJLEE, NGEF, MARATHON, KIRLOSKAR, CROMPTON GREAVES make or equivalent.

5.2.1.1. Motors should operate satisfactorily for:

Voltage variation of 415 V ± 10% & Frequency variation 50 Hz ± 5%

5.2.1.2. TEST: Test certificates as per IS-325 (particularly type and routine) shall be provided together with a record of any alterations which have been made since the type tests were carried out. The driven equipment shall be tested with the actual motor and starter that will be supplied with the unit. The testing of the main hoist motor including type and routine tests shall be carried out in the presence of purchaser’s representative. Tests for noise and vibration measurement shall also be offered for main hoist motor. For other motors routine test shall be offered in the presence of purchaser’s representative.

5.2.1.3. MAINTENANCE: Motor design and construction shall be suitable for easy dis-assembly and re-assembly. The enclosure shall be sturdy and shall permit easy removal of any part of the motor for inspection and repairs. The motors shall be provided with eye bolts or other means to facilitate safe lifting.

5.2.2. BRAKES: The Main/Aux. hoisting shall be provided with two electromechanical foot mounted shoe type brakes (one hydraulic thruster operated and the other DC solenoid operated). The long and cross travel motions shall be provided with one no. hydraulic thruster brake / DCEM brake. Brake linings shall not be subjected to more than 80% of the rated lining temperatures. All brakes shall be rated for half an hour continuous operating and for 150% load capacities. The solenoids shall be D.C. power operated and shall be energized for releasing the brakes. Brake coil rating shall be 150% of full load torque (150 operations / hour). Hydraulic thruster brake shall be of SPEED-O-CONTROL / EMM OR BETTER make or equivalent and DCEM brake shall be of BCH make or equivalent. A Parking brake shall also be provided

5.2.3. SOLENOIDS: For D.C. supply, full wave selenium metal rectifiers shall be provided from normal 3 phase 415V A.C. supply 50 Hz. (using suitable transformers in the circuit). They shall be min. 30 minute rated and shall be provided with class B insulation or better. This shall be BCH make or equivalent as per DCEM brake supplier.

5.2.4. MAIN ISOLATER: A suitable switch fuse unit with fuse holder for 3 phase A.C. supply for crane shall be provided at suitable position at one end of long travel of the crane and installed in a dust tight metal enclosure with a dust tight door. The door should be provided with suitable interlocking mechanism to cut off the electrical supply to the crane when the door is in open position for any maintenance. The complete switch fuse unit shall be capable of AC-24 duty. Provision of RYB LED lamp indication shall be provided in the crane room along with trailing cable/DSL. It shall be of SIEMENS/GE/L&T make or equivalent.

5.2.5. CONTROLS AND CONTROL SYSTEM:

5.2.5.1. Crane shall be operated with floor operated push button pendant and capable of withstanding rough handling without being damaged and shall be effectively secured and earthed. The pendant shall be of lightweight and latest design. The pendant and control panel shall be of CRCA of 14 SWG thick and powder coated with RAL 7032 shade.


5.2.5.2. Stop, start and directional changes shall be accomplished by reversing magnetic contactors, by push buttons operating a control circuit. In all cases the push buttons shall be spring-loaded and shall return to off positions when released. They shall be suitably interlocked such that the push buttons of two reverse motions (hoist up and down etc.) cannot be simultaneously operated.

5.2.5.3. All control equipment shall be suitable for operation on 230-V, AC, single phase 50 Hz. Electrical supply to the controls shall be provided from a separate electrical panel mounted on the bridge.

5.2.5.4. The weight of the pendant shall be supported independently by means of chain or wire ropes. If the pendant is of metal, it should be effectively earthed at two places.

5.2.5.5. Adequate guards shall be provided to prevent accidental contact of pendant rope or chain with down shop leads (DSL).

5.2.5.6. Separate isolator switch shall be provided for the electrical supply for control system and shall be of AC-24 duty.

5.2.5.7. Pendent and control panel shall be of TECHNO ELECTRICALS / KAIREL / RELIABLE / REFLEX / OWN make or equivalent. Push buttons shall be of SIEMENS / SCHNIEDER / TEKNIC make or equivalent.

5.2.5.8. Pendent should have lock and key arrangement to prevent unauthorized operation of the crane.

5.2.6. POWER SYSTEM:

5.2.6.1. Power supply of 415V, 3-phase, 4 wires, 50Hz AC shall be provided from separate electrical panels for each motion mounted on the bridge. All these panels shall be provided with suitable dust tight doors, having suitable interlocking devices for cutting of the electrical supply when the doors are opened.

5.2.6.2. Separate isolating switches shall be provided for the main power supply and power supplies to individual motions.

5.2.6.3. Pilot lamps shall be provided for indicating 3 Phase supply.

5.2.6.4. The provision shall be made for 3 phase and 1 phase supply point on the crane platform for maintenance work.

5.2.6.5. The transformers shall be of AE / JYOTI / KAPPA make or equivalent.

5.2.7. CONTACTORS:

5.2.7.1. All the contactors shall be rated to permit 150 switching operations per hour.

5.2.7.2. Each motor shall be provided with HRC fuses and contactors with suitable VVVF drives. Contactor type motor starter shall be of air brake, single throw electromagnetic type and shall conform to IS-2959.

5.2.7.3. Reversing contactors shall be provided with electrical and mechanical interlocks between forward and reverse contactors. Contactors shall be provided with at least 2 NO and 2 NC additional auxiliary contacts.

5.2.7.4. The contactors shall be provided with a three element, positive acting, ambient temperature compensated, time lagged, hand reset type thermal overload relays with adjustable setting to suit the rated motor current. Resetting of the relay shall be feasible from front door of the panel. The contactors shall be AC-4 duty only. Irrespective of lowest HP motors, rating of power contactors shall not be less than 32 A. It shall be of TELEMECHANIQUE / SEIMENS make or equivalent.

5.2.8. FUSES: All fuses shall be of the HRC cartridge type conforming to IS-2208 mounted on plug-in type fuse bases. All accessible live connections shall be adequately shrouded and it shall be


possible to change the fuses with the current alive, without the danger of contact with live metal. The fuses shall be of GE / SIEMENS / L&T make or equivalent.

5.2.9. CABLES AND CONDUITS:

5.2.9.1. All wiring shall be provided in rigid galvanized steel conduit with threaded type fittings, galvanized outlet and pull boxes. Pull boxes shall be located at frequent intervals to allow cable or conductor to be pulled without abrasion or injury. Conduits shall form a continuous system and shall be properly supported within structural frame works of the crane. The entire conduit system shall be grounded. Conduit for power and control circuits shall not be less than the size recommended by relevant Indian standards for conductors that are to be installed there in. The entire conduit system shall be installed such that any moisture will be drained away from the terminal boxes and electrical devices. Power wiring and control wiring shall be kept in separate conduits. No conduits of size smaller than 25mm diameter shall be used. Flexible conduits, when used, shall be of galvanization (GI) flexible conduits.

5.2.9.2. The cable and wires shall be of 1.1 KV grade and suitably HFFR (Halogen free fire retardant) insulated copper conductors for control circuit wiring.

5.2.9.3. Wiring adjacent to resistor and control panel shall be of standard 1.1 KV grade, flame, heat and moisture resistant insulation suitable for operation at high temperature.

5.2.9.4. Wires for motor primary and secondary circuits shall be of HFFR insulated copper conductors and capacities to carry maximum plugging current of the motors. All insulation and all clearances to the ground shall be designed so that the live points can withstand a high potential test of not less than 2500-V at 50 Hz for one minute.

5.2.9.5. Conductor sections of main power circuit shall be selected taking into consideration simultaneous operation of the main hoist and bridge motors.

5.2.9.6. All wiring shall be done in a neat and workman like manner and wherever possible shall be run in the conduits.

5.2.9.7. The cable shall be of UNIVERSAL / FINOLEX / RR CABLE / TORRENT / CCI make or equivalent.

4.2.10. SAFETY EARTHING: Crane structure, motor frames and metal cases of all electrical equipment including metal conduits and cable guards shall be effectively earthed with tinned copper conductor of not less than 12 SWG for motors up to 5 HP.

5.2.10. LIMIT SWITCHES:

5.2.10.1. Automatic reset type of limit switches of suitable design shall be provided to prevent over travel for bridge, trolley and hoists.

5.2.10.2. Two different types of limit switches shall be provided for hoisting motion of the crane. One is the rotary limit switch with a positively acting mechanism which cuts off the electrical supply and stops the hoisting when the hook approaches the predetermined level to prevent over winding and over lowering and the other is the linear limit switch actuated by gravity load. The control circuit shall be designed to stop all the motion of crane when the gravity limit switch is actuated. A key operated reset switch shall be provided. Main switch of the pendent should be under lock and key.

5.2.10.3. The linear limit switches for bridge and trolley motions shall be located in advance of the mechanical stoppers so that even if they were, moving at full speed at the time of limit switch actuation, the same shall be brought to a halt without excessive impact with the mechanical stoppers.


5.2.10.4. All limit switches shall of SOC / BCH / EMM make or equivalent.

5.2.11. ELECTRICAL SUPPLY LEADS AND CURRENT COLLECTORS:

5.2.11.1. It is desirable to provide electric supply to crane bridge (L.T.) through Shrouded Down Shop Leads of suitable copper conductor of 250 Amp rating. For cross travel, festooned type, flexible insulated cables mounted on rollers are preferable. The track trailing cable system with “T” track trolleys with supporting bracket, “T” track trolleys, copper conductor power and control cable, rollers, junction boxes complete with Elmex make or equivalent terminal block shall be used. Wire rope / SS chain shall be provided all along the trailing cable to avoid strain on the cable during operation. The Shrouded DSL of suitable copper conductor also can be considered for Cross Travel for gaining maximum C.T. approaches.

5.2.11.2. All the conductors shall be so arranged such that they are easily accessible for maintenance.

5.2.11.3. Current collectors for use with the DSL conductors shall be of sliding type and shall ensure continuous contact and avoid sparking as far as possible and shall be easily approachable for maintenance. It shall be of Safe Line make.

6 . S PE C IAL D E S I G N FEA T U R ES :

6.1. In order to make the design of crane crab compact and to achieve smooth operation, all motions for L.T., C.T, & hoisting (main & aux.) shall be given through VVVF controlled drives. The crane speeds for all motions i.e. 10%, 50% and 100% speed shall be achieved through VVVF drives. The model of VVVF drives shall be selected for crane duty as per crane motions. The increase in numbers of speed shall not increase pendent size and speed variation shall be achieved by providing a selector switch on pendent. The hoisting drives shall be provided with encoders for speed feedback. However, L.T. and C.T. drives do not require encoders. The VVVF drives shall be of industrially proven SCHNEIDER (TELEMECHANIQUE) / L&T (YASKAWA) make or equivalent. The encoder shall be of HUBNER / HENGSTLER make or equivalent.

6.2. The EOT crane shall be provided with radio remote control pendant (operating on radio frequency) in addition to normal push button control system for crane operations. The interlock shall be provided such that only one control pendant (remote or normal) can be operated at a time. Radio Remote pendent shall be of suitable model of Stromag / Acropolis make or equivalent.

6.3. The design of crane also shall meet the requirement of Safe Shut-down Earthquake (S.S.E.) conditions. The Tarapur site, where the above crane is going to be installed, falls in Zone-III as per IS: 1893-1987 and corresponds to an earthquake intensity of VII as per Modified Mercalli Intensity Scale. The zero period peak horizontal ground acceleration is of the order of 0.2g for S.S.E. The crane shall be provided with suitable anti-topple lugs to prevent toppling in case of earthquake. Crane Girder and anti-toppling lugs shall be designed for the building floor response spectra generated using Tarapur GRS. The design of girder, anti-topple lugs and their calculation shall be submitted to the purchaser for review and approval.

7. PAINTING AND SPARES & MAINTENANCE TOOLS:

All surfaces shall be cleaned thoroughly, preferably by sand blasting. All oils and greases shall be removed prior to painting. Two shop coats of primer shall be provided at the supplier’s works, two final epoxy coats after crane erection at the purchaser’s site. The primer and final coats shall be as per the paint material approved by the purchaser.


8. PACKING:

After carrying out the tests at manufacturing works as specified in 3.2.2 Annexure-III, and after match marking, the crane shall be carefully disassembled into major sub-assemblies and then properly packed, crated and protected from damage during transport, transit and storage at site. The packing shall include adequate cushioning, blocking, bracing, skidding, and hoisting and tie down provisions. All machined parts shall be protected with anti-rust grease. All electrical devices shall be sealed against dust and moisture or water, wherever applicable

9. SPARES:

The quotation shall include necessary spares for 5 years trouble free service. The bidder shall indicate the list of spares (which includes following spares) for 5 years trouble free service.

(a) List of mandatory spares parts

Sl. No. Items Description Qty. (nos.)

I Mechanical

1 First reduction pinion shaft for all main drives

2 no. of each type

2 Oil seals on input and output shafts of all gear

2 no. of each type

3 Brake shoes with liner 1 pair for each type 4 Geared coupling with pilot bore 1 no. of each type II Electrical

5 Linings for each of the brake shoes complete with rivets

1 set (1 set consists of 1 no. of each type)

6 Fuses of each type 2 sets (1 set consists of 1 no. each type)

7 Indicating lamps of each type 2 sets (1 set consists of 1 no. each type)

8 Fixed and moving contactors of each type

1 set (1 set consists of 1 no. each type)

9 Timers of each type 1 set (1 set consists of 1 no. each type)

10 Limits switches of each type 1 set (1 set consists of 1 no. each type)

II VVVF Drive Spares 1 Control Card 1 No. of each type. 2 Power Card and intelligent power

module 1 No. for main hoist drive only.

3 Feedback encoder and encoder card 1 No. of each type. 4 Braking unit 1 No. for main hoist

drives only.

The bidder shall indicate break-up price for individual spare parts. The purchaser reserves right to accept spares in toto or in part.

(b) Maintenance Tools: The quotation shall include the required maintenance tools for crane with the list of tools.


ANNEXURE-II

DESIGN, DRAWING, DOCUMENTATION & GUARANTEE

1. DESIGN: The supplier shall provide detailed design calculations for selection of mechanisms like motors, brake, wheel, rail, wire rope, rope drum, hook & its bearings, gear boxes, etc. and structural members like main girder, end carriage, crab frame etc. The design calculation shall be approved before the fabrication of the crane. The supplier shall verify the design of structural members for earthquake event and the same shall be submitted for approval. The swing calculation, design calculations for anti-topple lugs, wheel stoppers, end buffers shall also be provided. Four copies of approved design calculations shall be provided to the purchaser.

2. DRAWINGS:

2.1. The quotations shall accompany general layout drawings of the crane based on purchaser’s tender Drawing as given below:

Drg. No. AVS-A/10012222/DWG/001/R0

2.2. The supplier shall furnish following two sets of drawings to get the approval of the purchaser prior to fabrication.

a) General Arrangement (GA) drawing of crane. b) Crane clearance diagram. c) Assembly and detailed drawings of bridge. d) Assembly and detailed drawings of trolley. e) Detailed drawing showing hoist drive arrangement for main hoisting f) Detailed drawing showing hoist drive arrangement for auxiliary hoisting. g) Detailed drawing showing bridge and trolley drive. h) Bridge and end truck and wheel assembly drawing. i) Detailed drawing of crab structural frame. j) Detailed drawing of main girders with camber. k) Detailed drawing of end carriage. l) Detailed drawing of assembly of main girders and end carriage. m) Assembly and detail drawings of lower hook and pulley block. n) Drawings showing constructional features and construction details of brakes and limit

switches. o) Rails and their fixing arrangement for L.T and C.T along with end stopper details. p) DSL arrangement and fixing details. q) Schematic and wiring diagram of power and control system. r) Necessary installation, maintenance and operational Drawings.

It is the responsibility of the supplier to incorporate correctly all the comments conveyed by the purchaser on supplier’s drawings subsequently. The supplier shall provide four sets of approved fabrication drawings and one set of good reproducible to purchaser for his reference throughout the fabrication, installation and commissioning of the crane.

2.3. Drawings prepared by supplier and approved by purchaser shall be considered as part of specification. However, examination and approval of drawings by purchaser shall not relieve the supplier of his responsibility for proper engineering, design, workmanship and functioning of the cranes under the contract.

2.4. If any time before the completion of work, changes are made necessitating revision of approved drawings, supplier shall make such revisions and obtain the approval of the purchaser.


3. DOCUMENTATION:

Supplier shall furnish six bound volumes of following documents along with supply:

a) Quality Surveillance Document,

b) Design Documents

c) Operation & Maintenance Manual and

d) Instruction Manual

3.1. “Quality Surveillance Document” shall consist of Technical Specification of crane, copy of Purchase Order & Amendments if any, Shipping Release, Packing list, approved Quality Assurance Plan (QAP), Test Certificates for all raw materials and bought out items, Performance Test Reports, Internal Inspection Report, Assembly Inspection Report, Joint Inspection Report, Load Test Report, Minutes of Meeting (MOM), approved Procedures for Welding Qualifications (WPS, PQR and WPQ) and NDT Procedures (LPT, RT and UT).

3.2. “Design Documents” shall consist of design calculations for mechanisms, structural members, swing calculation & verification for earthquake event and all as built drawings mentioned in clause no. 2.2 of Annexure-1.

3.3. “Operation & Maintenance Manual” shall consist of manuals and instruction of crane for operation and maintenance. The catalogues/ technical literatures for the bought out components with its selection shall also be provided. Maintenance schedule and its frequency shall also be included.

3.4. “Instruction Manuals” shall be corresponding to the equipment supplied and not be general in nature. The supplier shall submit two preliminary instructional manuals to the purchaser before the submission of actual manuals and one approved copy will be provided to the supplier for preparing final instructional manuals.

4. GUARANTEE:

The supplier has to give a guarantee of the equipment for a period of 18 months from supply or 12 months from the date of testing and commissioning at site whichever is earlier. This guarantee shall cover free repairs or replacement of parts, which have failed during normal operation within the guarantee period due to defective design, material of construction, workmanship etc.

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ANNEXURE-III

FABRICATION, INSPECTION & TESTING

1. FABRICATION:

1.1. The materials may be cut and formed to the required shape by any process that will not unduly impair the physical properties of materials. The edges that will be exposed in the finished form shall be rounded off to a radius of at least 3 mm or chamfered at 45 degrees to at least 4 mm flat. All materials shall be grounded smooth and straightened and any slag of previous molten material shall be removed prior to further fabrication or use.

1.2. MATERIAL: Refer clause no. 4 of Annexure–I (Technical Specification for EOT Crane)

1.3. WELDING: Welding shall conform to IS-814, IS-816 & IS-823. The welding procedures and performance qualification of welders shall be in accordance with Section-IX of ASME Boiler and pressure vessel code. Electrodes for welding shall conform to IS-814.

1.3.1. The welding procedures and welder’s performance qualification report shall be submitted to purchaser for approval. The welding shall be carried out only by the qualified welder as approved by purchaser.

1.3.2. All welds should be free from defects like blow holes, lack of penetration, slag inclusions, porosity etc. and the welding shall be uniform.

1.3.3. Purchaser reserves the right to check any weld by suitable non-destructive test and if any weld is found defective, supplier shall repair the same free of cost after obtaining the approval from the purchaser.

1.3.4. Weld procedures adopted shall involve least amount of warping and not detrimental to the integrity of the sections being welded.

2. INSPECTION:

2.1. The inspection requirements for all components/equipment shall conform to design and fabrication requirements as defined in the relevant codes and standards.

2.2. The supplier shall maintain proper inspection records and make it available to purchaser’s representative whenever required. Supplier shall make necessary arrangements for the inspection by the purchaser or his authorized representative.

2.3. Supplier shall provide to the purchaser or his representative all the necessary test certificates for the standard components and materials bought out from the market. The test certificates for mechanical properties and chemical composition of the materials to be used for fabrication /construction of the crane shall be provided. The supplier shall make arrangements to scrutinize and purchase only good and trouble free components and preferably with the approval of the purchaser. The steel castings and forging for load carrying parts shall be tested by appropriate Dye-penetrant and ultrasonic tests for getting the defect free units.

2.4. The supplier shall offer the inspection of main girders in U-shape i.e. prior to welding of bottom flange and painting.

2.5. After assembly of bridge, the water level test for wheel assemblies shall be conducted at works.

2.6. Welds for major load bearing components like bridge girders, end trucks, trolley frames etc. shall be examined as follows:

a) All butt welds shall be 100% radiographed.

b) All butt, T-joints and fillet welds shall be checked by dye penetrant test for root and subsequent each pass of welding.


2.5. Purchaser reserves the right to inspect any material or equipment furnished or used by supplier under the contract and to reject any, which is found defective in workmanship or design, or otherwise unsuitable for the use and purpose intended, or which is not in accordance with the intend of contract.

2.6. Should purchaser waive the right to inspect any equipment, that waiver shall not relieve supplier in any way of his responsibility and obligations under the contract.

2.7. Purchaser reserves the right to call for certificates for all material and equipment at any stage of manufacture.

2.8. In the events of purchaser’s inspection revealing poor quality of goods, purchaser shall be at liberty to specify additional procedures, if required to ascertain supplier’s compliance with the equipment specifications.

2.9. Even though purchaser or his representative carries out inspection, such inspection shall not however relieve supplier from his responsibilities for furnishing the equipment conforming to the requirements of the contract.

3. TEST CERTIFICATES AND TESTING OF CRANE:

3 .1. TEST CERTIFICATES.

3.1.1. Following test certificates shall be furnished by the supplier and approved by the purchaser.

a) Manufacturer’s test certificates for mechanical properties and chemical compositions of structural steels, hooks, wire ropes, rope drums, wheels, gears and pinions, shafts and axles etc.

b) Functional tests for all equipment. c) Radiography test reports of butt welds and T-joints. d) Test reports of DP inspection of fillet, butt and T-joint welds. e) Rated and overload test of the crane. f) Insulation test for all electrical equipment and continuity test for all cables. g) Type and Routine tests for motors. h) Test certificates for brakes and clutches.

3.1.2. In the absence of test certificates from the manufacturer of the materials, the material shall be tested as per the specifications and approved by the purchaser prior to the starting of fabrication.

3 .2. TESTING OF CRANE:

3.2.1. Before shipment, the crane shall be carefully fitted and shop assembled, clearly match marked to facilitate assembly at the site. The shop operational and running tests for machinery assembled on the bridge structure shall be conducted for all mechanical and electrical parts and automatic devices to demonstrate that the crane is in satisfactory operating condition. Supporting arrangements shall be provided in a manner to allow free movement of hook for determining high hook elevation and hook lift.

3.2.2. The following tests on complete crane in presence of purchaser’s representative shall be carried out at manufacturer’s works.

a) Material inspection, visual inspection and dimensional checks shall be done.

b) No load test trials shall be conducted. Motor currents, functional checks of drives for each motion, functionality of all limit switches and interlocks shall be verified.


c) Rated load test: Checks for functioning of motions, travel limits, interlock operations, brake operations, functioning of drive mechanisms at rated load shall be conducted in addition to checks for specified speeds at rated load. The maximum deflection with rated load shall not exceed 1/1200 of the span. Each load path of main hoisting and individual brakes shall be tested.

d) 25% over load test:

1. The maximum deflection shall not exceed 1/1000 of the span.

2. Functioning of travel limits shall be checked.

3. Operating speeds shall be checked.

4. Hook shall be tested, as per relevant IS standard.

3.2.3. Following tests on the crane shall be carried after erection at site.

a) Rated load test: After erecting the crane at site, the crane shall be tested at the rated load. Checks for functioning of all motions, travel limits, interlock operations, positioning accuracy of drive mechanisms at rated load shall be conducted in addition to the checking of specified speeds at rated load. Maximum deflection of the bridge with the rated load shall not exceed 1/1200 of the span.

b) In case of any variations in the test results from those mentioned in 3.2.2. (b), reasons for these variations shall be detailed, and if necessary, the 25% overload testing shall be carried at site to check for the integrity of the crane.

3.2.4. All the tests shall be carried out as per latest IS-3177 unless otherwise specified.

3.2.5. No distortion, permanent strain, damages or deformation of any part of the equipment to be supplied under this specification shall occur as a result of the above testing.

3.2.6. The necessary loads for conducting load testing at site will be arranged free of cost.

3.2.7. Supply of Testing Instruments: The supplier shall arrange at his own cost the required testing and inspection instruments for use at ex-works and at site.

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ANNEXURE-IV

INSTALLATION & COMMISSIONING

1. The supplier shall install the cranes at the required area of AVS-Annex of INRP, Tarapur in consultation with purchaser’s site representative. For installation of cranes the purchaser will make only electrical power available to supplier and all other facilities shall be arranged by the supplier on his own.

2. Installation and commissioning of the complete crane at site shall be done in 4 months’ time. The complete responsibility for the safe transportation of the crane to site and its installation and commissioning shall rest with the supplier. The necessary loads for load testing will be arranged at site free of cost. However, the supplier shall bring necessary instruments for conducting testing of crane at site.

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ANNEXURE-V

INFORMATION REGARDING CONSTRUCTION OF THE CRANE

(TO BE SUPPLIED BY THE SUPPLIER/BIDDER)

Please follow the notes carefully as given below:

1. Provide details asked separately for LT, CT, Main and Auxiliary Hoists wherever required.

2. The specification for all components shall be provided.

3. The layout of the cranes shall be as per following crane clearance drawings:

Drg. No: AVS-A/10012222/DWG/001/R0

The information asked for as detailed below and any other missing information should be clearly indicated in the tender. Additional information supporting the points as asked below may be provided on separate paper and to be submitted along with tender. Any special features of the crane offered shall be clearly indicated.

4. All the dimensions shall be in SI Units

Technical Information to be provided by the bidders:

1. SPECIFICATION OF THE CRANE

1.1. GENERAL

1.1.2. Type of crane

1.1.3. Duty of the crane

1.1.4. Type of service

1.1.5 Safe working hoisting load in addition to dead weight for

a) Main Hoist

b) Aux. Hoist

1.1.6. Atmospheric condition

1.1.7. Hoisting method

1.2. OPERATING SPEEDS (at rated load)

1.2.1. Long travel

1.2.2 Cross travel

1.2.3 Hoisting

a) Main Hoist

b) Auxiliary Hoist

1.2.4. Whether all motions have 10 % reduction through VVVF controlled drive.

1.3. CRANE PERFORMANCE AND STRUCTURAL DETAILS

1.3.1. Span


1.3.2. Total lift required for Main and Aux. hoist.

c) Above floor (L)

d) Below floor (if any)

1.3.3. Distance between the Top of the LT crane gantry beam to the bottom of top RCC slab (Head room available) (A)

1.3.4. Minimum clearance required from topmost point of crane to lowest obstruction of roof / civil structure. (T1)

1.3.5. Minimum clearance required from working platform (LT) above the crane to lowest obstruction of roof / civil structure. (T2)

1.3.6. Distance between the centerline of the crane rail to the adjoining wall (H+100 Min.)

1.3.7. Distance of transverse approach for Main Hoist from L.T. rail (C)

1.3.8. Distance of transverse approach for Main Hoist from L.T. rail (D) (other side)

1.3.9. Distance of transverse approach for Aux. Hoist from L.T. rail (C+N1)

1.3.10. Distance of transverse approach for Aux. Hoist from L.T. rail (D-N1) (other side)

1.3.11. Distance of L.T. approach for Main Hoist from wall (X)

1.3.12. Distance of L.T. approach for Main Hoist from wall. (Y)

1.3.13. Distance between main and aux. hooks in Vertical direction (E)

1.3.14. Height of Lift

c. MH (L)

d. AH (L+E)

1.3.15. Distance between civil bracket to lowest obstruction of roof / civil structure (B)

1.3.16. Distance between LT rail top to lowest obstruction of roof / civil structure (R)

1.3.17. Distance between Top of main girder to lowest obstruction of roof / civil structure (G)

1.3.18. Distance between main and aux. hooks in transverse direction (N1)

1.3.19. Distance between main and aux. hooks in longitudinal direction (N2)

1.3.20. LT wheel base (J)


1.3.21. CT wheel base (Q)

1.4. Fixing arrangement for down shop leads (for long travel)

1.5. Fixing arrangement for down shop leads (for cross travel)

1.6. Fixing of crane rails to the gantry girder (RCC / steel beam)

2. BRIDGE CONSTRUCTION

2.1. Type of girder construction

2.2. Type, size and section modulus of end truck (carriage) construction

2.3. Material specification of girder and end trucks

2.4. Size and section modulus of the girder

2.5. Distance between two girders for double girder bridge.

2.6. Safety factor used in the design

2.7. Designed maximum deflection of the bridge girder for i) Rated load ii) 25% excess load

2.8. Does the bridge construction conform to IS-807 (Yes/No)

2.9. Whether all butt and T joint welds of major load bearing component would be radiographed (Yes/No)

2.10. Whether all welds would be dye penetrate tested (Yes/No)

2.11. Whether all supplier’s site inspection reports could be made available to the purchaser (Yes/No)

2.12. Whether spring loaded buffers will be provided on bridge for mechanical stopper.

3. TROLLEY CONSTRUCTION

3.1. Type and construction

3.2. Material specification

3.3. Size of trolley.

3.4. Whether spring loaded buffers will be provided on trolley for mechanical stopper.

4. WEIGHTS, LOADINGS AND DESIGN CONSIDERATIONS

4.1. Bridge wheel loading on the crane gantries

4.2. Trolley wheel loading on the bridge girders

4.3. Total crane weight


4.4. Total trolley weight

4.5. Maximum weight of the single unit for handling during transportation, storage and installation

4.6. Minimum safety factor used in the design of the crane

4.7. Minimum impact factor considered in the design of the crane

5. RAILS DETAIL

5.1. BRIDGE RAILS

5.1.1. Type and weight of the rail per meter

5.1.2. Size of the rail

Top width

Bottom width

Height

5.1.3. IS standard or other standard to which they conform to

5.1.4. Material Specification

5.1.5. Fixing arrangement of the rails and spacing in between successive mountings

5.1.6. Whether wheel stoppers for bridge will be provided on rails?

5.2. TROLLEY RAILS

5.2.1. Type and weight of the rail per meter

5.2.2. Size of the rail

Top width

Bottom width

Height

5.2.3. Material specification

5.2.4. State to which IS standard the rails conform to

5.2.5. Fixing arrangement of the rails and spacing in between the successive mountings

5.2.6. Whether wheel stoppers for trolley will be provided on rails?

6. DOWN SHOP LEADS

6.1. DSL FOR LONG TRAVEL

6.1.1. Type

6.1.2. Details of DSL

6.1.3. Mounting arrangement for DSL and spacing in between successive mounting brackets.


6.1.4. Specifications of current collectors

6.1.4.1. Type

6.1.4.2. Weight

6.1.4.3. Size

6.1.5. Insulation specification

6.2. DSL FOR CROSS TRAVEL

6.2.1. Type

6.2.2. Details of DSL

6.2.3. Insulation details

6.2.4. Mounting and rolling arrangements in case of cables

6.2.5. Mounting details of the rail on which the cable rollers move

7. MECHANICAL DETAILS

7.1. WHEELS

7.1.1. BRIDGE WHEELS

7.1.1.1. No. of wheels

7.1.1.2. Material specification

7.1.1.3. Diameter

7.1.1.4. Flange dimensions (Projection outside the rail on each side)

7.1.1.5.

Maximum wheel load with impact factor and without impact factor

7.1.1.6. Dimensional details of bridge end stoppers (wheel stopper)

7.1.1.7 Hardness of wheels in BHN

7.1.2. TROLLEY WHEELS

7.1.2.1. No. of wheels

7.1.2.2. Material

7.1.2.3. Diameter

7.1.2.4. Flange dimension (projection outside the rail on each side)

7.1.2.5. Maximum wheel load with and without impact factor

7.1.2.6. Dimensional details of trolley end stoppers (wheel stopper)

7.1.2.7. Hardness of wheels in BHN

7.2. WHEEL AXLES FOR BRIDGE AND TROLLEY

7.2.1. Type



7.2.3.

Size

7.3. BEARINGS FOR BRIDGE WHEELS, TROLLEY WHEELS, MAIN AND AUX. HOISTING GEAR BOXES AND THEIR HOOK BLOCKS AND ROPE DRUMS

7.3.1. Type

7.3.2. Size

7.3.3. Number

7.3.4. Make (SKF/ FAG)

7.3.5. Lubrication particulars including the scheme of centralized lubrication for the complete crane

7.4. HOISTING ROPE FOR MAIN AND AUX. HOIST

7.4.1. Type of construction

7.4.2. Factor of safety used


7.4.4. No. of strands

7.4.5. No. of wires per strand

7.4.6. Diameter of the wire rope

7.4.7. Minimum breaking load

7.4.8. No. of falls of the hoisting rope

7.5. HOISTING DRUM FOR MAIN AND AUX. HOIST


7.5.2. Type of construction

7.5.3. Diameter of the Rope Drum

7.5.4. Length of the Rope Drum

7.5.5. Ratio of diameter of the drum to diameter of rope

7.6. SHEAVES FOR MAIN AND AUX. HOIST


7.6.2. Ratio of diameter of sheaves to diameter of rope

7.7. GEAR BOX DETAILS FOR LT, CT, AND MAIN AND AUX. HOIST

7.7.1. Type

7.7.2. Make

7.7.3. HP rating, its speed

7.7.4. Lubrication type and specification


7.7.5. Does it conform to any relevant standards, and if so, specify the applied standard

7.7.6. Duty and centre distance

7.7.7. Gear ratios : LT,CT, Main and Aux. Hoist

7.8. HOOKS FOR MAIN AND AUX. HOIST

7.8.1. Type


7.8.3. Whether the Main hoist hook can swivel freely under load, and whether it can be locked at four positions (900 apart)

7.8.4. Does it conform to any relevant standards and if so specify applicable standard.

7.8.5. Type of sealing for hook block and its details

7.8.6. Height of the center of the hook above the floor level

7.8.7. Whether provided with any locking arrangement for swiveling

7.8.8. Opening, width, clearance available for hook block

7.9. TYPES & RATING OF COUPLING FOR

7.9.1. Long Travel

7.9.2. Cross Travel

7.9.3. Main Hoisting

7.9.4. Aux. Hoisting

7.10. TYPE OF THE PLATFORM PROVIDED

7.10.1. Whether covered with chequered plate

7.10.2. Thickness of platform cover plate

7.10.3. Dimensions of the platform

7.10.4. Details of railing provided

8. ELECTRICAL DETAILS

8.1. MOTORS

8.1.1. Motors for L.T, C.T, Main and Aux. Hoist

8.1.1.1. Type of motor

8.1.1.2. Make (Siemens/ Crompton Greaves/ NGEF)

8.1.1.3. No. of motors

8.1.1.4. Power rating (voltage, current, frequency, no. of phases and wattage in Kw)

8.1.1.5. Rating (duty)

8.1.1.6. No. and specification of bearings used per motor

8.1.1.7. Class of insulation


8.1.1.8. Earthing detail

8.1.1.9. Do they correspond to latest IS-325 (Yes/No)

8.2. BRAKES FOR LT, CT, AND MAIN AND AUX. HOISTING

8.2.1. Type

8.2.2. Make

8.2.3. Design value of holding torque in % full load torque

8.2.4. Brake coil rating for EM Brake

8.2.5. Voltage rating of the coil

8.2.6. Electrical supply to the coil

8.2.7. Specification

8.2.8. Numbers of safe operations allowed per hour

8.2.9. Specification of DC supply, whether it is of selenium metal diode full wave rectifier.


8.2.11. Earthing detail

8.3. LIMIT SWITCHES FOR LT, CT AND MAIN AUX. HOISTING

8.3.1. Type

8.3.2. Make

8.3.3. Mounting Details

8.4. PENDANT AND IT’S CONTROL SWITCHES

8.4.1. Type

8.4.2. Make

8.4.3. Material specifications

8.4.4. No. of switches

8.4.5. Whether mechanical and electrical interlocking is provided

8.4.6. Special features if any

8.5. TRANSFORMERS FOR POWER AND CONTROL CIRCUITS, FOR BRAKE SUPPLY, FOR LT, CT AND MAIN AND AUX. HOISTINGS

8.5.1. Power Rating

8.5.2. Voltage and current rating

8.5.3. Type

8.5.4. Make

8.5.5. Earthing Details


8.6. Isolators And Fuse Holders For Main Isolators (one at floor level and the other on the crane platform), for L.T, C.T, Main and Aux. hoisting, for control circuits and for electrical supply to brakes of L.T, C.T; Main and Aux. hoisting

8.6.1. Type

8.6.2. Make

8.6.3. Current rating (Amps)

8.6.4. Type and current rating of the fuses

8.7. ELECTRICAL PANEL FOR LT, CT AND MAIN AND AUX. HOISTING

8.7.1. Type

8.7.2. Make

8.7.3. Size

8.7.4. Whether door is interlocked


8.7.6. Earthing detail

8.7.7. Any other special features

8.8. CONTACTORS FOR LT, CT, MAIN AND AUX. HOIST BRAKE CIRCUIT

8.8.1. Type

8.8.2. Make

8.8.3. Specification

8.8.4. Voltage and current rating

8.8.5. Max. no. of operations/ hour

8.8.6. Conform to what standard

8.9. PILOT LAMPS & SUPPLY POINTS

8.9.1. Whether pilot lamps are provided for indicating the 3-phase supply

8.9.2. Whether provision for 3 phase and 2 phase supply points on the crane platform is made for maintenance

9. SPECIAL FEATURES/ REMARKS

9.1. (Make and model specification of VVVF drives for all motions. Catalog shall be provided)

9.2. (Make and model specification Radio Remote control shall be indicated. And catalog also shall be provided)

9.3. Whether the crane design will be verified for earthquake event.

9.4. Whether central lubrication system is provided


(Yes/No)

9.5. Any other special feature of the crane

10. Whether the supplier/ bidder will conduct and provide test certificates for all the tests specified in the tender specifications (Yes/No)

11. Whether load test for individual break for hoisting will be conducted at works and site

12. Any other remark the supplier/ bidder would like to add


A N N E X U R E - V I

B I D D E R E V A L U A T I O N F O R M

BIDDER EVALUATION FORM

Notes : The form shall be completed in all respects by the bidder. Comments/remarks like

“already given with the tender” or “details shall be on receipt of order” etc. are not acceptable.

Bidder shall obtain solvency certificate from his banker and attach with this form. If the bidder has more than one banker, a separate solvency certificate from each banker shall be submitted.

If space is not sufficient, bidder may give additional information on separate sheets. 1. Vendor’s Name

2. Quotation No. & Date

3. Equipment Offered

Tendered item

4.1 Product(s) Manufactured by the Bidder

4.2 Product(s) Marketed by the Bidder

5. Registration Details (With Registration Number)

6. Works Premises Owned By or Rented in Name Of :

7. Nature of Organization (Proprietary/Partnership/Pvt.Ltd./Public Ltd.)

8. Top Management (Names, Qualification, Position and Experience)

Name(s) Qualification

Position

Experience


9. Performance of Preceeding three years with profit and loss. (also indicate anticipated

performance for current year)

Year

Capital (Authorised /

Working)

Turnover Net Profit/Loss

Yr-1

Yr-2

Yr-3

Note: Copies of Annual Reports/Profit & Loss Accounts for periods mentioned above must be enclosed for reference.

10. Name of Banker(s) with full Address, Fax. No. & Tel. No.

11. Value of Solvency Certificate(s) issued by Banker(s). The certificate(s) shall be latest ones.

The Bidder shall obtain Solvency Certificate from each of firm’s banker and submit the same to the Purchaser.

12. Year of Starting the Factory

13. Year of Starting Manufacture of Equipment indicated in the Tender

14. License/Contract Details

15. Sub contract details for any of the parts of crane

16. List of Key Department (Enclose organisation chart for reference)


17. Staff Details Graduate

Engineers Diploma Holders

Supervisors Trained/Skilled Operators

Unskilled Operators

Others (Specify)

Design & Drawing

Production Planning & Control

Fabrication & Metal Finish

Quality Control & Testing

Sales

Others (Specify)

TOTAL

Note : In case of common staff for various departments, indicate the same as common staff

18. Details of Facilities Available 18.1 Office Area :

18.2 Works Area (s) : If manufacturing facilities are at more than one place, details of each works shall be separately given

Addresses of Works

Covered Area Uncovered Area

Total Plot Area

18.3 Design & Drawing Office Facilities Available : (Give details)

18.4 Facilities available for load testing at the bidder’s works

19. Quality Assurance

19.1 Quality Assurance Plan (QAP) followed : Note: Enclose QAP followed in respect of the equipment specified in the tender. If already furnished, please ignore.


19.2 Quality Control and Testing Facilities Available: (Specifications & other details of the Equipments, machines & Facilities, available at Works and Quality Assurance Plan shall be given separately )

19.3 Tie-up with Testing Agencies/Laboratories and details of tests carried out: Type of Tests/

Qualifications Address of Testing Agencies/Laboratories

with FAX & Tel Nos. Physical

Chemical

Radiography

Ultrasonic

Welder Qualification

20. List of Cranes/E.O.T. Cranes under manufacture at vendor’s works at present

Sl. No.

Details of Cranes under manufacture

Client’s address, Fax. No., Telex No., Phone No.

Remarks

21. Work Experience:

The BIDDER shall furnish here a list (as per format given hereunder) of similar capacity crane manufacturing &/ erection jobs executed by him to whom a reference may be made by the PURCHASER in case the PURCHASER considers such a reference necessary.

Sr.No Name of the Client

Details of EOT Cranes supplied

(20 T & above)

Value of Order Year & Period of Job execution

Name, address, Tel. & FAX No. of the officer of the client to whom reference may be made by the Purchaser.

22. Give a list of similar jobs executed in the recent past for the Govt. organization especially that of Department of Atomic Energy. (as per format given above)

Signature :

Name of the Officer :

Company Seal


A N N E X U R E - V I I

P r e f e r r e d M a k e s

Sr. No. Item Description Name of make/brand

1. Steel TATA / SAIL or equivalent

2. Gear box SEW / Elecon / Nutek or equivalent

3. Electro Hydraulic Thruster Brake SOC / Electromag or equivalent

4. DCEM Brake BCH/SPEED-O-CONTROL/OMEGA CONTROL/STORMCRAFT or equivalent

5. Hoisting rope USHA MARTIN or equivalent

6. Hook & Hook Block B.R. HERMAN & MOHATA / E.E KARACHIWALA / Smriti Forging / Hurculus Forging or equivalent

7. Bearing SKF / FAG or equivalent

8. Fasteners UNBRAKO or equivalent

9. Electric Motors ALSTOM / BBL / Seimens / CGL or equivalent

10. DSL SAFE LINE / SUSHIL or equivalent

11. VVVF control Drive along with drive enclosure

YASKAWA / SCHNEIDER or equivalent

12. Feedback Encoder

for VVVF control drive

Hubner / Hengstler or equivalent

13. Transformer AE / Kappa or equivalent

14. Fuses SIEMENS / L&T or equivalent

15. Main Isolator SIEMENS / L&T or equivalent

16. Contactors BCH/SIEMENS / L&T or equivalent

17. Limit Switches BCH / Electromag / SOC or equivalent

18. Fixed cabling system UNIVERSAL, FINOLEX,TORRENT or equivalent

19. Flexible Cable wiring

(HFFR / FRLS)

FINOLEX / RR CABLE/ Lapp or equivalent

20. Control Panel TECHNO ELECTRICALS / KAIREL / Rittal or equivalent

21. Pendent Push buttons SIEMENS / SCHNIEDER/Tecknic or equivalent

22. Switch Fuse SIEMENS / L&T or equivalent

23. LED indicating lamps Schneider / Siemens / Tecknic or equivalent

24. Radio Remote Pendent SNT controls / Stromag /Acropolis or equivalent


ANNEXURE-VIII

Quality Assurance Plan to be fol lowed

Bidders Name & Address Legends

MTC : Material Test Certificate TC : Test Certificate from Lab IR : Inspection Report P : Performed by W : Witness by V : Verified by

1-BARC 2-Bidder/Crane Manufacturer 3-Sub-Vendor/Testing Lab-Agency

Sr. No.

Components/ Operation

Characteris-tics Check

Category Quantum Reference Document

Format of Record

Agency Remarks

P W V

A RAW MATERIALS

A1 Plates, Rolled Section, Box Girder, End Carriage and Rope Drums, Sheaves, CRAB Frame

Chemical Major 1-2 samples per lot/size

IS-2062 TC 3 3 1, 2 Steel plates shall be identified by the Purchaser & stamped before tests. One test piece per heat run per size shall be subjected to Physical & Chemical tests. If correlation between MTC & TC is not found, all plates of the particular size & heat run shall be rejected.

Physical Major 1-2 samples per lot/size

Do TC 3 3 1, 2

Ultrasonic Major 100% IS-3664 IR 2 1 For all sheets used in fabrication of Rope drum and sheet having thickness of 20 mm & more.

Major 1-2 samples per lot/size

IS-3664 IR 2 1 One sheet per size per lot shall be subjected to Ultrasonic Test.

A2 Forgings for Gears, Pinion and Wheels

Chemical Major 1% Heat IS-170 C-45, C-50

MTC 3 3 1, 2

Physical (R2)

Major 1% Heat Do - MTC 3 2 1, 2

Ultrasonic Major 100 % IS-3664 IR 2 1

A3 Shafts Physical Major 1% Heat IS-1570 C-30 BS-970 BN-8

MTC 3 3 1, 2

Chemical Major 1% Heat Do - MTC 3 3 1, 2

Ultrasonic Major 100% IS-3664 IR 2 1 1, 2

A4 Sheaves & Brake drums ( made from cast steel)

Chemical Major 1% Heat IS-1030 Gr.II

MTC 3 3 1

Physical Major 1% Heat - Do - MTC 3 3 1 Physical test shall be witnessed by BARC-QS.


Sr. No.


Characteristics Check


Format of Record

Agency Remarks P W V

A5 Hook + Trunnion (Cross Head)

Chemical Major 100% IS-1875/ 3815Gr.II

MTC 3 3 1, 2

Physical Major 100% - Do - MTC 3 3 1, 2

Proof load Test

Critical 100% IS-3815 MTC 3 1 For Hook

M.P.I/01 Critical 100% IR 3 1 For Hook

U/T Critical 100% IS-3664 IR 3 1 For Trunnion & Hook

A6 Wire Rope (Fibre Core)

Break Load Test

Critical 100% IS-2266 MTC 3 3 1, 2 Required length of wire rope shall be cut from the drum inpresence of the Purchaser.

A7 CT & LT Rails Chemical Major 1/Lot IS-3443 MTC 3 3 1, 2

Hardness Major 4-5 spots in each Rail

Approved Drawings

IR 3 1

B INSPECTION IN PROCESS

B1 Welding + Welder Qualification

Weld Quality

Critical As pr ASME Sec. IX

ASME Sec. IX

PQR 2 1

- Approved Electrode & approved WPS shall be used

B2

Girder End Carriage & Trolley Frame

Dimensional Major 100% Approved Drawing

IR 2 2 1

Weld Set-up Major 100% IR 2 1

Butt Welds Radiography

Critical 100% ASME-SEC-VIII

IR 2 2 1 For Box Girder only.

Fillet Welds DP Test

Major` 100% IR 2 1

B3 Rope Drum Dimensional Major 100% Approved Drawing

IR 2 2,1

1 After Machining

Butt Weld Radiography

Critical 100% ASME-SEC-VIII

IR 2 2,1

1

Fillet Weld DP Test

Major 100% IR 2 1 - After Machining

Stress Relief Critical 100% ASME Sec. VIII

IR 2 2,1

1 TT Chart shall be signed by BARC-QS after checking the loading in approved furnace


Sr. No.




Format of Record


B4 Gear Box Stress Relief of Housing

Major 100 % ASME VIII

IR 2 2 1 SR Chart review by BARC-QS witness at random. Difference in hardness of Gear & Pinion should be about 50 BHN

Gear + Pinions Dimensional

Major 100 % Mfg. Drg. IR 2 2,1

2

Gear + Pinion Hardness after Case Hardening

Critical 100 % Mfr. Std. IR 2 1

Gear + Pinion DP Test

Major 100 % IR 2 1

Run Test for Noise Level

Major 100 % Mfr. Std. IR 2 2,1

B5 ST and LT Wheels

Surface Hardness

Major 100% 250-350 BHN

IR 2 1 -

U/T Critical 100% IS-3664 IR 2 1 -

C ELECTRICAL ITEMS

C1 Motors (a) Type Test

Major

Mfr. Std.

IS-325

TC

3

3

1, 2 Type test shall be carried on only Main Hook Main motor. All other motors shall be subjected to Routine test.

(b) Routine Test

Major 100% IS-325

TC 3 1 -

C2 Brakes, Limit Switch

Operation Test

Major 100% Mfr.Std. TC 3 3 1, 2 Approved makes

C4 DSL Visual Minor 100% Mfr. Std. IR 2 - - Approved makes

C5 Control Panel Continuity Major 100% No discon-tinuity

IR 2 1 Approved make

Insulation Resistance

Major 100% As per Spec.

IR 2 1

H V Major 100% As per Spec.

IR 2 1

Functional Critical 100% As per App. Drg.

2 1 -

Paint Quality/ Thickness

Minor 100% As per Drg.

IR 2 1 -


Sr. No.




Format of Record


D At Bidder's works & at purchaser's site after erection

D1 Crane Dimensional Major 100% Approved. Drawing

IR 2 1 - At Bidder's works

D2 Crane Load Test Critical 100% IS-3177 IR 2 1 - At Bidder's works & at purchaser's site after erection

D3 Crane Over Load Test (25%)

Critical 100% IS-3177 IR 2 1 - Measurement of current speeds, Drawn by motor, deflection etc. Tests to be carried out at Bidder's works & at purchase's site after erection.

D4 Crane Deflection Test

Critical 100% IS-3177 IR 2 1 - At Bidder's works & at purchaser's site after erection

D5 Crane Functional test of all components

Critical 100% Approved. Drawing

IR 2 1 - At Bidder's works & at purchaser's site after erection