ANNEXURE TO TENDER NO : DPS/ MRPU/HWP/CAP/9187/PT-2292 PreBid Meeting: A prebid meeting has been arranged in Madras Regional Purchase Unit, Department of Atomic Energy, VI Floor, Shastri Bhavan, No.4 Haddows Road, Chennai 600006 on 10/10/2017 at 11:00 a.m. Bidders intended to participate in this tender are requested to attend the meeting. For attending the prebid meeting prior permission or gate pass is NOT required. However, bidders attending the meeting are requested to send an email to apo2mrpu.tndae@nic.in, pomrpu.tndae@nic.in & rdpamrpu.tndae@nic.in for information. 1. Scope: 1.1. This specification intends to cover the responsibility of supplier relating to following scope:

S. No. Item description Unit Quantity

1. Design, engineering, manufacturing, shop fabrication. assembly,documentation, inspection & testing at manufacturer’s works,packing, dispatch, transportation, safe delivery to site, required fabrication at site, installation, site testing & commissioning, guarantee, final painting at site (if required)DOUBLE GIRDER (Box Plate type- pendant controlled) Electric Overhead Travelling Crane ( as per IS: 807, IS 3177, IS 4137 ) 10 MT SWL complete withall electrical and standard accessories& spares required for efficient and uninterrupted trouble free crane operation for two years to Magnesium Recycling Technology Development and Demonstration Facility (MRTDDF) at Zirconium Complex Pazhayakayal Tuticorin – 628 152as per tender specification, relevant drawings, codes indicated there in.

Nos. One

1.2. The scope of supply shall also include but not be limited to the following, along with necessary fittings, fixtures and accessories:

a. Bridge Structure with platform and hand railing

b. Travelling mechanism for long travel (LT) and cross travel (CT) shall include end carriage, trolley, drive motor, gearbox, couplings, guards; track wheels, runway rails with all structural connectors and anchor bolts/holding downbolts, crab girders, end stops with spring/ rubber buffers/bumpers, and wheel stops;

c. Hoisting mechanism(including wire ropes, rope drums, hook block& hooks, mountings etc.)

d. Brake mechanism separately for LT, CT and hoisting e. Pendant push button control (Pendent cable, pendent festoon, pendent track) and

wireless remote operation for all movements f. Electrical Motors, AC variable frequency controls for all motions of the crane,

control gear and switch gear, limit switches, trolley lines and power supply arrangements (including trolley conductor track, trolley festoon, long travel conductors, trailing / flexible cables), cable trolley etc.

g. Lighting fixtures and accessories, earthing of all electrical equipment in crane

h. Service Platform on both sides of crab girder Exclusions:

a. Civil work including grouting b. Long travel supporting girder structure.

1.2. Following items are also included in bidder’s scope:

• All drawings / documents along with operation and maintenance manuals as per requirement mentioned elsewhere in the tender document. Getting approval of design/drawings and any other design calculations related to the equipment from purchaser. Carrying out any modifications/ deletions /additions / alteration in design / drawings/ documents as required by client for proper execution of works at site till completion and handing over of item to the client.

• Consumables like first fill of lubricating oils, grease, kerosene, solvents, sealing compounds and brake oil etc. for the initial operation of the equipment till handing over. The scope of consumables shall also include shims, pickings, bolts, nuts, rivets, joining compounds, gaskets, rivets, washers, tapes, connectors, brazing and soldering materials, welding and brazing gases and rods, electrodes and wires, temporary supports, sand and emery paper etc. The Bidder shall indicate the annual requirement of all such consumables.

• Special tools & tackles, if any required shall be supplied. o All tools and tackles, apparatus, special instruments required for erection,

testing, commissioning, maintenance, overhaul or complete replacement of the equipment and establishment of the Performance Guarantee Test, measurements as required shall be arranged by the successful Bidder.

o The necessary equipment such as special purpose welding machines, fixtures, tools & tackles and other equipment required for fabrication/ assembly (necessary for erection) work to be done in the plant premises shall be arranged by the successful Bidder.

o For load testing of handling equipment, loads shall have to be arranged by the successful Bidder. Electrical/ operation tests, as per standard practice, shall also be arranged and completed by them.

• Commissioning spares and start-up spare parts if any required, during erection and commissioning shall be in scope of supplier. Any leftover commissioning spares shall be the property of the Purchaser.

• Recommended spare parts for (2) two years of trouble free operation of EOT crane rate shall be quoted in the online price bid. As a minimum, following spares shall be supplied: S.No. Item Description Quantity

1 2 3 4 5 6 7

Bearings Thrusters Brake liner with rivets Brake shoes with complete lining Main spring for thrusters brakes Limit switches for all movements (MH,CT,LT) Gaskets

One set One set One set One set One set One Set Two sets

8 9 10 11 12 13 14

Solenoids Rubber items (O rings & oil seals) Clamps Relays (over load) Fixed & Moving contact for each type contactors Current collectors Fuse links (one set of each size)

One set Two sets One set One set One set

Two sets Two sets

Note: One set consists of 100% installed quantity

• 3 Phase, 415V, 50 Hz power supply at switch fuse unit shall be provided at one point for EOT Crane at ground floor. Further distribution including supply, laying & termination of cables shall be in Bidder’s scope.

1.3. General Requirements:

• It is not the intent to completely specify all details of design and construction of these; nevertheless, the equipment shall conform to high standards of engineering, design and workmanship in all respects. Unless otherwise specified, the main equipment and their various components as specified in drawings and tender document shall be included in supplier’s scope of work.

• The vendor shall make all possible efforts to comply strictly with the requirements of this specification and other specifications / data sheets as mentioned. In case, any deviations are considered essential by the vendor after making all possible efforts, these shall be separately listed in the vendor’s offer under “List of deviations / exceptions to the inquiry” for the purchaser’s considerations with cross-references and proper reasons for the deviations /exceptions. In the event of any deviation not listed under the ‘List of deviations / exceptions to the inquiry’, even though it is appearing in other part of the offer, shall not be considered applicable. Hence all the requirements shall be binding on the vendor without any cost and schedule implications to the purchaser.

• The offered model shall be from the regular manufacturing range of the supplier and the design shall have had a minimum experience of two years successful field operation with the same model having the same design and materials of constructions. Relevant information of the offered equipment like catalogues, references, user’s certificates etc. shall be furnished along with the offer.

• Offer shall be submitted as per Annexure – A (Schedule of Quantities & Rates)

• Refer Civil Drawing of Building Elevation: Drg No: HWP/TUT/ARCH-003, Sheet3 of 3, dated15/04/2015 for crane installation.

2. Reference Codes& Standards: • IS 807: Design, Erection and testing (Structural Portion) of Cranes and Hoists – Code of

Practice

• IS 3177: Code of Practice for Electric Overhead Travelling Cranes

• IS 3443 : Crane rail sections

• IS4137: Code of practice for heavy duty electric overhead travelling cranes including

special service machines for use in steel works.

• ISO 12488-1: Cranes – Tolerance for wheels, travel and traversing tracks.

• IS 13558 (Part-5)/ ISO 7752-5 Cranes-Controls-Layout and Characteristics

• IS 15560 : Point Hooks with Shank up to 160 Ton — Specification.

3. Technical Requirements:

3.1. General Design:

• EOT cranes shall be designed, manufactured and tested in accordance with the latest revision of IS 807, IS 3177, IS 4137 and other code and standards as indicated above under paragraph 2.0.The EOT crane to be designed for the parameters indicated in the table below:

DATA SHEET

S.N. Item Parameter

Location Magnesium Recycling Technology Development And Demonstration Facility (MRTDDF) At Zirconium Complex Pazhayakayal, Tuticorin – 628 152

Duty Class of Crane (As per IS 807)

Class II/B (M5)

1. Hoisting Capacity (SWL) 10 MT

2. Crane Span 13.12 m

3. Long Travel 45 ± 0.5 m

4. Lifting Range 10 m± 0.2 m (Hook Height)

5. Hoist Speed 2.0 m/ min By pendant control & also through wireless remote control. 6. Long Travel Speed 10.0 m/min

7. Cross Travel Speed 5.0 m/min

8. Creep Speed Pre-settable Minimum 10% to 100% in steps of 10% of full speeds by VVVF

9. Main Hook Forged construction Swiveling 360⁰ rotation typewith suitable thrust bearings, plain shank having trapezoidal section and in built sling locking facility

• Environment: Crane and associated equipment shall be suitable for daily use in the environment having atmosphere laden with vapour of MgO&Cl2 gas. Ambient temperature 55⁰C, Relative humidity @ 65%. The equipment should be suitable for smooth, efficient and trouble free service in the tropical humid climate prevailing at plant site and under the ambient temperature conditions indicated above. Factor of safety for the design of components shall be as per relevant code.

• The crane components shall be standardized to keep the number of spares to the minimum.

• All parts requiring replacement or inspection or lubrication shall be easily accessible without the need for dismantling of other equipment or structures.

• Crane shall be designed with headroom and for closest approach of the hooks to each end stop as specified in data sheet and attached drawing.

• All machinery or equipment included under this specification must be equipped with safety devices and clearances to comply with recognized standards, Purchaser's requirements along with safety codes. The crane should comply with the relevant safety regulations under the Factories Act, Indian Electricity Rules and other statutory regulations as applicable.

• Materials shall be of tested quality, conforming to the standards specified, and shall be new and unused. No cast iron, until permitted by code, shall be used for crane components except for electrical equipment. Defects in the material like fractures, cracks, blow holes, lamination, pitting etc. are not allowed. Rectification of any such flaw is permissible only with the approval of the Purchaser.

• Plates, bars, angles and where practicable other rolled sections used in the load bearing members of structures shall not be less than 6 mm in thickness. The minimum thickness of chequered plates shall be 6 mm.

• The Supplier shall ensure that the crane shall be manufactured with permissible tolerances as per applicable IS standards & standard engineering practices. A certificate in this regard stating compliance with requirements of code and standards shall be submitted along with final documentation.

3.2. Bridge Girders: • The crane should be rigid, robust and of sturdy construction. The crane bridges shall be

mild steel in compliance with the relevant standard. It shall be of welded double/single web box construction and designed as per IS: 807 and IS 3177. All welded subassemblies of box-girders should be stress relieved before final welding. Transverse fillet welding on load carrying members shall be avoided. All Welded joints shall be subjected to magnetic particle test / dye penetrant test. In addition to that all butt welds subjected to tensile stress shall be 100% radiographed.

• Girder shall be designed so that the vertical deflection caused by the safe working load and the weight of crabin central position (without taking into consideration impact factor) does not exceed 1/750 of the span. Deflection of member of the structure as a whole shall not impair the strength or efficiency of structure or lead to damage. Bridge girder shall be cambered by an amount specified by relevant IS code.

• Handling points shall be marked clearly on girders to enable handling of crane girder without any damage during erection. Black bolts shall not be used in the main structure of the cranes.

• The platforms along the bridge girders and over the crab shall allow convenient access for replacement, inspection, lubrication etc. for different mechanical and electrical components. Foot-walks shall be of sufficient width to give at least 500 mm clear passage at all points. Two spotlights shall be provided on each girder for operating convenience. Walkways shall be of chequered plate of non-slip steel surface.

• Breathing holes shall be provided in completely enclosed welded box type girders. Drain holes shall be provided in all places where water or oil is likely to collect. Wherever practicable, means of access shall be provided for inside inspection of completely enclosed box girders.

• Bottom of the drive mechanism of Bridge, Trolley & hoist shall be covered by the platform to avoid any free fall of the loose components.

• Spring loaded type buffers shall be provided on all the 4 corners of the bridge girders and the end carriages for cross and long travel motions respectively.

3.3. End Carriage:

• The end-carriage shall be of double web plate box construction and shall be connected to the girders by welding at shop or by large gusset plates and fitted bolts to ensure maximum rigidity. End carriage shall be made from rolled steel sections or plates to IS: 2062welded together to form a box. The design shall be such that the load isuniformly distributed. In the attachment of end carriages to the main girders, gusset plates ordiagonal bracing shall be employed to provide lateral strength.

• The end-carriage shall be fitted with substantial safety stops to prevent the crane from falling more than 25 mm in the event of breakage of a track wheel, bogie or axle. These stops shall not interfere with the removal of wheels.

• Ends of the main girder shall extend over the full width of the end carriages and the extension shall have sufficient shear section to take the maximum reaction from girders. The reaction from main girders shall be distributed over the width of end carriage.

• End carriages shall be designed so as to enable the track wheels to be withdrawn readily. Jacking pads shall be provided for jacking up the crane for changing crane wheels.

• End carriage shall be provided with spring buffers at each end to enable smooth stopping of the crane at end of runway.

• Repair cages shall be provided below the end carriage for maintenance ofDSL and current collectors.

3.4. Lubrication:

• Grouped grease lubrication shall be provided for each mechanism (CT, LT,and Hoist). Each mechanism shall have hand grease pump for lubricating all parts ofthe mechanism simultaneously. All grease piping shall be securely fixed. For LTmotion, two groups (one at each end) shall be provided.

• Lubrication of the gears and pinions in the gear-boxes shall be splash fed from the sump. In case of three reductions, vertically mounted gearbox (having limited motion), an oil pump shall be fitted to ensure lubrication of all gears.

3.5. Crab Construction: • Crab frame shall be fabricated from steel plates and rolled sections in welded construction

as per IS: 2062, designed to transmit the loads to the bridge rails without undue deflection. It should be made rigid and robust. Frames carrying mechanical and electrical driving equipment shall be fitted with doubling plates of adequate thickness welded on and

machined to true surfaces. • Crab frame shall be fabricated in one piece if there are no transport limitations. If the

trolley is fabricated in more than one piece due to transport limitation, the design of the splice shall be such that one unit of mechanism mounted on one part of the trolley, does not come over the other part.

• End stops shall be fitted to prevent the crab from over running. Crab structure shall be provided with buffers to enable smooth stopping of the crab at runway end. Crab structure shall be provided with safety stops to prevent its jumping off the rails in the event of breakage of track wheel bogie or axle.

• Floor of crab shall be covered with checkered plates except for opening required for ropes and other parts. Hand railing shall be provided on the two open sides of the crab.

• Crab shall be provided with jacking pads for its lifting during removal of wheels and other repairs.

• All rotating parts including revolving shafts shall be adequately guarded to meet safety requirements.

3.6. Runway Rails:

• The crane rails as per IS 3443 along with fixtures such as shims, anchor bolts, inserts, and sole plates shall be supplied. For both LT & CT the (forged steel) Rails fitted shall be anchored properly & of suitable size to with stand the load. The vendor shall arrange for the supply & erection of these rails for both long travel & cross travel, with stopper cum shock absorbers at both terminals of the rails. Rail alignment shall be within tolerances specified by the relevant code or +/- 2mm over a length of 3.0metres whichever is minimum, after installation at site. Distance between consecutive anchor bolts along the axis of rail shall be as per applicable code.

• Torque checking of the base bolts of the crab & stability checking of the crane during Long Travel with test load on, shall be demonstrated at installation site.

3.7. Crane Wheels: • Crab/crane wheels shall be double flanged straight tread type with tread and flange

machined accurately to size and suitable to the crane rails. Wheels shall be mounted in anti-friction roller bearing housed in `L' shaped bearing brackets for easy removal during maintenance. Wheel & Axle joint shall be as per applicable code.

• Material grade, size & other dimensions of track wheels and wheel flanges shall be as per applicable code. Solid wheels shall be of high quality forged rolled/cast steel duly impact tested for a maximum load situation with test load on its Crab Trolley. The provided hardness on rail & wheels and their difference shall be in-line with applicable code requirements. Rail & wheel hardness values shall be verified during inspection stages.

3.8. Rope Drums:

• The drum shall be round in construction with multiple sheaves /grooves on it for guiding the hoist rope correctly during winding. Size of Pulley grooves, sheaves shall be such that it exactly matches with the rope diameter. Rope alignment shall be as straight as possible.

The grooves of the drum shall be smooth finished. Drum strength, drum diameter and drum grooving shall comply with the requirements given in IS: 3177.

• Drums shall be fabricated from IS: 2062 (hard-faced) or suitable alternatives Circumferential welded joint shall not be permitted. All Butt welds shall be 100% radiographed and fillet welds dye checked at root and Final runs. The plate material for the drum shall be accepted only after this plate has been successfully passed in ultrasonic testing. The fabricated rope drum shall be stress relieved.

• Drums shall be flanged at both ends and flanges shall project a distance not less than two rope diameters above the rope. A spur or wheel secured to the drum may be regarded as forming one of the flanges.

• Drums shall be sufficiently wide to accommodate in one layer the length of rope required for specified lift and in addition free extra turns as specified in IS 3177 shall also be provided. However in no case, not fewer than two dead turns ateach anchored end and one space groove at opposite end shall be provided.

3.9. Pulleys:

Material grade, physical properties and hardness of rope pulley/ sheaves shall be as per IS 3177.Pulley size/diameter, sheaves grooving, its lead angle and equalizing sheaves shall comply with the requirement specified in IS: 3177.Pulley shall be provided with guards to retain the ropes in the grooves.

3.10. Wire Ropes:

• Wire rope shall conform to requirement specified in IS: 3177.It must be lubricated, kink free and its free end shall be suitably held to prevent unwinding of the strands. Preferably “Hyflex” type wire ropes should be used. If it is conventional type, then it should be 6 x 36 constructions. Wire ropes shall be of reputed make like Usha Martin or equivalent with relevant test certificates.

3.11. Bearings:

• Type of bearings recommended for various parts shall be as per IS: 3177 and shall be of FAG/SKF/NTN make. Anti-friction bearings shall be used throughout except where required otherwise for technical reasons.

• Provision shall be made for service lubrication of all bearings. Bearing enclosure shall be designed as far as practicable to exclude dirt and prevent leakage of oil or grease. Suitable drip pans shall be provided as required to collect oil and grease, which may drop from operating parts. All drip pans shall be accessible for draining and cleaning.

3.12. Couplings:

Couplings shall be of forged steel and shall be designed to suit the maximum torque that may be developed. Service factor of coupling shall not be less than that of gearbox. Type of coupling shall be as per IS 3177. All Rotating parts shall be suitably covered by 3.15-mm thick sheet steel hinged covers for safety.

3.13. Buffers

Suitable buffers shall be fitted to each end of the end carriage assemblies and on both sides of crab or the bridge.

3.14. Shafts:

Shafts shall be made from rolled/ forged steel bars meeting requirement specified in IS 3177.All forged shafts / axles shall be ultrasonically tested. Physical and chemical tests shall also be conducted.

3.15. Gears, Pinions & Gear Box

• Straight and helical spur gearing shall be used for all motions. Worm & bevel gearing may be used in exceptional cases with the specific approval of the Purchaser. All first reduction gears shall have helical teeth. All pinions shall be integral with the shaft. All gears shall be hardened and tempered alloy steel for resistance to wear having metric module. Overhung gears shall not be used. All bearings of gears shall be anti-friction type.

• Material grade, size & other dimensions of gears shall be as per applicable code. The provided hardness on matching pair of gears and their difference shall be in-line with applicable code requirements and same shall be verified during inspection stages.

• Gears shall have tooth form and modules adequately designed to withstand shock load, vibration& noise within limit for smooth operation.

• Gearbox shall be designed and manufactured taking into consideration the requirements given in IS: 3177. All gearing shall be totally enclosed in oil tight gearboxes. No open gearing shall be allowed to be used in any motion. Gearboxes shall be of high grade cast iron/cast steel or fabricated and split at each shaft centerlines. Fabricated gearboxes shall be stress relieved before machining. Gearboxes shall have drip pans to avoid oil falling on the shop floor.

• Preferred makes of gear box shall be Elecon/ NAW/ Flender/ Premium energy transmission/ Shanthi gears.

3.16. Lifting Hook:

• Hook block shall be designed to lift without twisting. It shall have load locking facility and anti-swiveling arrangement. Multiple pulley arrangement shall be provided for maximum Mechanical Advantage. The sheaves shall be fully encased in closed fitting guards fabricated out of steel plates. Smooth opening shall be provided in the guards to allow the free movement of rope, and holes shall be provided for drainage of the oil. The make of bearings shall be FAG/NTN/SKF.

• Hook shall be trapezoidal section, have in built sling locking facility, with suitable thrust bearings and 360⁰ rotation type. It shall be solid, forged, heat treated, of rugged construction and of material grade as per IS 3177/ IS 15560. The hook shall be supplied with physical /chemical test reports shall be proof load tested marked and duly certified by laboratory. It shall also be magnetic particle tested before and after proof load test.Safety latches shall be provided on hooks to prevent coming out of the slings.

3.17. Brakes:

• Brakes shall be fail safe type and shall be applied automatically when, power to drive motor fails. Brake shall be applied directly to the motor shaft and shall be equally effective in both directions of rotation. Design and rating of brakes shall be as per IS: 3177. The brakes shall be provided for all motions on the high-speed pinion shaft of the gear train. For hot metal hoists, two brakes shall be used per motor.

• Brake shoes shall be self-aligning type and shall have large cooling surface for low temperature rise.

• Bridge and trolley shall be provided with following type of LT & CT motion brakes :

o For Long Travel (Bridge travel) – Electro-hydraulic thruster brakes - 1 No. (Each drive unit).

o For Cross Travel (Trolley travel) - – Electro-hydraulic thruster brakes - 1 No.

• Main hoist brake shall be provided with two motion brakes one no. each of Electro-Mechanical (EM) Fail-Safe D.C. Disc Brakes and Electro Hydraulic Thruster (EHT) Brakes. The design of brakes and braking torques shall be as per IS 3177.

• For thruster brake used for hoisting, anti-drop feature shall be provided to prevent lowering of load during application of brake by suitably connecting the hoist motor in reverse direction with the help of suitable control scheme.

• Emergency braking: All brakes shall, irrespective of control or position, be applied immediately on operating the emergency stop push button or switches.

3.18. Drive Unit

• Equal driving efforts through synchronized motors shall be applied at each drive wheel of bridge to prevent one end travelling faster than the other. Minimum 50% of wheels shall be power driven. Cross travel of Trolley shall be achieved by single motor in which the motor shall drive a common output shaft through gearbox. Refer Electrical details.

4. Electrical Details:

4.1. Scope of Supply:

• All accessories and auxiliary electrical equipment including drive motors, electrically operated brakes, controllers, panels, motors, drive controllers, DSR, main current collectors, limit switches, socket outlet, pendant remote, protective devices, cables, conduits, metal halide luminaire (250 W, four nos.) etc. necessary for the safe and satisfactory operation and maintenance of the cranes shall be included in the bidder’s scope of supply. Electrical equipment shall be adequately rated and of suitable duty to permit simultaneously operation of any combination of motions of the crane for its duty service.

• The scope of work also includes complete assembly and wiring and testing of crane at site, erection and testing and commissioning of all electrical equipment along with spares as specified. Department shall provide 415 V, 3 Phase, 4 Wire, 50 Hz of suitable capacity at one point further distribution of supply shall be in the scope of bidder.

4.2. Standards:

• The equipment should be selected, assembled and tested as per guide lines provided in the latest edition of Indian Standard Specification Nos. IS: 3177 for Class-II/B (M5) duty. The equipment should also conform to the latest Indian Electricity Rules and regulations as regards Safety requirements, earthing and other essential provisions specified therein. The equipment should be designed and selected to facilitate inspection, cleaning, replacement and repair and for use where continuity of operation.

• Climatic conditions: All electrical equipment shall be designed as per environmental condition defined in the tender sr. no.1

• Power supply and Standard voltage levels: The power supply of 415V, 3 phase, 50 Hz, 4 wire solidly earthed system. shall be made available at one point at ground floor of the building. Further distribution and derive of different voltage shall be in the scope of bidder.

• The following standardized voltage levels (indicatively) are as follows:

1. 400/415 + 10% V, 3 ph,50hz, AC For motors and electro-hydraulic thrusters

2. 415/220V, single phase Isolating Transformer

For control circuit, lighting and fan

3. 24V,single phase, 50hz, AC For hand lamp socket outlets

4. 220 V, AC, 1- ph, 50 Hz For control circuits as applicable

• The different voltages mentioned above other than 415V, 3 phase, 50Hz, AC should be obtained through individual separate transformers and transformer rectifier units connected to 415 V, AC. Each transformer should be provided with tapping at secondary side.

• The three phase symmetrical short-circuit ratings of the switch gear at 415 V is 50 kA for 1 second.

4.3. Power Distribution and Panel :

• One adequately rated load break manual isolator with locking facility shall be provided immediately after current collectors on incoming line on the crane. The further distribution of the supply to be done through power distribution board. Each circuit shall be provided with facility for isolation and protection against short circuit.

• The panel shall be of flame proof type compatible for gas Group II B.

• Panel shall be painted with good quality powder coated paint

• Panels shall be front wired with readily accessible terminal blocks for making connection in the external equipment.

• All cables (power and control) are FRLS and minimum 2.5 sq. mm copper cable to be used for control cable

• All contactor shall be of AC4 class of duty with rating 1.5 times higher than the full load current of the respective motors at the specified duty cycle. The directional contactors of all motors shall be suitable interlocked (mechanically and electrically) for correct sequence of operation.

• Door hinges shall be such type that during the repair work inside the panel the entire door can be lifted out and placed away enabling better access inside the panel.

• Each motion shall have individual panel. However common panel with separate compartment for each motion shall be acceptable.

• All panels shall be of free-standing floor-mounting construction, suitable to withstand vibrations encountered on crane.

• Minimum 20 % spare terminals to be provided in terminals strip.

• All equipment inside the panel shall have permanent identification labels in accordance with circuit diagram

• All the panels and cabinets shall also be provided with CFL luminare for interior illumination.

4.4. Motors:

• The crane should be provided with crane duty AC motors .

• The motors of adequate power are to be selected to provide sufficient drive force in the entire range of speed.

• The motor shall be S1 class of duty (based on application) and CDF 40% (for a period 60 minute) The class of insulation shall be Class F but temperature rise restricted to class B.

• The synchronous speed as suitable to various motions.

• The motor should be of flame proof type suitable for Gas Group II B.

• The bidder should furnish test certificates at the specified duty cycle for the individual motor. All the motors offered should be suitable for heavy duty reversible crane service.

• The pull out torque of the motors at rated voltage and frequency should be not less than 2.25 times of the nominal torque.

• The bidder should be responsible for selecting ratings (as per IS 3177) that will meet the specified duty with the type of control specified. Ambient correction factors depending upon ambient temperature should be applied to de-rate the motor. During detailed engineering all sizing calculation has to be submitted for the approval of purchaser.

• The rated capacity and frame sizes should be attached with the offer.

• All electrical equipment associated with the crane including motors push buttons, switches, control panels, starters, control transformers, relays, shall be in accordance with

relevant Indian and International standards. The starter panel and push button pendant should also be of “Flame proof” compatible for Gas Group II B

• Type and routine test certificate to be furnished by the bidders.

• Routine test shall be done in presence of purchaser representative.

4.5. Festoon System:

• Heavy duty “ I” – beam supported Festoon cable System shall be designed for Long Travel & Cross Travel movement of the crane.

• Power cables shall be FRLS with PVC insulated and copper conductor.

• Minimum size of control cable to be 1.5 sq. mm.

• System consists of an end clamp which secures the cable at the non-moving end, a tow trolley or control unit trolley which is moved back and forth manually by a series of intermediate trolleys supporting the cable.

• Adequate nos of intermediate trolleys shall be designed for the total the travel distance of the system and the depth of the cable hanging

• Minimum 10" clearance should be maintained between bottom of loops and any fixed obstructions in total system length.

• The end clamp is fastened to the track beam. The end clamp should be installed and adjusted with a deviation of no more than 1° from the longitudinal and transverse axes of the track beam. A shear plate must then be welded on. Select the position of the end clamp so that when arranging the cables, the smallest bend radius of the cables can be maintained.

• The installation length is to be selected so that the cable is lying completely on the cable support and that the clamping is sufficient during operation.

• Cable package shall be placed towards the middle of the track beam so that the torque is in balance.

• Suitable copper cables are to be placed towards the center of the trolley and arranged symmetrically.

• When using cable trolleys with multiple cable support, the heaviest cables are to be placed on the uppermost support.

• When using cable trolleys with multiple cable support, the uppermost cables should be made slightly shorter than the cables below. Each layer of cables should be given somewhat less play than the cables below them.

• When using round cable clamps, cables should be arranged on the outer surface of the supports that are suitable for anchoring the round cable clamps.

• Unshielded cables with a large copper diameter are preferred. The diameter of the round cables should be fairly uniform for tight clamping of cable on the supports.

• Trolley wheel shall be easily maintained / replaceable with out disturbing the cable.

4.6. Limit Switches:

• All hoist motions should be provided with rotary and extra counter weight Limit Switch for over hoisting. For CT and LT, Cam operated limit switches should be provided.

• Two limit switches should be provided for proper back up protection. The first limit switch to act in the event of over hoisting and over lowering, should be rotary type with self-resetting feature, and be incorporated in the control circuit of the respective drive motor and the second one should be gravity operated switch (Push button bypass) connected in the trip circuit of the Line Contactor. Limit switch incorporated in the motor control circuit should act first, but in case this limit switch fails to operate the second limit switch should operate and trip the line contactor.

4.7. Crane Control:

• Hoist motion controls are required. For hoist control in hoisting and lowering directions, suitable schemes and complete equipment to meet functional requirement shall be provided. The hoist control shall be designed to achieve in changing speed of approximately 10% of rated speed in both hoisting and lowering directions with loads (from no load to full load) on hooks.

• Pendant push button control and wireless remote control for long travel, cross travel and hoist motion to be provided.

• As a minimum, following operations shall be possible with the help of pendent push button station and wireless remote control:

o Start / stop

o Hoisting up/down with normal speed

o Hoisting up/down with creep speed

o CT left/right with normal speed

o Emergency stop

o Luminaire start / stop

• The supply voltage to the pendant control shall be 24 V AC / DC.

• Necessary flexible multi core cable with sufficient length to be provided to enable the crane to be operated from ground floor level.

• The cover of pendant shall be firmly secured and capable of withstanding rough handling without being damaged.

• Crane operating nomenclature (crane direction, speeds, luminaries, start / stop, emergency stop etc.) should be clearly mentioned on the pendant.

• The mass of the pendant shall be supported independently of the electrical cable by means of wire rope / chain. Adequate guard to be provided to prevent accidental contact of pendant rope or holding wire rope / chain with cross traverse.

• Along with the push button pendant a wireless remote control (with a range of 100 meter of operation)should also be offered for operation of LT, CT, hoist motion and luminaries under the crane.

• Selector switch to be provided on pendant for pendant operation or remote operation.

• Pendant shall be flame proof and suitable for gas Group II B.

4.8. Cabling:

• All wiring for power and control circuit shall be carried out with FRLS and PVC insulated

• Minimum size for control cable shall be 1.5 square mm. whereas cable for current transformer minimum size is 2.5 sq. mm.

• Flexible trailing cable systems mounted on retracting support system. The flexible trailing cables shall have ample length and shall be supported by means of properly designed clamps. These clamps shall be fitted with cable trolly and shall run freely on a guide rail.

4.9. Emergency Stop Push Buttons:

• Safety switches of sustained contact type shall be provided at each end of crane bridge so that under any emergency conditions by operating any one of the switches theI/C CB is tripped thus cutting power to all motions. One number of emergency stop push button should also be provided at pendant and wireless remote control.

4.10. Lighting:

• Lighting should be provided areas where control panels, resistors and transformers are installed. Bulkhead fitting with Flame proof type should only be used for the above areas. Four numbers under bridge lights of 250 W HPMV lamps complete fitting with reflector to be used. Lighting transformers should have 50% reserve capacity. The lighting distribution board and metal clad switches incorporating MCBs, and ELCBs.

4.11. Socket Outlets:

• Minimum of three socket outlets for hand lamps should be provided at long travel Side Bridge and in the area where control panels, resistors and transformers are installed. Hand lamps should operate at 24V AC supply. Industrial type metal clad plug and sockets should be provided.

4.12. Earthing:

• Earthing to the crane should be effected through track rails and crane structure. Double earth to be provided from Track rails to the nearest earth pit by suitable GI earth strip. As such, all the electrical equipment mounted on crane should be connected to the crane

structure by means of earth links. The crane structure in turn should be made electrically continuous by proving jumpers over riveted or bolted joints. Equipment fed by flexible cables should be earthed by means of spare core provided in the flexible cable. The earthing point at two different location at ground floor shall be made available by purchaser, further hookup of the earthing connection for complete system shall be in the scope of bidder.

4.13. Approved Vendor List For Electrical Items:

• The preferred make for some of the items is given here under:

Sr. No. Item Make

1. Motors

SIEMENS / ABB / BHARAT BIJLEE / KIRLOSKAR / CG/ L&T Flame Proof Motor compatible Gas Group II B

2. Control transformer Kappa / Meco / AE / Silcon / Pragati

3. Indicating lamps BCH / Siemens / Technik

4. Sound Alarm BCH / Siemens / Technik

5. Panel component like MCB, relay, contactor, switches ,fuses etc.

Siemens / ABB / Schneider / L&T / havells / BCH

6. Luminaire Bajaj / Philips / Wipro / Havells / CG

7. Limit switches SOC / Siemens / BCH

8. Cables and wires Havells / CCI / Polycab / KEI / finolex / Torrent / RPG

9. Lugs and Gland Dowell / Janson / comet

10. Brake Pethe / stromag

• However under specific circumstances, other reputed equivalent make can be considered. The decision of purchaser in this regard shall be final and binding on the contractor.

4.14. Data Sheet (Electrical): Enclosed with Main Data sheet To be filled by bidder,

5. Inspection & Testing: 5.1. EOT Crane shall be subjected to stage wise expediting, inspection and testing and

vendors/sub vendor’s works by Purchaser/or its authorised inspection agency inspector. Vendor shall submit Quality Assurance (QA) procedures before commencement of fabrication. Approved QA procedures shall form the basis for equipment inspection.

5.2. Testing& Inspection at vendor’s works and site shall be carried out in line with the approved QAP. All the mandatory and optional tests as specified under IS 3177 and IS 807 shall be performed. Acceptance criteria shall be in accordance with various codes and

standards indicated under paragraph 2.0 above. As a minimum requirement following tests will be conductedand certified records of test results (works and site) shall be submitted along with the equipment. Test certificates of all bought out components shall also be provided:

• Testing and inspection shall be done as per approved QAP.

• Testing of electrical and mechanical equipment in accordance with appropriate standards.

• Full load and 125% overload test for hoist and cross travel motions at site.

• Hoist speed verification test at works and site.

• Deflection test at works and site.

• Functional test at site.

5.3. Any or all the tests, at purchaser’s option, may be witnessed by purchaser/ inspector from authorised inspection agency. However, such inspection shall be regarded as check-up and in no way absolve the vendor of his responsibility.

5.4. For site testing, the lifting tackle, slings, test gauges and instruments shall be arranged by the vendor. Test Load shall be arranged by the purchaser.

5.5. Operability tests and overload tests at site shall be carried out to demonstrate satisfactory operation of crane without undue friction or display of any other un-favorable characteristics. Equipment shall meet the performance requirements specified in this specification and data sheets.

6. Name Plate: Suitable manufacturer’s nameplates shall be supplied with the equipment. The nameplate shall be of corrosion resistant material, which may be an aluminum alloy or austenitic stainless steel. The nameplate shall, as a minimum, include all major design and fabrication data as approved with fabrication drawings. Further, Safe working Load (SWL) shall be displayed over the crane body/Girder by writing on a name plate (1000mm x 450mm wide x 3mm thick, M.S Plate duly painted) and fixed at a conspicuously visible location on the main girder. This plate shall also indicate the date of installation, date of next load test due.

7. Cleaning, Painting, Packing and Dispatch: 7.1. After successful PDI and before dispatch, all external surfaces of C.S. to be painted shall be

degreased and all rust and mill scale removed with suitable method. All machined surfaces shall be properly protected from rust and mechanical injury during transit and storage.

7.2. After all inspections, internal as well as external surfaces shall be painted with two coats red oxide primer followed by two coats of synthetic enamel paint. Painting shall be carried out as per manufacturer’s standard. The Girder structures shall be painted yellow. Before dispatch of the crane, complete crane covering structural, Mechanical and Electrical parts shall be cleaned by suitable approved method. After cleaning one coat of primer and two coats of Halogen gases resistant epoxy/chlorinated paint shall be provided, & the total D.F.T shall be of 150 microns.

7.3. Item shall be packed with proper packing material so as to avoid any damage during transit and shall be suitable for longer period storage. End connections shall be blanked, plugged, capped or otherwise suitably sealed to prevent the ingress of moisture, weld preparation

from damage. Attachments, spare parts of the equipment and small items shall be packed separately in wooden-cases. Each item shall be appropriately tagged with identification of main equipment, item denomination and reference number of the respective assembly drawing. All parts/consumables shall be properly packed, marked and sent separately along with the equipment. Detailed packing list in waterproof envelope shall be inserted in the package together with equipment.

7.4. Package box shall be provided with proper identification mark such as material specification, size, weight, box orientation, shipping address. All assemblies shall be properly match marked for site erection. Transit at supplier’s risk and cost and delivery F.O.R to the storage site.

8. Installation, Operation, Maintenance & Technical Data Manuals: Manufacturer shall compile a manual and shipped with the equipment information identified in accordance with the following:

8.1. An index sheet containing section titles, and a complete list of referenced and enclosed drawings by title and drawing number.

8.2. Written instructions and cross referenced list of drawings to enable the purchaser to correctly install, operate, and maintain all the equipment ordered.

8.3. Manuals prepared for the specified installation.

8.4. Installation manual shall include the following:

• Information such as special alignment and mounting procedures and all other installation design data.

• Utility specifications (including quantities) and special tools & tackles required.

• Special information required for proper installation design that is not on the drawings shall be provided separately from the operating and maintenance instructions.

8.5. Manual containing, operating, maintenance, and technical data shall be shipped with the equipment and shall include the following:

• Instruction for EOT Crane operation at specified environment conditions such as temperature.

• Required / recommended maintenance procedures. 9. Erection & Commissioning: 9.1. The erection of complete EOT including erection, its hook-up and integration with existing

electrical/ instrumentation system pre-commissioning checks, commissioning and testing at site is in the scope of contractors work.

9.2. The contractor shall arrange erection and commissioning of the crane. Adequate number of teams of technical experts should be made available so that erection and commissioning delays are eliminated. Such personnel will be required to be present immediately as soon as clearance for erection and commissioning is given from purchaser.

9.3. Adequate Supervision for Safe working by Contractor’s personnel is to be provided by the Contractor. All Safety & Security rules in vogue at site shall be followed by them, during the execution of work at Site. The personnel engaged by the vendor at site shall restrict

themselves within the work area and shall always take prior permission for moving away from the work spot.

9.4. After successful commissioning crane shall be subjected to thorugh inspection and testing as indicated in earlier paragraphs. Various tolerances of crane rail installation and operation like span of crane, horizontal & vertical straightness/ alignment of travelling track, height of cross travel track shall be also be verified.

9.5. Any equipment/instruments found defective during test, after installation or during operation shall be replaced and re-installed by manufacturer without delay and free of charge.

10. Training: Technical experts of the manufacturer during erection & commissioning of cranes will fully and adequately train operators/ maintenance staff nominated by the consignees.

11. Guarantee: 11.1. Mechanical: Vendor shall stand guarantee against defective materials and workmanship for

period specified in commercial terms and condition. Crane as a unit and all its components mechanical/electrical/structure shall be guaranteed against Design, material, selection, workmanship and satisfactory performance for a period of 12 months from date of commissioning and 18 months from supply for acceptance of the total supplied system whichever is earlier.

11.2. Performance: The equipment shall be guaranteed for satisfactory performance at all operating conditions on the data sheet. Field checks on performance, when made by the purchaser, shall be made within the agreed time ofinitial operation.Contractor shall guarantee the following:

• Full load capacity

• Hoist speed

• CT speed

• LT speed

• Effectiveness of brackets

11.3. Equipment shall be in commercial operation at least for specified duration before the performance tests are carried out to prove the performance guarantee. Should the unit supplied fail to achieve the specified performance under the given conditions, contractor shall carry out such modifications or replacements to the unit as necessary to meet the required performance within the mutually agreed time period.

12. Delivery: 12.1. Supplier has to plan / schedule the delivery and completion of all site jobs within 6 months

from the date of LOI. The supplier shall submit a detailed activity chart indicating the milestones. The item shall be delivered to Stores Officer, Zirconium Complex, Pazhayakayal, Tuticorin – 628 152.

12.2. Bidders to note that bids will be evaluated based on lump-sum quoted cost and the quoted cost shall remain firm for entire delivery period. No change in quoted price shall be entertained/ allowed.

13. Documentation:

13.1. Documents to be furnished with offer:

• Signed & Stamped Tender Document. • Price Schedule for supply & erection work as per the format enclosed. • Bidder to submit a compliance sheet indicating compliance with each clause of this

technical information alongwith relevant information of offered equipment against each clause.

• Technical data sheets duly filled by the vendor (blank data sheets enclosed). • Catalogues/ Leaflets and O&M Manuals. • Reference list of your Customers for the similar supply of items. • Un-priced Copy. (Furnish un-priced copy of Price Schedule along with the Technical

Bid.). • Any other information as required in support of bidder eligibility.

13.2. Documents for review: Successful vendor shall submit following documents/ data for

purchasers approval at various stages of manufacturing before initiation of fabrication activity and within six weeks of issue of purchase order. The documents not mentioned below but relevant may also have to be supplied on demand:

S.N. DOCUMENTS 1. General Assembly drawings of crane and its components/parts showing full details

in plan and sections. 2. GA drawing of individual mechanism 3. Sub assembly drawing for wheels, block, hoist drum and other major assemblies 4. Design calculations for major components such as structure, crane mechanisms and

components. 5. Make and details of components and sub assembly suppliers. 6. Design Calculation for Electrical Cable sizing and motor rating selection 7. Intermittent Ratings for Resistors 8. Drawing for Electrical Control Wiring 9. Power & Control Cable Schedule & termination Schedule 10. Detail specification of motor indicating type, KW, rpm, starting torque requirement,

class of insulation, type of enclosure, frame size etc. 11. Detailed fabrication drawing for each component/part 12. Detailed Quality Assurance Plan (QAP) 13. Structure drawing 14. Material Test Certificate (MTC) 15. WPS, PQR & WPQ 16. Procedure for various Non-Destructive Testing Note: Fabrication work shall commence only after approval of above drawings/ documents by purchaser.

13.3. Documents along with equipment: A bounded history docket containing all test records shall be prepared and submitted to purchaser in six copies as final documentation(with four soft copies in four separate CDs). The history docket shall consist of the copies of following documents / records

S. No. DOCUMENTS 1. Purchase Order 2. As built drawing of the equipment along with Editable Soft Copy in CD form

3. All the approved documents against above paragraph including Drawings of all equipment/component received from sub supplier.

4. Record of dimensional measurements certified by the Inspection Agency. 5. Records of NDT tests 6. Supplier’s guarantee certificate. 7. Original mill test certificate / lab check test certificate of the material used 8. Stage & Pre-dispatch inspection reports 9. Copy of Shipping Release 10. Instruction manuals for testing and commissioning 11. Operation, maintenance and safety manuals 12. Requirement of special tools and tackles.

13. Detail drawing list and specifications of all wearing out parts and parts subject to breakage during normal operating conditions.

14. List of spare parts with drawings, sketches, specifications and manufacturer's catalogue.

14. Bid Evaluation Criteria: 14.1. Bidder shall be a reputed EOT manufacturer having in-house facilities required to design,

fabrication, Testing and assembly shop for manufacturing EOT cranes of similar or higher capacity.

14.2. Bidder should have adequate infrastructure including qualified man-power.

14.3. Manufacturer should have valid ISO 9001certification for quality management system.

14.4. Bidder should have manufacture and supplied at least five nos. of EOT cranes of same or higher capacity during last 5 years. Details of such orders along with end-user certificate shall be submitted with the offer.

Annexure – A

SCHEDULE OF QUANTITIES & RATES(To be quoted in online pricebid)

Sr. No. Item description Unit Qty Rate, Rs.

Amount, Rs.

1. (a) Design, engineering, manufacturing, packing, dispatch,

installation, site testing & commissioning of 10 MT SWL

Electric Overhead Travelling Crane complete with all

electrical and standard accessories

Nos. One

1(b) Supply of the following spares a. Bearings

b. Thrusters c. Brake liner with rivets d. Brake shoes with complete lining e. Main spring for thrusters brakes f. Limit switches for all movements (MH,CT,LT) g. Gaskets h. Solenoids i. Rubber items (O rings & oil seals) j. Clamps k. Relays (over load) l. Fixed & Moving contact for each type contactors m. Current collectors n. Fuse links (one set of each size)

Set Set Set Set Set Set Set Set Set Set Set Set Set Set

One One One One One One Two One Two One One One Two Two

2. Packing & Forwarding Charges lump sum

--

3. Total Ex works Cost – Rs. (1+2) -- -- 4. Excise Duty on 3 % -- 5. Sales tax / VAT on (3+4) % -- 6. Freight Charges lump

sum --

7. Total Cost Rs. (3+4+5+6) -- --

Total Cost in words Rupees. ________________________________________________/-

Note: 1).Bidder should quote for all the items in the price bid and partially quoted bids will not be considered.

2).Order will be placed on overall L1 basis and order will not be splitted.