TENDER SPECIFICATIONS FOR 175t/25t FLAMEPROOF EOT CRANE · TENDER SPECIFICATIONS FOR 175t/25t...

SATISH DHAWAN SPACE CENTRE SHAR

SOLID PROPELLANT PLANT

File No: SHAR/SPP/2015002267

TENDER SPECIFICATIONS FOR

175t/25t FLAMEPROOF EOT CRANE

of 3

BID QUALIFICATION CRITERIA FOR SUPPLY OF 175t/25t EOT CRANE

Bidders who are qualifying/meeting following Technical and Financial capabilities are eligible to participate in the bid for supply of 175t/25t EOT crane. Bidder shall furnish all the requirements asked in this criteria with documentary proof and submit along with quotation. Bids of the parties which are not meeting the following criteria will not be considered for evaluation and will be rejected without seeking any further clarifications.

I. Technical Qualification Requirements:

The bidder should meet the following technical qualifying requirements and

shall submit relevant certificates to establish his credentials.

1. The Bidder should be an organization with experience in having executed contracts for design, engineering, manufacture, supply, erection, testing and commissioning of

Double girder EOT cranes & Hoists Package for last 25 years in India.

2. The firm should have successfully completed Design, Manufacture, Installation, Testing and Commissioning of at least 5nos. of double girder EOT cranes of capacity 200t and

above and Span equal to 20m and above during last 7 years ending 31.12.2014.

Bidders have to provide relevant certificates from the Owners (end users) along with

the submission of bid for consideration of bid document.

3. The firm should have successfully completed Design, Manufacture, and commissioning of EOT cranes with VVVF (VFD) drive & control systems at least 10 nos. of cranes

and at least one crane of capacity not less than 150t in last 10 years.

4. The firm should have successfully completed Design, manufacture and establishment of fail safe mechanisms & controls like Emergency disc brake on rope drum (actuated in

case of failure in power transmission line), wire rope spooling monitoring and

redundant (double) wire rope reeving system at least in 2nos. of EOT cranes in last

10years.

5. The firm should have experience and knowledge in the Design and manufacture of EOT crane with dual drive hoist (Twin load path). It is preferable to have completed

realization of such cranes.

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

of at least 05 nos. of EOT cranes (not less than 100t capacity) with twin motor with

planetary gearbox system for Hoist mechanism for last 10 years.

7. The firm should have successfully completed Design, manufacture, and establishment

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

metal handling cranes) for reputed steel mills for last 10 years.

8. The firm should have facility to full load test and over load testing of 200t EOT crane (hoist and cross travel) at their factory.

9. The firm should have successfully completed Design, manufacture and establishment

of 3

of high capacity EOT cranes (100t and above) to the satisfaction of reputed third party

inspection agencies like M/s MECON and M/s M.N.Dastur.

10. Bidder shall furnish the details of their factory like manpower, machinery, quality system etc., for department to access their capability. Bidder shall submit above

information in the format given in “Questionnaire” attached as Annexure to this BQR.

II. Financial Qualification Requirements:

The bidder should also meet the following financial qualification requirements:

2.1 The Bidder should have annual turn over of not less than a value of Rs. 10 crores per year last three financial years ending 31-03-2014.

2.2 Firm should have undertaken and successfully completed following value of works related EOT cranes at least in last 05 (Five) years :

Single work of EOT cranes not less than : Rs.10 Crores.

(or)

Two works of EOT cranes not less than : Rs.5 crores (each)

(or)

Three works of EOT Cranes not less than : Rs.4 crores (each)

2.3 Bidder should possess a current Solvency Certificate from Nationalized Bank for an amount of not less than 10 crores.

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

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

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

prequalification of Bid:

1. Firm establishment certificate and nature of work (for Sl no.1).

2. Detail of work of similar type completed during the last seven years ending 31.12.2014 ( for Sl. No.2).

3. Satisfactory work Completion certificates from the clients, with the work order copies (for S.Nos 2 & 3).

4. Performance Report of EOT cranes established (with years of service) from End users, with addresses and contact person with phone numbers.

5. Documentary evidence (Technical details & drawings) for fulfilling special technical conditions (Sl. no. 2, 3, 4 & 5).

6. Copy of audited Balance Sheets for last three years.

7. IT / TDS certificates for last three years.

8. Current Solvency Certificate.

9. List EOT crane projects ( for capacity 100t and above / Span 20m and above) completed for last 10 years with PO copies.

of 3

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

11. Duly filled “Questionnaire” with signature, name, phone no and company seal.

12. Structure and Organizational Chart

13. List of personnel with qualification & experience in the firm in the areas of design, production, quality, safety, administration etc.,

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

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

IMPORTANT NOTES :

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

support of the eligibility criteria will be summarily rejected.

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

IV. Bid Selection Procedure and Process of BID Qualification

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

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

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

rejection of Bid)

Step - 2: Subsequently Bidder’s competency, their technical achievements and financial status will be evaluated suitable for his project. Feedbacks from Bidder`s clients will be verified.

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

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

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

specification and supply conditions.

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

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

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

Criteria/requirements will be finally qualify for opening the Price Bids for evaluation.

Annexure to Bid Qualification

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

(INFORMATION TO BE PROVIDED BY BIDDERS)

Name & Address of EOT Crane supplier:

Phone : Mobile : Fax : Email :

Sl. No.

Items/ Information

Specification/ details of items

Remarks

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

2. Year of Establishment

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

3.1 Turn over – 2013-14

3.2 Turn over – 2012-13

3.3 Turn over – 2011-12

4.

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

a. 2013-14

b. 2012-13

c. 2011-12

5.

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

Page 1 of 6


6.

Nos. of EOT Cranes of capacity 200t and above and Span :20m and above manufactured during last 10 years ending 31.12.2014

7.

No of EOT Cranes of capacity not less than

100t with SIEMENS VVVF (VFD) drive &

control systems produced in last 10 years.

8.

No. of EOT Cranes of capacity not less than

100t supplied with Emergency Rope drum

caliper brake.

9.

No. of EOT cranes produced (not less than

100 ton capacity) with twin motor with

planetary gearbox system for Hoist

mechanism for last 10 years.

10.

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

capacity) produced for molten metal ladle

handling in last 10 years.

11. Shop floor Area Covered

12.

No of Employees (Supplier shall mention contract personnel separately)

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

13.

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

Page 2 of 6


14.

Sources of Bought out components: a. Electric Motors b. Brakes Flameproof c. Gearboxes d. Couplings e. Limit switches f. Wire ropes

15.

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

16.

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

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

17.

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

18.

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

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

19.

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

Page 3 of 6


20.

Welding Professionals: a. No. of welders (MMAW)

Qualification details Qualified by

b. No. of welders (GMAW) Qualification details Qualified by

c. No. of welders (TIG) Qualification details Qualified by

21.

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

22.

Forming Facilities available (with brief specification of each machine)

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

23.

Machining Facilities available (with brief specification of each machine)

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

(Conventional/CNC) g. Any other machines

Page 4 of 6


24.

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

25.

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

26.

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

27.

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

28.

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

29.

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

30.

Design facility available: a. Drafting & Modeling software

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

& experience)

Page 5 of 6


31.

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

32.

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

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

33. Any awards or recognitions obtained through product excellence

34.

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

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

36. List of documents enclosed with this questionnaire

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

Signature of competent person Name : Designation :

Date : Company seal :

Page 6 of 6

SATISH DHAWAN SPACE CENTRE SHAR SOLID PROPELLANT PLANT

Ref: SHAR/SPP/2015002267

TENDER SPECIFICATIONS OF 175t/25t EOT CRANE

Facility : Propellant Machining Facility - II

Sl.

No. Type of crane

Capacity

of crane

(ton)

Span

(m)

Height of Lift

(m)

Crane Travel

(m)

Duty

class of

crane

Quantity

( No)

1

Double Girder

Flameproof

EOT Crane

175t / 25t 21.0 MH – 22.50m AH – 24.50m

32.00

Class - II

of

IS 3177

01

175t/25t EOT crane shall be supplied, transported, erected and commissioned as per the Technical Specifications, Terms & Conditions given in following pages of this document.

Ref : SHAR/SPP/2015002267

CONTENTS OF BOOKLET

Sl. No

Contents

Page No.

1

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

1 to 44

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

45 to 48

3 Annexure – 2 : Schematic of Pendant Button operating station

49

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

50 to 60

5 Annexure – 4 : Price format for Spare parts for EOT crane.

61

TECHNICAL SPECIFICATIONS OF


SECTION – I

GENERAL SPECIFICATIONS

SDSC SHAR

SPP

175t / 25t FLAMEPROOF EOT CRANE

SPECIFICATIONS CUM COMPLIANCE STATEMENT

Page:1 of 41

A

B

C

Contact Person :

FAX No :

Mobile No : Email :

Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /

ACCEPTANCE

1

DNAME & ADDRESS

OF THE Bidder :

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

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

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

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

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

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

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

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

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

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

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

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

SCOPE OF SUPPLY

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

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

of around 32.0meter. (Gantry girder is in the scope of Department / Purchaser).

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

must be done to the EOT crane at gantry girder height of 19m as per clerance

diagram enclosed.

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

specifications mentioned.

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

erection, commissioning & performance proving of Heavy duty 175T/25T

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

specifications and IS 3177, IS 807 & relevant codes & standards.

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

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

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

supplier works.

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

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

Main Hoist (175t) shall be provided with dual rope reeving system i.e., two

independent wire ropes shall be provided with balanced reeving system, wire

rope spooling & monitoring as per the specifications mentioned in this

document.

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

Technical Specifications, conditions given below and also in accordance with

latest editions of IS: 3177, IS: 807 & relevant codes and standards.

SDSC SHAR

SPP



Page:2 of 41


ACCEPTANCE

2 Quantity of Crane : 01 No. (One)

Main hoist drive system shall be designed to provide assurance

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

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

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

dual hoist drive unit described below.

Dual Hoist Drive with two gearboxes and rope drum (Twin Load path) :

The dual-hoist drive shall have rope drum, two parallel shaft helical gear

trains ( on each side of drum), two drive motors (each gearbox driven by

motors) and at least two holding brakes located on input shaft of geartrain

and realted couplings. This shall ensure two independendant load paths for

main hoist drive and each of two independant load paths shall be capable of

driving & holding the rated load of 175t.

1.9

Supplier shall arrange "Third party inspection Agency " for design

verifications, approvals, inspection during manufacture, load teasting,

and certfying the EOT crane as per QAP.

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

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

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

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

between ISRO and Bidder.

1.10

3

3.1 Application

This Heavy duty EOT crane is used for handling of

hazardous / dangerous materials like rocket motors,

propellant containers, delicate flight hardware etc., for

positioning and assembly during process operations.

Failure of EOT crane & its components during handling

may result in loss of life and property. Hence Bidder

shall design, manufacture and erect the crane with

emphasis on quality, reliability and safety and shall

ensure smooth & reliable operation of crane with long

service life.

3.2Usage period &

desired life of crane

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

Days’ intermittent duty (Class II duty as per IS3177)

with CT, LT and Hoist movements. EOT Crane shall

be designed for minimum life of 30years.

4

4.1

4.2

5

Operating

Environment of

Crane / Weather

conditions

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

saline atmosphere), with ambient temperature of 50ºC

and with relative humidity of 95%. Weather conditions

are tropical. Bidder shall consider above while design

of EOT crane, electricals, painting of crane & related

parts.

Hazardous area conditions

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

cabling must be done to the EOT crane which is at a height of ~19m. The

VVVF panels shall be suitable for normal atmospheric conditions.

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

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

per relevant IS 5572 / IEC standards.

Usage of EOT crane

SDSC SHAR

SPP



Page:3 of 41


ACCEPTANCE

6

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

Crane

Structures : Class-II duty as per IS 807

Mechanisms : Class -II duty as per IS3177

Main Hoist Gearboxes: Class IV duty of IS:4137-1985

6.3EOT Crane capacity (in

ton)

175t (Main Hoist)

25t (Auxiliary Hoist)

6.4 Span 21.00 meters

6.5

6.5.1 Main Hoist (meters)Above FFL - 17m , Below FFL - 5.50m,

Total : 22.50m

6.5.2 Auxilary Hoist (meters)Above FFL - 19.00m , Below FFL - 5.50m,

Total : 24.50m

6.6 Operation Speeds ( meters/minute)

6.2

Lift Height

Class & duty of EOT

Crane

MAIN PARAMETERS OF EOT CRANE

6.6.1

Main Hoist with dual

load path (four motors

& two gearboxes)

Main speed : 2.0 m/min & creep speed: 0.2m/min with

all motors running--Main speed :1m/min & creep speed

:0.1m/min when half the motors are running.

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

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

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

6.7

Side clearance

(Distance from centre

of gantry rail to nearest

obstruction)

400mm (minimum) on both sides.

6.8

Head room available

(Vertical distance from

top of gantry rail to

lowest overhead

obstruction)

6.00 meters (maximum) (Refer clearance diagram).

6.9Distance from floor to

top of gantry rail~ 19.00 meters

6.10 Bay length in meters ~ 32.00 meters

SDSC SHAR

SPP



Page:4 of 41


ACCEPTANCE

6.11

DSL side :

Main Hook : around 2.00m

Aux. Hook : around 3.50m

6.12Non-DSL Side Main Hook : around 3.20m

Aux. Hook : around 1.70m

6.13CT DSL side : not more than 4 m (LT forward side)

Non DSL side : not more than 4m (LT reverse side)

6.14 LT wheel base as per IS807 / shall not be less than 1/5th of span.

shall be as minimum as possible for having optimum

LT hook approaches for better utilization of crane &

building.

Max. Width of crane around 8.00m.

6.16

6.16.1

6.15

Main hoist drive system shall be designed to provide assurance

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

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

accomplished by the application of dual hoist drive units. The wire rope

drum, hook, hooknut, and load block structure are exempted from this

Main Hoist Drive

Hook Approaches

(Refer Clearance

diagram) (supplier shall

optimise these values)

Width of Crane

drum, hook, hooknut, and load block structure are exempted from this

requirement. Supplier shall accomplish above failure proof design feature as

described below.

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

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

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

decoupling of defective drive system.

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

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

Proper Electrical and drive interlocks shall be provided betwee motors and

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

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

6.16.2

Dual Hoist Drive with two planetary gearboxes, 4 drive motors and rope

drum (Twin drive Load Path) : The dual-hoist drive shall have rope drum,

two parallel shaft helical planetary gear trains (on each side of drum), four

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

per motor located on input side of each gearbox and related couplings. This

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

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

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

torque with appropriate service factor as per IS4137. All motors shall be driven

through two/four VVVF drives with syncronization with proper control &

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

holding the rated load. Refer Schematic arrangement given in Fig .1. Supplier

can suggest & design alternate configuration to meet above safety,

redundancy, and reliable Main Hoist system with optimum hook

approaches.

SDSC SHAR

SPP



Page:5 of 41


ACCEPTANCE

6.16.3

6.17

6.17.1

6.17.2

6.18

6.18.2

6.18.3

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

flameproof brakes per motor shall be provided.

LT drive shall be provided with twin drive system at two corners of crane.

Horizontal foot mounted helical gearboxes, motors and thruster brakes shall be

used.

Each corner drive components shall be easily accessible and shall be designed

with inter changeable components.

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

of standard make mentioned in this specification.

LT Drive

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

side of input shaft of gearbox.

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

wheels.

6.18.1

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

drives with one VFD.

Auxiliary Hoist Drive ( conventional hoist system)

6.18.4Number of wheels for

LT drive

8Nos or 16Nos. & Drive wheels : 50% of total wheels

based on design.

6.18.5Diameter of wheels for

LT driveNot less than 710 mm.

6.19

6.19.1

6.19.2

6.19.3

6.19.4Number of wheels for

CT drive

4Nos or 8nos.,and Drive wheels : 50% or 25% of total

wheels based on design

6.19.5Diameter of wheels for

CT driveNot less than 630 mm.

6.19.6Maintenance of CT

drives

Maintenance platform shall be provided for CT drives

covered with chequered plate.

6.20Type of bearings for

LT/CT wheels

Anti-friction, Heavy duty Double row Spherical Roller

Bearings

6.21Type of mounting of

LT/CT wheels"L" type brackets with fit bolts and locknuts.

CT Drive

CT drive shall be provided with sufficient no. of drive systems / central drive.

Helical parallel shaft gearbox, motor and imported thruster brakes shall be

used.

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

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

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

wheels.

SDSC SHAR

SPP



Page:6 of 41


ACCEPTANCE

6.22Total Weight of EOT

Crane (tons) Bidder to Specify

6.23 Weight of trolley (tons) Bidder to Specify

6.24Weight of each Bridge

Girder (tons) Bidder to Specify

6.25Weight of each End

Carriage (tons) Bidder to Specify

Weight of Electricals

on top of crane Bidder to Specify

Weight of electrical

Panels in room (tons) Bidder to Specify

6.27 LT wheel load (tons) Bidder to specify

6.28 CT wheel load (tons) Bidder to specify

6.29Size of Cross Travel

Bridge Girder RailCrane rails not less than CR-100 as per IS 3443

6.26

6.30

Size of Crane gantry

rails (for Long Travel) -

Scope of Crane Bidder

Crane rails not less than CR-100 as per IS 3443



SECTION – II

MECHANICAL DESIGN AND DETAILS

SDSC SHAR

SPP



Page:7 of 41


ACCEPTANCE

7

The design of components shall be done on the basis

of ultimate tensile strength, the value of stress factor

used shall be the product of the basic stress factor and

the duty factor for the appropriate mechanism class as

mentioned in IS:3177.

The design of all mechanical components shall be done

as per IS:3177 & as per this technical specifications

and also on the basis of minimum ultimate tensile

strength with factor of safety of not less than 5.

7.1.1

7.1.2

7.1.3

7.1

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

infinite fatigue life. Fatigue analysis shall be based on the crane maximum rated

load.

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

mechanical load bearing component except for electrical motors, panels and

MECHANICAL DESIGN AND ELEMENTS' DETAILS

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

exceed 66% of yield point (proof stress) of the material for the component

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

Factor of Safety

7.1.3

7.1.4

7.1.5

7.2 Hoist hook type

Main Hoist : Ramshorn type hook with swiveling anti-

friction thrust bearing and safety latch as per IS:5749.

Aux. Hoist : Single Point hook with swiveling anti-

friction thrust bearing and safety latch as per IS 3815

& relevant standards.

7.2.1

7.3Number of falls for

Hoist

Main Hoist : ~ 16 (8 + 8).

Aux. Hoist : ~ 8

7.4

7.4.1

7.4.2

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

for electrical equipment. Similarly wood or combustible material and Bush

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

Stress Concentration factors shall be considered in mechanical design for

calculating working stresses and also combination of stress concentration

factors shall be considered at required conditions.

mechanical load bearing component except for electrical motors, panels and

hydraulic components.

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

ROPE DRUM

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

relieved. Rope drum shall be designed as specified in IS:3177 in general.

Allowable stress in drum shall not be more than 1/5th of UTS.

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

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

be provided with a means for lubrication.

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ACCEPTANCE

7.4.3

7.4.4

7.4.5

7.4.6

7.5

7.5.1

7.5.2

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

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

sytem shall be provided on each rope system.

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

grooves shall be dimensioned as per IS3177.

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

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

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

and drawings & calculations shall be provided in this regard.

Rope dead ends shall be clamped with minimum three clamping wedges with

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

clamp and shall be wire locked.

MAIN HOIST WIRE ROPE - Double rope reeving system

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

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

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

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

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

corners.

7.5.2

7.5.3

7.5.4

7.5.5

7.5.6

7.5.7

7.5.8

7.5.9

7.5.10

Minimum factor of safety of 10 shall be provided for wire rope of Main Hoist on

Minimum Breaking Strength (MBS) of rope with two ropes combined together.

With single rope the factor of safety shall be 5 on the MBS of main hoist rope.

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

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

preformed, Minimum tensile strength / Grade : 1960MPa.

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

either side shall be provided.

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

wireropes to take equal load.

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

minimized.

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

rope breakage or failure in one rope system.

Upper block assembly and lower load block assembly shall be designed

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

in the event of failure of single wire rope.

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

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

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

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

with load.

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

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

with No load & Full load conditions.

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ACCEPTANCE

7.5.11

7.6

7.6.1

7.6.2

7.6.3

7.6.4

7.6.5

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

with true vertical lift as per IS3177. Wire rope shall have factor of safety of 6

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

USHA MARTIN only. Wire rope shall be Non-rotating type, Hotdip Galvanized,

35x7 construction, Core : IWRC, RH, Regular lay, preformed, Minimum tensile

strength/Grade : 1960MPa.

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

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

ROPE SHEAVES

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

lubricated sheave bearings should be provided with individual grease

lubrication fittings and shall be easily accessible for maintenance.

Design of sheaves in general shall be as per IS:3177.

All sheaves shall be of forged steel only.

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

20 times the diameter of wirerope for Aux Hoist.

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

7.6.6

7.6.7

7.6.8

7.6.9

7.6.10

7.7

A) Main Hoist (Twin

drive & Dual load path)

Hoist drive shall be provided with two parallel shaft

helical planetary gearboxes each driven by two

motors. Standard make, Crane duty, Horizontal foot

mounted, Parallel shaft, Helical Gearboxes shall be

used.

B) Aux. Hoist

Standard make, crane duty, parallel shaft, Helical,

horizontal foot mounted gearboxes shall be used for

Aux. hoist motion.

7.7.1

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

ease of maintenance and inspection.

GEARBOXES

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

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

prevent the wire rope from leaving the sheave grooves.

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

least 136° angle of contact over its circumference.

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

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

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

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

Equalizer sheave /Bar shall be arranged such that reeving equalization

shall not be restricted under normal operating conditions. Adequate free

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

stretch shall be provided.

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ACCEPTANCE

Helical parallel shaft, Crane duty, gearboxes, shall be

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

horizontal foot mounted gearboxes.

Travel drive gearbox ratings for bending strength and

pitting resistance shall be based on 2 times rating of

AC motor.

7.7.3 Make of Gearboxes

Heavy duty, and crane duty gearboxes of Elecon /

Shanti/ GREAVES (Premium transmission) /

Flender/ DB-Radicon / Sumitomo / Renold only.

Other make & Own make gearboxes are not

acceptable. Bidder shall confirm the acceptance.

Tender will be rejected for not meeting this

requirement.

1) Gearboxes selection shall consider starting torque

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

motors.

2) The gearing shall be designed for strength,

durability, and momentary high overloads which

includes the loads imposed during starting,

braking and failure of components.

7.7.2Gear Boxes for CT &

LT drives

3) Due consideration shall be given for braking torque

on input shaft of Gearboxes.

4) The stresses in all components of hoisting

machinery and gearboxes should not exceed 66% of

yield point of the material for the component under

break down conditions ( Pull Out Torque) of motor.

5) In design of gearboxes, due consideration shall be

given to creep speed and also ramping down of rated

speed (rpm) to zero speed through VVVF drives.

7.7.5

7.7.6

7.7.7

7.7.8

7.7.9

7.7.10

7.7.11

Torque & Power rating

of Gearboxes / Pinions

/ Gears / Shafts

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

7.7.4

All pinions shall be integral with shafts.

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

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

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

during design engineering phase.

Main hoist gearboxes shall be designed & manufactured as per class '4' duty

of IS:4137.

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

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

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

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

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ACCEPTANCE

7.7.12

7.7.13

7.7.14

7.7.15

7.7.16

7.7.17

7.7.18

Gearboxes shall have fill and drain connections, BREATHERS, lubricant

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

and oil filling.

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

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

maintain lubricant at temperatures below maximum operating

temperature

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

steel.

Vertical Gearboxes shall have an oil pump lubrication system when

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

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

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

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

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

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

plate. All fabricated gearboxes shall be duly stress relieved.

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

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

7.7.18

7.7.19

7.7.20

7.7.21

7.7.22

7.7.23

7.7.24

7.8

7.81

7.8.2

7.8.3

Drive Shafts (LT & CT)

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

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

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

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

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

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

Open gears should not be used in any drive / motion.

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

of next stage of non meshing sets to avoid interference.

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

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

inside gear box or 20 mm whichever is higher.

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

without disturbing the bottom half.

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

arrangment shall be provided for shafts of gearboxes.

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

around the gearbox.

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

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ACCEPTANCE

7.9

MAIN HOIST BRAKES

2 brakes per motor.

Aux. Hoist : 1 motor

and 2 brakes.

Torque rating of each thruster brake shall be minimum

2 times motor full load torque. Torque adjusting

Brake performance certificate, test certificate, and Exproof (ATEX) Certificate

shall be provided from original manufacturer of brakes.

7.9.1

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

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

SIBRE-Germany, M/s Galvi-Italy, M/s Wittonkramer-UK , M/s SIME-GKN

Stromag-France. Thrusters for all brakes shall be Explosion proof (Ex d),

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

UK. ATEX/ PTB/ Exproof Certificates for brakes & thrusters shall be submitted

for Approvals.

Two nos. of imported electro hydraulic flameproof

thruster drum brakes per motor with Manual release

and antiwear compenstor shall be provided (the second

brake is for redundancy). Minimum time lag shall be

provided between two brakes of main hoist and Aux.

Hoist as per standard.

Brakes

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

7.9.2

7.9.3 Brake Rating Hoist.

2 times motor full load torque. Torque adjusting

provision shall be available in the Brakes. Selected

Brake shall have sufficient margin with maximum

catalogue torque rating.

7.9.4Braking distance/brake

path for hoist

Hoist components and brake shall be selected such

that the braking distance for lowering motion shall be

as IS3177 with one brake at full rated speed.

Necessary calculations shall be submitted in this regard

during design phase.

7.9.5 Brakes for CT & LT

Imported, flameproof Electro hydraulic thruster drum

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

provided.

7.9.6

7.9.7Brake rating for CT

and LT motions

Braking torque shall be checked so that it is capable of

arresting the motion within a distance in meters equal

to 10% of speed when travelling with rated load at

rated speed, provided there is no skidding.

7.9.8Manual release for

Brakes

Brake manual release mechanisms shall be

provided to permit drive movement during

power stoppage. Manual release shall be of self-

reset type and operative only when held manually in

the release position.

7.9.9

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

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

of hazardous area.

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

under thrusters.

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ACCEPTANCE

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

Drums shall be completely machined to smooth surface

and Statically & dynamically balanced.

Hardness of surface of finished drum shall be 38-43

Rc.

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

width of the brake shoes.

7.11 Mounting of equipment

All the gearboxes, motors, brakes, bearing pedestals,

etc. shall be mounted on machined and levelled

surfaces.

7.12

7.12.1Couplings between

motors and gearbox

Flexible Full / half geared couplings. Make of

Couplings shall be of FENNER/ELECON/ Shanthi

Flexible Couplings

between gearbox and

rope drum for main

hoist ( For dual load

path/ twin drive)

Drum/ Barrel couplings of M/s Malmedie, Germany

shall be used for Main hoist . Selection criteria, service

factor (as per ISO-M8 class), Torque rating, drawing

shall be submitted for approval.

Brake drums

Couplings

7.10

path/ twin drive)shall be submitted for approval.

Flexible Couplings

between gearbox and

rope drum for Aux.

hoists

Drum/ Barrel couplings of M/s Malmedie, Germany

shall be used for Aux hoist . Selection criteria, service

factor (as per ISO-M8 class), Torque rating, drawing

shall be submitted for approval.

7.12.3

7.12.4

7.13

7.13.1

7.13.2

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

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

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

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

applicable service factors for heavy duty cranes compared to the applied

torque on the coupling and as per IS3177. Consideration shall be given to

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

Track Wheels

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

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

and matched in pairs with minimum deviation.

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

shock absorbing couplings. Geared couplings shall be used between gearbox

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

intermediate lengths of long travel and cross travel shafts. Between

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

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

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

7.12.2

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ACCEPTANCE

7.13.3

Galvanized, high tensile fasteners of tensile quality not

less than 8.8 shall be used in crane parts, except for Fit

bolts of Girder. Make of all fasters shall be of M/s TVS

/ M/s UNBRAKO

Maximum combined stresses induced in the fasteners

by normal operating loads (but not including

pretensioning loads) shall not exceed 20% of the

ultimate strength of the fasteners.

7.15

7.15.1

General design & sizing of wheels shall be as per IS:3177.Crane wheels of

minimum 630mm dia for cross travel and minimum 710mm for long travel shall

be used. Necessary sizing & contact stress calculations as per IS:3177 shall

be submitted.

Semi centralized lubrication system shall be provided for all mechanixms in

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

bearings, gearboxes etc.,

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

Lubrication of Crane

Fasteners7.14

7.15.2

7.15.3

7.15.4

7.15.5

7.15.6

All keys where ever used should be of parallel keys as

per IS:2048 (Couplings / gear boxes / motor shafts)

Material of keys shall be 45C8 or alloy steel.

Proper fits and tolerances shall be used between key

and key ways, such that key should not get loosened in

service life. Key end arrestors shall be provided.

Ball and roller antifriction bearings of approved make

SKF/ TIMKEN/ FAG/ INA only shall be used throughout

the drives except where specified otherwise.

Rated life of ball and roller bearings shall be not less

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

than 20,000 hrs .

Keys & Keyways

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

of wheel and shall be made approachable.

Suitable provision shall be provided for lubrication of hook and sheave

bearings.

Adequate provisions/arrangements shall be made to prevent lubricants

falling from the crane.

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

the sides of the pins.

Hoisting ropes shall be lubricated with lubricant approved by rope manufacturer.

7.16

7.17 Bearings

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ACCEPTANCE

Main hoist gearbox's bearings shall be selected based

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

Special consideration shall be given to bearings

which operate at low speeds. Certified

confirmation of the bearing's capacity at low

speeds must be obtained from the

manufacturer during design phase.

All bearings shall be provided with proper

lubrication or means of lubrication. Mounting fits,

tolerances and clearances shall be as recommended

by the bearing manufacturer.

Life of bearing shall be calculated in accordance with

bearing manufacturer’s recommendations.

7.17.1 Bearing Housings

All bearings housings shall be of STANDARD MAKE

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

steel or fabricated steel bolted to a rigid portion of

crane structure by at least 4 bolts. Housings shall be

split on the shaft centre line to permit removal of the

Bearings

(Continued from

previous page)

split on the shaft centre line to permit removal of the

shafts. The underside of the base of each bearing

pedestal shall be machined and shall bear upon a

machined surface. Standard make Bearing housings.

7.18

In Mian hoist motion of EOT Crane, wire rope spooling monitoring shall be

provided. The wire rope spooling monitor is an electro-mechanical assembly

that senses improper or mis spooling of wirerope from drum grooves. Improper

spooling is sensed prior to wire rope damage. Since, wire rope damage and

loss of the load can result, if improper wire rope spooling is detected, the wire

rope spooling monitor actuates the Failure Detection System (i.e., limit switches

) and stops main hoisting motion.

Hoist Drum Wire Rope mis-spooling monitoring in Main Hoist Motion of

EOT crane :



SECTION – III

STRUCTURAL DESIGN AND DETAILS

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ACCEPTANCE

8.0

8.1Design of structural

work of Crane

The crane should be rigid, robust and of sturdy

construction. The design of all structures shall be Class

II as per IS:807 and as per this technical

specifications.

8.2

8.3

8.4

8.5

8.6 Material of structurals

All the structural plates used in fabrication of Girders,

Trolleys and End carriages, machine bases shall be of

minimum 10 mm thick of IS 2062 Gr. B.

8.6.1Covering chequered

plates

Trolley and platforms shall be covered with Chequered

plates of minimum of 6mm thick.

STRUCTURAL DETAILS OF EOT CRANE

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

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

protected against corrosive environment.

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

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

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

its equivalent.

plates plates of minimum of 6mm thick.

Shall be of double Girder Box Type construction having

Maximum rigidity.

For box plate girders in addition to the required full-

length diaphragms, short diaphragms shall be inserted

where required to transmit the trolley wheel load to the

web plates and to limit the maximum stress in the

trolley rail within safe permissible stress.

Girders shall be cambered and amount equal to the

deflection caused by the dead load plus one half of the

live load and the trolley.

8.8 Deflection of Girders

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

mm with safe working load, with trolley stationed at mid

span and excluding deflection due to dead load.

8.9 Girder Joints

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

piece only. Number of weldable butt joints along the

total length of the girder should not exceed two.

8.10Ratio of span to depth

of Girder

For Box Girders Span to Depth ratio shall not exceed

18. Other ratios for construction of girder shall be

maintained accordingly as per standard.

8.11Local Buckling of top

flange

Local buckling of top flange and compression members

shall be considered and necessary calculations shall be

submitted for approval.

8.7 Girders

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ACCEPTANCE

8.12 End Carriages

End carriage shall be fabricated as solid box section

made from rolled steel plates IS:2062, except for

essential openings which shall be reinforced.

8.12.1

8.12.2

8.12.3

8.12.4 Rail Sweeps.

A rail sweep shall be provided in front of

each outside wheel. The rail sweep shall

project below the top of the bridge runway

rail.

8.13

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

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

loads resisted by the end ties and by the girders.

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

movement and the load combinations as per IS807 & IS3177.

Equalizer bridge trucks shall be incorporated into the end carriage

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

pins shall be provided between the equalizer trucks and equalizer beam

and/or the rigid bridge frame structure.

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

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

8.14

8.15

8.16

8.17

Structural bolted

Joints/ Girder to End

carriages

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

reamed holes shall be used for all structural joints

between girder & end carriages, wheel L - bracket &

end carriages etc.,

8.18

8.18.1

8.18.2

8.18.3

8.18.4

8.19

Trolley

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

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

mounted on the top of trolley platform only.

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

lubrication points.

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

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

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

exceeding allowable stresses.

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

robust structure and shall be arranged to afford maximum accessibility to

mechanical and electrical parts placed on it.

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

cause deflections that impair the proper operation of machinery.

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

must be ensured without any additional scaffolding.

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

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

the highest point of bottom block.

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ACCEPTANCE

8.20

8.21

Full length chequered platform of width 750mm shall be

provided for both bridge girders in order to access for

LT drive and CT cable track for maintenance and with

hand rails of height 1000mm. The platforms shall be

jointed to Girders with fasteners.

Additional maintenance accesss platforms on four

inside corners of the girder shall be provided between

inside faces of girder for repair & maintenance inner LT

wheel bearings & mountings of End carriage. These

platforms must not hinder with the CT hook

approaches.

8.22.1Hand rails along girder Handrails of 1000mm height shall be provided along

8.22 Platforms

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

damaged and can be easily inspected and maintained.

All parts requiring replacement or inspection or lubrication shall be easily

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

8.22.1Hand rails along girder

platform

Handrails of 1000mm height shall be provided along

the length of the girder near to platform.

8.22.2Hand rails for around

trolley

Handrails of 1000mm height shall be provided on all

the four sides of the trolley.

8.23Maintenance of CT

drives

Maintenance platform shall be provided for CT drives

and shall be covered with chequered plate.

8.24Top chequered plate of

trolley

Chequered plate of 6mm shall be used all over trolley

except for openings required for the ropes for bottom

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

equipment shall be placed above trolley top only .

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

provided under the trolley rails.

8.25.1 Rails

All bridge and trolley rails required to transmit

vertical down and horizontal loads due to

operation, and shall conform to the IS3443.

8.26 CT rail welding

CT Rails shall be made continuous by welding standard

lengths. Welding shall be done as per standard

procedure approved by Third Party Inspection Agency

and Purchaser.

8.27 CT & LT rail clamping

CT & LT Crane rails shall be clamped to the girders

with double bolt clamping plates. The rail clamps shall

be spaced not more than 450mm apart. Rail clamps

shall be of Make : M/s GANTREX only.

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ACCEPTANCE

8.28Rail stoppers /Wheel

ramps

CT & LT Rails shall be prevented from creeping in the

longitudinal direction by welded rail stops and Wheel

ramps.

8.29 Jacking pads

Suitable jacking pads should be provided on end

carriages and trolley for jacking up the crane & trolley

for changing track wheels & bearings .

8.30 Safety Pads

Safety pads shall be provided under the end carriages

and crab to prevent the crane/ trolley from falling more

than 25mm in the event of breakage of a track

wheel/axle or bogie pin.

8.31

8.31.1

8.31.2

8.32

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

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

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

End Buffers

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

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

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

8.33Metric Component

Systems

All components including fasteners should be in metric

system only

8.34 Locking of All fasteners

Bolts in rotating parts shall be locked with spring

washers & lock nuts. All couplings & brake drums shall

be provided with "Fit" type bolts.

8.35NDT of Butt joints of

girders

All butt joints shall be 100% radiographed or Ultrosonic

tested for both compression and tension joints.

8.36 Toe gaurds

Toe gaurds shall be provided for all openings, on trolley

and on bridge platforms with minimum height of

100mm.

8.37

Mounting of machinery

on machined bases on

trolley / LT

Parts of steel frames carrying machinery should be

provided with doubling plates (including stiffners) of

adequate thickness welded and machined to true

surface.

8.38

8.39

8.39.1

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

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

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

screws for side alignment.

Ladders

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

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

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ACCEPTANCE

8.39.2

8.40Protection Gaurds for

rotating equipment

Guards: All the moving parts couplings, shaft should

be duly covered with guards as per safety norm. Proper

guard / cover / tray to prevent falling of bolts from

coupling etc should also be provided, wherever

required. The covers shall be strong enough to take

person weight ~ 100 kg.

8.41

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

the span of the girder.

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

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

as fasteners for mechanical items except for fixing covers.



SECTION – IV

ELECTRICAL DESIGN & DETAILS

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ACCEPTANCE

9.0

All Electrical equipments shall be supplied for tropical

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

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

cables etc., shall be done for ambient temperature of

50°C.

Flame proof electrical fittings and controls shall be

selected, assembled and tested as per relevant Indian/

IEC standards like IS:5571, IS:2148, and IS:5780.

However for control circuit, intrinsic safe modules of

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

9.2 Power supply condition

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

Hz near by the Crane panel. The power and control

equipment selected shall be suitable for operation on ±

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

supply frequency. Power source available to tap for

protective panel (where main power source is located

ELECTRICAL DESIGN AND DETAILS

9.1

Electrical equipment

environment

The Electrical equipment shall conform to IS3177 and also to the latest Indian

electricity rules and regulations as regards safety requirements, earthing and

other essential provisions specified therein.

protective panel (where main power source is located

approximately 50m distance).

9.3Power Supply for

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

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

panel

9.5

For Push buttons,

Indication lamps, limit

switches in the field

(top of the crane) and

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

9.6Under slung HPMV

lights.

4nos of 400watts, well glass flame proof lights shall be

provided.

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

chain (plastic) with guided cable tray only.

9.8

9.8.1

9.8.2

9.8.3

9.8.4

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

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

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

Main Hoist panel - 2 or 4 Nos. (as per design).

Aux hoist panel – 1 No. (One)

Protective panel – 1 No. (One)

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ACCEPTANCE

9.8.5

9.8.6

9.8.7

9.8.8

9.8.9

9.8.10

9.8.11

9.8.12

9.8.13

CT panel - 1 No. (One)

LT Panel - 2 Nos. (One)

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

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

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

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

condensation.

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

persons stand on rubber mats during maintenance.

The bottom most row of equipment mounted inside the panel excepting terminal

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

inspection and repairs.

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

and the panel bottom cover to facilitate cabling.9.8.13

9.9

9.9.1

9.9.2

9.9.3

9.9.4

9.10Mounting of panels

and resistance boxes

Panels are to be mounted on the floor with required

anchored Bolts and nuts.

9.11 Switchgears Make: SIEMENS only

AC4 Duty

The contactors shall be able to withstand their rated

current for one second without welding / fusing of the

contacts

Manually operable

To be provided for all panels except protective panel.

All the power and control terminals are to be provided with suitable terminal

numbers.

Contactors

TPNSFU with Semi

conductor fuses

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

insulated spacers.

All the power terminals are to be selected for connecting the ring type lugs (in

both panel and FLP junction boxes)

All the power terminals and live parts are to be covered with proper terminal

covers.

Group terminal markers to be used for the clear identification.

and the panel bottom cover to facilitate cabling.

9.12

9.13

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ACCEPTANCE

9.14 Fuses

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

drives to be routed through Semi conductor fast acting

Fuses of adequate rating only. Semi conductor fuses

shall have a indicator for fusing.

Make: M/s Siemens

Qty: as per design 6 Nos. (shall be wired for individual

panel)

Input voltage – 110V / 230 V AC

Output voltage – 24 V DC

Current rating – as per the circuit load

9.16

9.16.1

9.16.2

9.16.3

Terminal blocks and labels

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

Insulating barriers shall be provided between adjacent terminals.

9.15 SMPS

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

terminal blocks.

9.16.4

9.16.5

9.16.6

9.17To be provided for the motor which is not powered viz.

VVVF drive. (ie., all thruster brakes).

9.17a

MPCB to be selected with 2 nos. of NO and NC points

as auxiliary contacts and preferably one no. of alarmn

contact.

between neutral and earth - 19 mm

Labels shall be of acrylic sheet with white engraving on black background /

computerized labels.

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

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

marking provided by the switchgear manufacturer.

Safety in arrangements

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

between phases - 25 mm

9.18between phases and neutral - 25 mm

between phase and earth - 25 mm

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

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

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

proceeding for fabrication.

Motor protection circuit

breaker (MPCB)

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ACCEPTANCE

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

touching.

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

shrouded to prevent accidental contact.

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

protective cover.

9.19

VVVF Drives

The power/current rating of VVVF drive shall be one step higher than the

selected rating of motor.

Main Hoist – as per design 2 or 4 nos.( Capacity of drive shall be suitable to

motor kW selected)

Aux Hoist – 1 No.

LT – 2 Nos.

CT – 1 No. Depending on drive motors.

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

VVVF Drives shall have PROFINET Communication facility.

9.18

cont.

Suitable input and output chokes are to be provided for

controlling the harmonics from VVVF drive to source for

all VVVF drives.

THD should not exceed 5 % and individual Harmonics

should not exceed 3 %.

It needs to be demonstrated at site during erection and

commissioning.

Both control and lighting transformers can be located

outside the panel with suitable enclosure for ventilation.

Transformer terminals are to be covered with hylum

sheet or acrylic sheet to prevent from inadvertant /

accidental contact.

9.22 DBU Suitable size and rating of DBU for all the above drives.

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

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

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

9.21Input and output

chokes

9.21a Transformer

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

are applied near about zero speed of rotation.

9.20

VVVF Drives shall have PROFINET Communication facility.

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ACCEPTANCE

Dynamic braking resistors of suitable capacity/rating

shall be provided to all VVVF drives. For Hoist motions

DBRs shall be sized for a minimum of 150% of

motor full load torque and it shall not be less than the

torque limit setting of the VFD in the hoisting

direction.

Necessary forced cooling needs to be planned.

Controlling of the cooling fans needs to be linked with

control supply ON.

The DBR panels shall be designed such that during

maintenance activities the entire door has to be dis-

asssembled for enabling the better access to the

components inside the panel.

Each motion shall have its individual panel.

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

Volts AC FLP switch cum socket with plug top and 1

No. on the Crab.

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

switch shall be provided inside for the all the panels

except protective panel.

9.23Dynamic braking

resistors

9.24 Power Sockets outlets

Separate control is required for the following:

Under Slung Lights (In pendent)

Socket outlets on the Crane platforms (In protective

panel)

Control circuits (In pendent)

9.25.1Training on Siemens

Drives

Training shall be offered for our engineers by M/s

Siemens about operation, maintenance and trouble

shooting of VVVF drives during commissioning of

Crane.

9.26

9.25 Isolating Switches

MOTORS

Crane duty Motors suitable for Inverter Operations shall be as per IS3177.

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

Squirrel cage induction motors kW rating as per IS3177

Temperature classification - T4.

Class of insulation - Class F

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

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

and specifically designed for crane duty application .

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

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

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

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ACCEPTANCE

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

rpm speed.

Long Travel and cross travel motors shall be 8 poles

with ~ 750 rpm.

Bidder shall provide following details of motors like:

No. of motors

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

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

the top of the stator frame.

9.27 Speed rating of Motors

The Motors shall have preferably ZZ type bearings.

No of motors required

Main Hoist Motion - 4 Nos. (as per design, required power/torque capacity )

Aux Hoist Motor -1 No.

Long travel - 4 Nos. (as per design)

Cross travel - 1 or 2 Nos. (as per design)

The Motors shall have both side extended shaft

Power of motor

Frame size

make

duty : Crane Inverter duty,

no. of starts/hr (300 starts/hr)

CDF : 60%

No. of poles :8

amb.temp : not less than 50 deg C

9.29Current drawn by

motors

Maximum Current drawn by all motors with full load

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

9.30Torque Rating of

motors

Motor full load torque rating shall be min. 120% of

calculated rating on full load.

Imported Electro Hydraulic flame proof Thruster Drum

Brakes for

Main Hoist motion - 2nos. Per motor

Aux. Hoist Motor - 2 nos.

CT Motors - each one no. per motor.

LT motors - each one no. per motor.

Rating, duration and frequency of operation shall be

mentioned in quotation.

9.28

Details to be provided

related to motor

selection and

calculations

9.31 Brakes

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ACCEPTANCE

Main Hoist motors - one no. per motor

Aux Hoist Motor -1 No.

Shall have FLP / Intrinsic safe hollow shaft

incremental encoder for better dynamic performance.

The same to be used to achieve vector control mode of

operation.

All Encoders shall be of Flameproof / Intrinsic safe in

nature.

Encoders' signal shall be of intrisic safe only. Screened

cable as per manufacturer recommendations shall be

used for all encoders.

9.33

9.32 Encoders for motors

Pendant Push button station

Floor operated pendant (Push Button Station) shall be provided with 3-way

Selector Switch for selecting the hoist motors.

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

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

Selector switches shall be of semi flush mounted type.

Only the front plate and operating handle projecting.

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

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

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

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

Number and arrangment of push buttons and indication lamps in Pendant

shall be as per the Annexure - 2A

9.34 Selector switches

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

ON command),

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

Bridge platform).

Crane ON indication Lamp – Powered through Intrinsic Safe circuit.

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

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

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

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

switch, etc..,

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ACCEPTANCE

Interlocking is to be carried out for selection of

command for all the motions.

Pendent level: Hard wired interlocks are to be

provided at push button station. For example when

Main Hoist UP motion push button is pressed Hoist

Creep / Hoist Down (Main and Creep) motions should

not be activated even if pressed and Vice versa.

Auxiliary contactor level: Hard wired interlocks are to

be provided such that when Aux.contactor operates

with respect to the motion selected, remaining Aux.

contactors with respect to other Aux. hoist motions

should not be operated.

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

only one motion has to be selected for operation at a

time in the VVVF drive.

1. Selection of Hoist motor / each load path.

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

switch

9.35 Interlocks

switch

3. Wire rope mis-spool limit operation

4. Auxilary Hoist operation

6. Thruster Brakes' MPCB condition.

7. Provision shall be made for two extra interlocks for

future usage.

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

operation limit.

2. Gravity limit switch

3. Main Hoist operation

4. Thruster Brakes' MPCB condition.


future usage.

1. Right and Left limit switches for respective motion

of the drive.

2. Brakes' MPCB condition.


future usage.

9.37

Auxiliary Hoist VVVF

drive ON command is

to be interlocked with

the following.

9.36

Main Hoist VVVF drive

ON command is to be

interlocked with the

following.

9.38

Cross Travel VVVF

drive ON command is


the following.

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ACCEPTANCE

1. Forward / Reverse limit switches for respective

motion of the drive

2. Brakes' MPCB condition.


future usage.

Indication lamps shall be provided for all 3 phases for

the protective panel.

Control ON / OFF (based on the pendent push button

control) indication lamps shall be provided on the

protective panel.

Indicating lamps shall be of Cluster LED type only,

provided with translucent lamp covers.

Lamps and lenses shall be easily replaceable from the

front.

Cluster LED module shall be suitable for direct

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

indication lamps planned in push button station.

Long Travel VVVF

drive ON command is


the following.

9.40 (a) Indication lamps

9.39

Indication lamps in push button station to be powered

viz. Intrinsic safe relays only.

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

running in the IGUS cable drag chain) shall be carried

out with 1.1.K.V grade XLPE Armored copper

conductor cables.

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

running in the IGUS cable drag chain) shall be carried

out with 1.1.K.V grade flexible copper conductor

cables.

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

in control circuit.

All wiring to be done neatly through perforated trays

from the protective panel / VVVF panel to the top

junction boxes fixed in suitable places.

Wiring shall be neatly bunched, adequately supported

and properly routed to allow easy access and

maintenance.

Wires shall be identified by numbered ferrules at each

end.

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

deteriorating material.

Cable tags to be provided for cable connections as per

circuit diagram.

9.41Power and Control

Cables

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ACCEPTANCE

9.42 Earthing

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

enclosures of all electrical equipment, conduit and trays

shall be effectively grounded with double earthing and

shall be connected to building earth through gantry

rails. The laying of Earth strip from Gantry rail to Earth

pit ( which is around 10meter away from the crane

bay) outside the building is in the scope of EOT

Crane's supplier.

Labels of permanent nature to be specified.

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

both the ends.

FLP junctions Boxes are to be planned for inter facing

the connections between field connections and panel

connections. Sufficient space to must be available for

the maintenance.

The probable locations of the JBs are

Crane LT Girder

Crane Platform

9.43

9.44 Junction Boxes (FLP)

Identification of Circuit

& Cables

Crane Platform

Crane Trolley / crab

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

motors and linked to the control circuit according to the

operational requirement) (For hoist and lower limit).

Gravity Limit Switch – 1 No.

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

Gravity Limit Switch – 1 No.

9.47Limit Switches for CT

& LTLever type - 2 Nos. for CT & 2 Nos. for LT

9.46Limit Switches for Aux

Hoist

9.45Limit Switches for Main

Hoist

SECTION – V

OTHER SPECIFICATIONS AND TERMS &

CONDITIONS OF SUPPLY OF


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ACCEPTANCE

10

10.1 Surface Cleaning

The entire surface of fabricated materials, girders,

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

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

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

grease & dirt.

10.2

Painting with Epoxy

Primer (Total thickness

of 80 microns)

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

Asian Paints or equivalent) shall be applied to a Dry

Film Thickness (DFT) of 80 microns.

10.3

Painting Epoxy Paint

(Total thickness of 120

microns)

Two coats of epoxy paint of Golden Yellow color

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

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

micron and 40 micron for first and second coats with

proper drying in between coats. Final touching shall

be done after erection & commissioning at site.

Painting quality shall ensure austhetic looking of crane.

Total paint thicknessNot less than 200 microns. This will be tested during

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

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

10.4Total paint thickness

including primer

Not less than 200 microns. This will be tested during

stage inpsections and final inspection at supplier

works.

10.5

10.6

11

11.1

11.2

11.3

11.4

11.5

INFORMATION/DOCUMENTS TO BE SUBMITTED ALONG WITH

QUOTATION (offer will be rejected unless these information / documents

are submitted)

Bid Qualification Record (BQR) with duly funnished information, as given

"Appendix" along with this Specifications

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

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

coats of oil resisting durable paint.

Questionnarie, attached with BQR, duly filled by Vendor given along with the

"Appendix" of this specifications.

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

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

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

page 1).

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

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

weights, wheel loads, major components and general arrangement of main

Hoist Drive etc..

In addition if any intermediate cleaning required between successive coats of

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

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

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ACCEPTANCE

12.1

12.2

12.3

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

following drawings & calculations along with technical specifications to Third

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

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

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

necessary correction / modifications and resubmit the drawings and

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

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

documents approved from Third Party Inspection Agency (TPIA) ]

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

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

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

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

approved from TPIA/ Purchaser (SDSC SHAR).

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

PLACEMENT OF ORDER FOR APPROVALS.12

DESIGN APPROVALS:

12.3

12.4

12.5

12.6

12.7

12.8

12.9

12.10

12.11

12.12

12.13

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

as per IS 3177 and Main Hoist Gearboxes as per IS4137 and also as per

technical specifications in to consideration.

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

blocks etc.,

General Arrangement drawing of Dual wire rope reeving with dimensions and

rope equlizer assembly.

Bridge Girder CT rail arrangement drawing to scale with BOM.

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

LT. G.A drawing of Main Hoist drive shall be submitted.

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

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

comments.

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

(BOM).

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

with manufaturer's data sheets as per this specifications and conditions.

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

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

GA Assembly Drawing of Trolley with all components.

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

connections with bill of materials.

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ACCEPTANCE

12.14

12.15

12.16

12.17

12.18

12.19

12.20

12.21

12.22

12.23

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

stages.

Selection of bearings for EOT Crane.

Selection of sheaves & sheave pin with calculations.

Calculations for selection of CT & LT rails.

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

carriage, with weight breakup.

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

in Annexure - 3.

Calculations for selection of wheels & wheel bearings.

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

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

shafts, bearings etc.,

Calculations for drive shafts and plummer block bearings.

Selection of keys, key ways & couplings

12.24

12.25

12.26

12.27

12.28

12.29

12.30

12.31

12.32

12.33

12.34

12.35

Lubrication arrangement of EOT crane with points indicated in drawing.

Total weight of structural, mechanical and electrical components separately

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

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

during final design :

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

without mechanical and electrical components.

Calculations for selection of wheel bogie connecting pins.

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

checked for erection / lifting loads and necessary Calculations shall be

submitted.

GA drawings of Protective Panel and other panel and inside components

arrangements

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

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

curves shall be submitted for approval.

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

circuit, and with interlocks' circuits.

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

Weight and name of individual heaviest mechanical components.

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ACCEPTANCE

12.36

12.37

12.38

13

13.1

13.2

13.3

13.4

Total weight of trolley including electrical equipment.

2 sets of spare parts manuals

Total weight of crane including electrical equipment.

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

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

as per QAP & standards.

Weight of trolley structure ready for erection shall be provided.

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

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

commissioning at ISRO, SHAR

4 sets of Crane operation & maintenance manuals

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

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

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

clearance report.

13.5

13.6

13.7

13.8

13.9

13.10

13.11

14

14.1 Span over LT wheels + 4mm maximum

14.2 Diagonal on wheels ± 5mm maximum

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

interval)

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

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

SHAR).

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

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

and Memory stick in the latest software format.

Trouble Shooting Chart for Main and all Sub-Systems.

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

Manufacturer installation & maintenance manuals, test certificates and

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

Lubrication schedule, diagram with details of lubrications.

Final test certificate of EOT crane from TPIA with inspection report

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

tolerances specified below. Final inpection reports shall be submitted in

drawing format.

Tolerances on Crane dimensions and manufacturing :

SDSC SHAR

SPP



Page:35 of 41


ACCEPTANCE

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

14.5Verticality of End

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

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

14.7 LT wheel alignment ± 1mm (maximum)

14.8Difference in height

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

14.9CT Rail alignment w.r.t

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

14.10Tilt of wheels ( both

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

14.11CT/LT wheel

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

14.12CT / LT wheel

diameter variationless than 0.1 mm in diameter of wheel

14.13Squareness of Girders

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

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

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

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

15

15.1

DESIGN / DRAWINGS

APPROVALS &

CERTIFICATE from

TPIA before crane

manufacture.

Supplier shall obtain all design/ drawings approvals

from third party inspector (TPIA) before starting

crane's production. Crane & components shall be

manufactured & inspected as per the approved

drawings only. All inspection/test repots shall be made

with respect to approved drawing with ref. no.

INSPECTION & TESTING DURING MANUFACTURE & SHOP TESTING OF

CRANE

SDSC SHAR

SPP



Page:36 of 41


ACCEPTANCE

15.2QAP & Third party

agency

INSPECTION and testing shall be carried out as per

QAP enclosed here with in Annexure-3. Supplier shall

hold the manufacturing at specified "HOLD" places and

call for inspection. The Schedule of Inspections shall

be strictly adhered to and shall be witnessed by THRID

PARTY and/or ISRO. All the critical inspections and

load testing shall be done in the presence of Third

Party and /or ISRO.

15.3

Raw materials

identification &

stamping

Raw material identification for structures, wheels, hoist

mechanisms, Gears, load pins etc., shall be done by

Third party inspectorate and/or department. Raw

material test certificates, traceability of materials with

identification marks shall be made available during

identification.

15.4Welding inspection &

Testing

All Butt Welded Joints (both compression & tension

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

Testing and X-Ray Films to be produced for TPIA

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

the quality (QA) documentation submitted to purchaser.

15.5Inspection major parts

and records

Inspection of Bridges, End Carriages, trolley, rails

gauge, Wheels and Measurement of Camber,

mechanical assemblies checking as per QAP. Reports

shall be made in drawing format.

15.6

Dimensional inspection

& alignment checking

& records

Inspection of Span & Diagonal Dimensions (Minimum

~10Kg pull should be applied while checking),

Checking bridge & end carriages' squareness,

Checking of Wheel Alignments, Mechanical drive

Assemblies alignment and Pulley blocks alignment.

Reports shall be made in drawing format.

15.7

15.8 Load testsNo load test, Full load tests and Deflection

measurement as per as per QAP and as per IS: 3177.

15.9 Load tests

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

and Permanent Set Measurement as per QAP and as

per IS 3177.

15.10 Clearance for despatch

The equipment shall be despatched only after

satisfactory performance testing/ inspection at

supplier's works and on written clearance from ISRO &

TPIA.

15.11Testing the extra safety features in EOT crane i.e. performance & interlock

checking of twin hoist system.

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

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

SDSC SHAR

SPP



Page:37 of 41


ACCEPTANCE

16

16.1 At ISRO- SHAR worksFully in the supplier's scope. Inspection and testing

during/after erection shall be as per QAP.

16.2Erection Plan &

Procedure

Before erection, supplier shall submit detailed erection

plan and procedure along with erection loads on

building & also on parts being lifted shall be submitted

for approval.

16.3 Erection Supervision

Supplier shall depute adequate qualified personnel i.e.,

Two Engineers/supervisor/ foreman, (one for

mechanical and one for electrical), fitters, riggers, and

electricians and helpers for carrying out quality

erection work at our site within schedule.

16.4

16.5

Material (lifting

equipment, lifting

tackles, etc) required

during erection.

Fully in the supplier's scope. All lifting machines /

tackles used shall be tested & certified as per

standards before their usage for lifting crane.

ERECTION & COMMISSIONING OF EOT CRANE

Initial unloading of EOT crane parts shall be done by supplier. Equipment

support ( with available equipments if any) will be spared for unloading like

Mobile crane / Forklift / Pick & carry mobile crane (Hydra).

16.6

16.7

16.8

Performance Proving &

Smooth running of

EOT crane

No Load test, Full load test and overload test (for

125%SWL) shall be done as per QAP and as per

IS3177. Proving out for the Crane’s Capacity and

Smooth Functioning of the Crane at Full load (SWL)

and Over load (125%SWL) shall be the responsibility of

the supplier.

16.9Test/Clearance

certificates for crane

To be inspected and certified by "Competent Person of

Third party Inspection Agency " as per Industrial Laws

and shall provide Certification from Third Party

Inspection Agency for final clearance & regular usage

of EOT crane .

17

17.1GEAR BOXES and

Geared Motors

Elecon /Shanti /GREAVES(Premium transmission) /DB-

Radicon/ Renold/ Sumitomo/ Flender.

MAKE OF THE BOUGHT-OUT ITEMS

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

crane components. Supplier can use these hooks for lifting of crane

components during erection of Crane. The capacity & location of erection

hooks shall be given by manufacture during detail engineering. However the

lifting machinery ( power winch, pulley blocks, wire ropes, lifting gear, etc.,) and

accessories are in the scope of supplier. All lifting machines/tackles' Test

certificates shall be furnished.

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

shall be provided by the supplier.

SDSC SHAR

SPP



Page:38 of 41


ACCEPTANCE

17.2

Structural Steel

Materials Plates, rolled

sections

All the structural raw materials (plates, angles, beams)

shall be NEW and of reputed make of M/s SAIL / M/s

JINDAL/ M/s ESSAR/ M/s TATA STEEL / VIZAG-RINL

17.3

Forged steel materials

wheels, shafts, keys,

gears

SAIL / JINDAL / TATA STEEL / ESSAR / VIZAG-RINL

/ SUNFLAG STEEL / TIMKEN / Mahindra Ugine Steel

(MUSCO) / BHARTH FORGE

17.4 Wire Ropes M/s. Usha Martin only.

17.5 Bearings SKF / FAG / TIMKEN / INA

17.6Imported flameproof

Thruster Brakes

Pintsch BUBENZER / SIBRE / WITTON KRAMER /

GALVI/ Sime GKN Stromag

17.7 Hooks EEK / Hercules/IRZAR/ Shilpa Udyog

FENNER / Elecon / Shanti / Renold

Drum/Barrel coupling - Malmedie, Germany

17.9 RailsSAIL / IISCO / JINDAL / ACCELOR / TATA STEEL /

ESSAR

17.8 Couplings

17.9 RailsESSAR

17.10 Paints Asian Paints / Berger

17.11All Electrical Switch

gearM/s Siemens

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

17.13 VVVF Drives M/s. Siemens only.

17.14 Pushbutton switches M/s Siemens

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

17.16LT power & control

cablesM/s. Lapp / Universal / Nicco / Finolex / RPG / Uniflex.

17.17 Panels M/s. Rittal

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

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

Hollow shaft type Encoder can be planned.

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

17.21Junction Boxes (Non-

FLP)M/s. Rittal

17.22 Intrinsic Safe realys M/s P&F only

17.23 UB lights M/s Baliga

SDSC SHAR

SPP



Page:39 of 41


ACCEPTANCE

17.24

18

18.1

18.2

18.3

18.4

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

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

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

consideration.

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

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

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

Agency at the suppliers site as per the QAP schedule.

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

Assembly at site is to be kept as minimum as possible to enable early

No cast iron part should be used on the crane except for electrical equipment.

Similarly wood or combustible material and Bush bearing should not be used in

any part of the crane. Open gears should not be used in any drive / motion.

General TERMS & CONDITIONS during Supply and Installation :

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

detail engineering with submission of technical details, references and

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

18.5

18.6

18.7

18.8

18.10

18.11

The supplier should satisfy himself about the site condition beforehand to avoid

any difficulty during erection and commissioning of the crane

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

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

procedure, material handling procedure etc.

A toolbox containing all necessary tools as given in Page no. 40 required for the

maintenance of the crane should be from part of supply along with the Crane.

Free electricity and water will be provided by the purchaser for the erection,

testing and commissioning of the crane at the site.

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

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

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

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

chargeable basis, if available.

Assembly at site is to be kept as minimum as possible to enable early

commissioning of the crane. Welding of crane at site is to be avoided as far as

possible.

For unloading the crane parts at site (in respective building) material handling

support like Forklifts (~12 ton cap.) and mobile crane (~20 ton/50ton cap.) will

be provided by department at free of cost.

Supplier shall make his own arrangements for welding and gas-cutting works if

any, that are required for erection and commissioning of Cranes.

18.9

SDSC SHAR

SPP



Page:40 of 41


ACCEPTANCE

18.12

18.13

19

19.1

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

COMMERCIAL TERMS & CONDITIONS :

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

crane within 10 months from date of Order and shall be erected &

commissioned with in 2 months from date of supply.

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

inspection and supervision of the manufacturing process adopted by the

supplier for the manufacture of equipment at various stages through their

authorized representatives. In case the manufacturing process adopted is not

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

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

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

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

Bidder should quote separately for spares as considered necessary

for two years of normal operation of crane as given in Annexure-4. Bidder

can suggest any extra spare parts with cost in this regard. However, purchaser

may use his discretion in selecting/removal of spares at the stage of

ordering.

19.2

19.3

19.4.1

19.4.2

19.5

19.6

19.7

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

from the date of acceptance & taken over by the purchaser at our site. During

this period any defect noticed on design, materials, workmanship shall be

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

Excise duty (ED) exemption Certificate will be issued by the Department for the

final product. (Hence, ED shall be NIL). Also Octroai exemption will be provided

by department on request from supplier. ED exemption will not be provided for

input materials.

Liquidates Damages (LD): In case of delay in fabrication, supply, testing and

commissioning beyond the stipulated delivery period LD will be levied at 0.5%

per week or part thereof subject to a maximum of 10% of total order value.

Supply Prices shall be F.O.R Sriharikota.

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

indicated clearly in quotation.

Customs duty (CD) exemption certificate shall be issued by the purchaser for

the imported components used for this EOT crane. Hence, details of items, qty

and cost of the imported items shall be mentioned in the quotation. Bidder shall

provide necessary details accordingly for availing CDEC.

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

be provided by the Vendor for a period of 12 months from the date of

commissioning and acceptance of the crane at purchaser’s site at Sriharikota.

SDSC SHAR

SPP



Page:41 of 41


ACCEPTANCE

19.8

19.8.1Advance along with

Order30% of supply value against Bank guarantee

19.8.2Payment after crane

receipt at site60% of Supply value along with taxes & duties.

19.8.3

Balance Payment after

completion of erection

& commissioning &

acceptance

10% of Supply value + 100% TPIA charges + 100%

erection & commissioning charges against submission

of Performance Bank Guarantee as per clause 19.7.

19.9

Date : Signature & Office Seal of the bidder

Validity of Offer shall be minimum period of 120 days from the tender due

date.

Payment Terms in three stages. Vendor shall comply with following

payment terms only :

Date : Signature & Office Seal of the bidder

42

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

Sl. No.

Description of Item Units Required Qty

1 Double end Spanners from 10-11 to 36-41 (set of 13nos.) of make : M/s Snap On / Taparia)

Set 01

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

3

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

Set 01

4 Heavy duty single end spanners of size 55 Nos. 01

5

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

No No

01 01

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

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

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

9 Circlip plier

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

No No

02 02

10 Special tool driver kit suitable for SIEMENS Drives

Nos. 01

11 Nut driver kit suitable for selected terminal blocks inside the panel

Nos. 01

12 Calibrated steel tape of 30m length of reputed make.

Nos. 02

13 Suitable hydraulic jack capacity 50t. Nos. 02

43

CODES AND STANDARDS FOR 175t / 25t FLAME PROOF EOT CRANE

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

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

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

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

IS:2062 Steel for general structural purpose.

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

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

IS:3681 Gears tooth form and modules.

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

IS 4460 : Parts 1 to 3 : 1995

Gears - Spur and Helical Gears - Calculation of Load Capacity

IS:1835 Steel Wires for Ropes

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

IS:2266 Steel Wire Ropes for General Engineering Purposes.

IS:2363 Glossary of terms relating to wire ropes.

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

IS:3443 Crane Rail Sections

IS:5749 Forged Ramshorn Hooks

IS:3815 Point Hook with Shanks for General Engineering purpose

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

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

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

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

IS:325 Three Phase induction Motors.

IS:4029 Guide for Testing Three Phase induction Motor.

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

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

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

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

IS 2148 : 1981 Flameproof enclosures for electrical apparatus

IS 2206 : Specification for Flameproof Electric Lighting Fittings

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

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

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

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

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

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

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

IS 8623 : 1993 / IEC Pub 439-1 : 1985

Specification for Low-Voltage Switchgear and Control gear Assemblies - Part 1 to Part 3

IS 13947 : Part 4 : Sec 1 : 1993 / IEC Pub 947-4-1 : 1990

Specification for Low-Voltage Switchgear and Control gear - Part 1 to Part 5 : Suppliers and Motor-Starters - Section 1 : Electromechanical Contactors and Motor Starters

IS 10118 : 1982 Code of Practice for Selection, Installation and Maintenance of Switchgear and Control gear

Part I : General

Part II : Selection

Part III : Installation

Part IV : Maintenance

IS 1024 : 1999 Use of Welding in Bridges and Structures Subject to Dynamic Loading - Code of Practice

44

SECTION – VI

ANNEXURES

Annexure – 1A

Rope drum

Top pulley block

Brake 2Brake 1

Planetary gear box 1

Motor 1

Motor 2

Brake 3 Brake 4

Encoder 1

Encoder 2

Motor 3

Motor 4

Encoder 3

Encoder 4

Planetary gear box 2

Brake 6Brake 5

Brake 7 Brake 8

Overspeed sensor

Rotary limit switch

Pedestal bearing

Drum / barrel coupling

Overspeed sensor

Rotary limit switch

Pedestal bearing

Fig 1 : 175t Main Hoist Configuration, Dual drive and Twin load path. 45

48

EOT CRANE CLEARANCE DIMENSIONS – 175t / 25t FLAMEPROOF EOT Crane

(Top running, Double Girder, Flameproof EOT crane)

Refer Annexure – 1A (Fig) for details All Dimensions are in meters

Sl.No Facility Name

Rated SWL

In tons

Span (S)

A B C D F G H P N M X Y

01 Propellant Machining – II

MH– 175t AH – 25t

21.0 m 6.0m 2.20m 1.70m 2.0m 0.1m 0.4m 0.3m 19.00m ~ 6.0 m Not more

than 8.0m

~ 3.0m ~ 3.0m

Height of Lift (m)

Main Hoist Auxiliary Hoist

I J K L

17.0m 5.50m 19.00m 5.50m

Note :

1. The above dimensions are indicative only. EOT crane supplier shall work out the exact dimensions by keeping the view to minimize the end hook approaches and head room and shall provide the same in Cranes GA, drawing along with quotation.

2. EOT Crane span & lift are subjected minor changes which shall be accommodated by supplier during detail engineering.

49

Annexure – 2

SCHEMATIC OF PENDANT PUSH BUTTON OPERATING STATION

Crane Motion / Requirement Selector Switch

No. of push

button

Indication lamps

Selection of Hoist Motor

1 & 2 3-way Selector

switch - - 1

2

Hoist

Main UP

-

1

- Main DOWN 1

Creep UP 1

Creep DOWN 1

Aux. Hoist

Main UP

-

1

- Main DOWN 1

Creep UP 1

Creep DOWN 1

Cross Travel

Main Right

-

1

- Main Left 1

Creep Right 1

Creep Left 1

Long Travel

Main Forward

-

1

- Main Reverse 1

Creep Forward 1

Creep Reverse 1

Emergency Stop with Lockable Key - 1 -

Control ON - 1 -

Control OFF - 1 -

Control ON Indication lamp - 1

Push Button for Bell (Flameproof bell) - 1 -

UB lights Two way

selector switch - -

QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE

Legend

1 Third Party Inspection Agency

2 Vendor (Suppliers)

3 Sub Vendor / Item Supplier

(TPIA) Place:

Date:

Signature of Crane Vendor

with Designation

Annexure - 3

50

Sl.

No

Components/

Operations

Characteristic to

be checked

Category

Type /

Method of

check

Extent

of

check

Ref.

Document

Acceptance

Norm

Format of

record

Agency

Remarks

Pe

rfo

rme

d

Wit

ne

sse

d

Ve

rifi

ed

A B C D E F G H I J K

i)

H

Identification of Raw

materials structural

plates, forged steel

material, Alloy steel etc.,

All raw materials shall be offered with test certificates for identification for Crane manufacture

before start of fabrication. Stamping shall be done for verification at later date.

Component

Specs./ IS 2062/

IS1570/ En steels

Stamping on

parts &

Identification

record

1

-

_

All materials shall be Identified by

Third

Party Agency . (HOLD)

1 STRUCTURAL WORKS : BRIDGE GIRDERS, END CARRIAGES, CRAB FRAME, DRIVE BASES & PLATFORMS ETC.

1.1

Materials -

Plates/rolled sections

Chemical composition/

Mechanical Properties Major T.C. Correlation

(if not available

then test)

One per

heat Approved

drawings/

Specs./ IS 2062

Approved

drawings / Tech.

Specs./ IS 2062

Material T. C. /

Supplier's Test

Report

3,2

-

1

Reports / TC review by TPIA .

1.1.1 Lamination /Internal

defects Major Ultrasonic

Testing 100% ASTM A-435 ASTM A-435 Supplier IR

3,2

-

1

For a l l plates of thickness > 20mm,

UT qualification ( volumetric test)

1.2 Welding Welding procedure &

Welders qualification. Critical Test piece visual

& physical test.

One for

each

position

ASME Sec.IX ASME Sec.IX WPS/ PQR

format

2

-

1

1.2.1

Load Bearing Butt

welds (both tensile and

compression)

a) Welding quality &

Surface defects

Critical Visual &

D.P. Test

100% IS:3658 &

AWS D14.1 IS:3658 &

AWS D14.1

Supplier’s IR

2

-

1 Visual inspection & Use weld

gauges for measurement of weld

size

b) Sub surface defects

Critical

Radiography

100 %

ASME Sec.VIII

Div I

ASME Sec.VIII

DivI

Supplier’s IR

2

1

-

Review of radiography films by I.A.


Legend




(TPIA) Place:

Date:


with Designation

Annexure - 3

51

Sl.

No

Components/

Operations

Characteristic

to be checked

Category

Type /

Method of

check

Extent

of

check

Ref. Document

Acceptance

Norm

Format of

record

Agency

Remarks

Pe

rfo

rme

d

Wit

ne

sse

d

Ve

rifi

ed


1.2.2 Other than load

Bearing Butt welds &

fillet welds

Surface defects & Size Major Visual & DPT 100%

Visual

check &

DP test

10%

random

IS:3658

IS:3658

Supplier’s IR

2

-

1

Use weld gauges for

measurement of weld size

1.2.3

H

Bridge Girder & End

Carriage inspection

before closing the box

Visual, & Welding

Measurement Major Visual &

welding quality Visual

100% DPT-

random of

10%

Component

drawing AWS

D14.1

Component

drawing/ AWS

D14.1

Supplier’s IR

2

1

-

Use weld gauges for

measurement of weld size

(HOLD)

1.2.4 Final Welding

Inspection Visual Inspection Major Inspection of

Welding quality 100% Specification/

AWS D14.1 AWS D14.1 Supplier’s IR

2

-

1 Visual final welding inspection by

TPIA

1.2.5 Final Inspection of

fabricated components

Girders, End carriages,

Trolley, LT drive frame,

etc..,

Dimensional , Camber ,

straightness, level,

Parallelism, verticality,

etc.,

Major Measurement

tolerances as

per

specifications

100% Tech.

Specification/

Component

drawing/IS

807

Tech.

Specification/

Component

drawing/IS 807

Supplier’s IR

2

-

1

Measured Dimensions shall be

marked on component drawing.

Review of reports at next stage by

TPIA. (HOLD)

2.0 ROPE DRUM Fabricated/

Heavy duty Seamless pipe

Material composition/

Mechanical Properties

UTS, YS, % elongation

Major T.C. Correlation

(if not available

then test)

One per

heat Spec/drawing/

ASTSM A106/

IS 2062

Spec/drawing/

ASTSM A106/

IS 2062

Material T. C. /

Supplier’s Test

Report

3,2

-

2, 1

Reports / TC / pressure test

reports review by TPIA

2.1 ROPE DRUM joint

Welding / Seamless pipe

Welding Joint quality &

Weldment defects Critical Visual/DP

Test/RT/ UT 100% Component

drawing ASME Sec.VIII

Div I Supplier’s IR

3/2

2`

1

Measured Dimensions shall be

marked

on component drawing.

Examination of RT films by TPIA. Stress relieving Major Verification 100% Mfg’s std. Stress relieving

chart Supplier’s IR

3/2

2

1


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Date:


with Designation

Annexure - 3

52

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Components/

Operations

Characteristic

to be checked

Category

Type /

Method of

check

Extent

of

check

Ref. Document

Acceptance

Norm

Format of

record

Agency

Remarks

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3.0

Gear box Housings

Fabricated


Mechanical Properties

UTS, YS, % elongation

Major T.C. Correlation

(if not available

then test)

One per

heat Spec/drawing/

IS 2062 Spec/drawing/

IS 2062 Material T. C. /

Supplier’s Test

Report

3,2

-

2, 1

Reports / TC to be

review by TPIA

3.1 Stress relieving Major Verification 100% Mfg's std. Stress relieving

chart Supplier's IR

2

-

1 SR chart will be reviewed by TPIA.

3.2 Surface defects &

dimensional check Major Visual/DP Test/

Measurement DPT 10%

random &

100%

visual

IS:3658/

Component

drawing

IS:3658/AWS

D14.1 Supplier's IR

2

-

1

Measured Dimensions shall be marked

on component drawing

4.0 a) Platform

b) LT Frame

c) Hand Rails

d) chequered Plates

Dimensional

Conformity/

Visual checking /

Mfr’s TC

Minor Measurement 100%

Critical

dimension

s / others

at random

Component

drawing/ Mfr’s

TC/ Industrial

standards

Component

drawing/ Mfr’s

TC/ Industrial

standards

Supplier's IR

2

-

1

5 MECHANICAL COMPONENTS – GEAR BOXES

5.1 MH, AH , CT & LT Input

shafts, Gears , Pinions,

keys, spacers


Mechanical properties

Hardness value / UT /

MPT/ DPT of materials

Major Correlation with

Mfr’s TC ( if not

test materials)

100% Specification

IS:1570 / BS 970

/ IS:2048

Component

drawing/ IS2048

Specification/

IS:1570 / BS 970

Mfr's TC/

Supplier's IR

3,2

-

1

1) UT volumetric test for wrought or

forged materials as per ASTME

114 and A388.

2) DPT or MPT shall be performed as

per ASTM A 275, E709

5.1.1

Machined components

for Gear boxes like input

shafts, gears, pinions,

keys, spacers etc.,

Dimensional conformity

Hardness of gear teeth/

Bearing s/ Oil seals/ keys

and key ways.

Major Measurement/

Visual

examination for

finishing

100% Component

drawing/

IS4460/

AGMA/DIN

IS:2048

Component

drawing/ IS4460/

AGMA/DIN/ Heat

treatment chart

Supplier's IR

2

-

1

Key ways shall be inspected by TPIA

before assembly of gearboxes.


on component drawings.


Legend




(TPIA) Place:

Date:


with Designation

Annexure - 3

53

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No

Components/

Operations

Characteristic

to be checked

Category

Type /

Method of

check

Extent

of

check

Ref. Document

Acceptance

Norm

Format of

record

Agency

Remarks

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5.1.2

H Gear box Assembly Dimensional

conformity/ Inspection

of machined surfaces

like gearbox base,

bearing mounts etc.,.

Major Measurement/

Visual check of

Internal

painting

100% Gearbox GA

drawing Gearbox GA

Drawing. Supplier's IR

2

-

1


on Gearbox GA drawings with

allowed dimensional variations.

(HOLD)

5.1.3

Gear box assembly

testing (No load run test for

minimum of 4 hours )

Contact ratio of

surfaces/ Backlash/

Noise level & Bearing

temperature/ Breather/

Oil level gauge

Major Measurement &

no load running 100% Gearbox GA

drawing /

IS4460/ AGMA

/ Specification

Gearbox GA

drawing / IS4460/

Specification /

Noise level of

gear box ≤ 80dBA

Supplier's IR

2

1

-

No Load Test shall be witnessed

by TPIA. Noise level of gearboxes

shall be ≤ 80dBA. Temperature rise

shall be as per gearbox manufacture

standards.

5.2 MECHANICAL COMPONENTS – LT AND CT DRIVE SHAFTS

5.2.1 Materials of LT & CT

Shafts, and Keyways &

Keys



Hardness of material /

UT / DPT


Mfr’s TC ( if not

test materials)

100% Approved

drawing/ IS2048/

Specification

IS:1570/BS970/

Approved

drawing/ IS2048

Specification/

IS:1570 / BS 970

Mfr's TC/ Test

reports/

Supplier's IR

3, 2

-

1

UT of wrought and forged materials as

per ASTM

5.2.2 Machining of LT & CT

Shafts, and Keyways &

Keys ( Dimensional

measurement)

Straightness &

Dimensional conformity

Checks & Inspection of

Key way milling

Major Dimensional

Measurement/

Visual

examination

100% Approved

drawing/

Specification

IS:1570 /

BS 970/IS2048

Approved

drawing/ IS2048

Specification/

IS:1570 / BS 970

/IS 2048

Supplier's IR

2

-

1

Keys & keyways shall be inspected

by

TPIA before assembly.

5.3 COUPLINGS

a) Materials

b) Torque capacity

c) Key ways

Coupling s Size/


Mechanical properties /

Hardness value / UT /

DPT


Mfr’s TC 100% Approved

drawing/

Specification

IS:1570 / BS 970

Approved

drawing/ IS2048

Specification/

IS:1570 / BS 970

Mfr's TC/

Supplier's IR

3, 2

-

1

Keys & keyways shall be inspected by

TPIA before assembly.

UT of wrought and forged materials

as per ASTM


Legend




(TPIA) Place:

Date:


with Designation

Annexure - 3

54

Sl.

No

Components/

Operations

Characteristic

to be checked

Category

Type /

Method of

check

Extent

of

check

Ref. Document

Acceptance

Norm

Format of

record

Agency

Remarks

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5.4 Plummer blocks &

bases PB & bearing sizes/





drawing/

Specification

Approved

drawing/

Specification/

Mfr's TC/

Supplier's IR

2

-

1

Review of Test certificates by TPIA and

issue Compliance certificate.


on Component drawings with allowed

dimensional variations.

5.5 LT & CT Wheels

5.5.1

a) Material Forged steel

C55Mn75






drawing / Tech.

Specification

IS:1570/BS970

Approved

drawing / Tech.

Specification

IS:1570/BS970

Mfr's TC/ Test

reports/

Supplier's IR

3, 2

-

1



UT of forged blanks Major UT checking 100% ASTM A-388 ASM A-388 Mfr's TC

Supplier's IR

3, 2

-

1 Review of Test certificates by TPIA and


5.5.2 b) Wheels after

machining with Keys &

key ways

Dimensional Conformity

for Bore, wheel tread,

taper of flange /

Hardness/depth

Major Measurement 100% Approved

Component

drawing

Approved

Component

drawing

Supplier's IR

2

-

1


on each Component drawings with


5.6 WHEEL AXLES with key

ways & keys Material composition/


Dimensional inspection

UT & DPT /MPT


Mfr’s TC /

Measurement

100% Approved

drawing / Tech.

Specification

IS:1570/BS970

Approved

drawing / Tech.

Specification

IS:1570/BS970

Mfr's TC/ Test

reports/

Supplier's IR

3,2

-

1




5.7 Pulleys with Roller Bearings

5.7.1 a) Material (Forged Steel )




UT & DPT / MPT



drawing / Tech.

Specification

IS:1570/BS970

Approved

drawing / Tech.

Specification

IS:1570/BS970

Mfr's TC/ Test

reports/

Supplier's IR

3, 2

-

1




Legend




(TPIA) Place:

Date:


with Designation

Annexure - 3

55

Sl.

No

Components/

Operations

Characteristic

to be checked

Category

Type /

Method of

check

Extent

of

check

Ref. Document

Acceptance

Norm

Format of

record

Agency

Remarks

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5.7.2 b) Visual Inspection

c) Dimensional Inspection Overall visual inspection

/ All dimensions as per

drawing like bore,

width, groove,

etc.,/hardness of

Major Measurement

with vernier /

Micrometer

100% Component

drawing /

Specification

Component

drawing /

Specification

Noise level of

gear box < 80db

Mfr's TC

3

-

1,2




5.8 Snatch block Cross

head



Dimensional

inspection, 100% UT &

MPT


Mfr’s TC /

Measurement

100% Approved

drawing / Tech.

Specification

IS:1570/BS970

Approved

drawing / Tech.

Specification

IS:1570/BS970

Mfr's TC/ Test

reports/

Supplier's IR

3,

2

-

1




5.9 Snatch block assembly Dimensional Conformity Major Measurement 100% Approved

Assembly dwg . Assembly

Drawing Supplier's IR

2

-

1 Review of reports by TPIA

5.10

Hook


Mechanical properties/

and 100% UT& DPT /

MPT

Major Correlation

with TC. 100% Component

drawing / IS1875 Component

drawing /IS 1875 Mfr's TC

3

-

2, 1 Proof load test from Govt. approved

test house.

Proof Load Test Major Testing 100% IS5749/IS3815 IS5749/IS3815 Mfr's TC

3

-

2, 1

Stress relieving Major Verification 100% Component

drawing/ IS3815 Component

drawing /IS3815 Vendor TC

3

-

2,1

5.11

Brake Drums with key

and Key ways


Mechanical properties Major Correlation with

Mfr’s TC /

100% Approved comp.

drawing / Tech.

Specification

IS:1570/IS1030

Approved comp.

drawing / Tech.

Specification

IS:1570/IS1030

Mfr's TC/ Test

reports/

Supplier's IR

3,

2

-

1




5.12

Dimensions/ Dynamic

balancing/ Key way and

key inspection.

Major Balancing test/

Measurement

with

100% Component

drawing /

Specification

Component

drawing /

Specification

Mfr's TC

2

-

1

1. Dynamic balance report shall be

reviewed by TPIA.

2. Measured Dimensions shall be

marked on each Component drawings

with allowed dimensional variations.


Legend




(TPIA) Place:

Date:


with Designation

Annexure - 3

56

Sl.

No

Components/

Operations

Characteristic

to be checked

Category

Type /

Method of

check

Extent

of

check

Ref. Document

Acceptance

Norm

Format of

record

Agency

Remarks

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6 BOUGHT-OUT & Other items

6.1

Wire Rope

Dimensional, Genuine

of make, Lay, core and

stands, Tensile grade

Major Mfr's TC 100% Component

drawing/ BOOM Component

drawing / BOOM Mfr's TC

3,2

-

1

Review of Mfr's TC by TPIA.

Visual examination of wire rope for any

defects by 2 & 1.

Breaking Load test Major Mfr's TC 100% IS2266 IS2266 Mfr's TC 3 - 1

6.2 Bearings Bearing No./ Genuine

Major Mfr's TC/

Invoice 100% Approved make

and type SKF/FAG/TIMKEN Mfg TC/

Supplier IR

2

-

1

6.3 Machined Fit Bolts &

Nuts


Mechanical properties /

Measure dimensions


Mfr’s TC /

Measurement

100% Approved comp.

drawing / Tech.

Specification /IS

Approved comp.

drawing / Tech.

Specification

IS:1570/IS1030

Mfr's TC/ Test

reports/

Supplier's IR

3,

2

-

1




6.4 FASTENERS (Bolts, nuts,

washers, lock nuts)

Type / Genuine make

conformity Major Mfr's TC/

Invoice 100% Approved make

and type TVS/UNBRAKO Mfg TC/

Supplier IR

2

-

1

7 ELECTRICAL EQUIPMENT

7.1 Electrical Control

Panels ( VVVF drive

panels)

Dimensional, Visual

Sequence / Functional

and high voltage Test

Major Electrical test 100% Electrical Circuit

diagram/

Approved

drawing/

Specifications

Approved

drawing/

Specification.

Supplier's IR

3

1

Review of test certificates of all bought

out items by IA

7.2 Motor Visual/ Name Plate Major Name Plate 100% IS 325/ Spec IS 325/spec Mfr's TC

2

-

1

7.2.1 Routine / No load test Major Elec. test 100% IS 325 IS 325 Mfr's TC

3

-

2, 1 Review of TC & Flameproof

certificates by TPIA 7.2.2 Flameproof test cert. Major Gap measure 100% IS2148/ CMRI IS2148/ CMRI Type test cert.

3

-

2,1

make conformity


Legend




(TPIA) Place:

Date:


with Designation

Annexure - 3

57

Sl.

No

Components/

Operations

Characteristic

to be checked

Category

Type /

Method of

check

Extent

of

check

Ref. Document

Acceptance

Norm

Format of

record

Agency

Remarks

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7.3 Brakes and

Thrusters,

Brake Coil

Visual/ Name plate/

Make Torque & Thrust /

Material TC verify / Test

certificate/ Ex proof

certificate

Accessibility of parts.

Major Name plate

details, make

Verification of

TC

Verification of

Ex-proof TC

100% Approved

Drawing/ Make/

BOM/Spec

Approved

Drawing/ Make/

BOM/Spec/

ATEX- PTB/

IS2148 -CMRI

Mfr's TC/ Type

test cert for

Flameproof /

Supplier IR

3

-

1

Review of TC & Ex-proof certificates

by

TPIA

7.4 Resistance box Megger test, Resistance

value Major Electrical test 100% BOM/ drawing

/ Specifications. BOM/ drawing /

Specifications. Mfr's TC

3

-

1 Review by TPIA.

7.5 Master controller /

Limit switches / Switch

Gear

Sequence, Number

of cams, Idle

operational test

Major Visual 100% BOM/ drawing /

Specifications. BOM/ drawing /

Specifications. Mfr's TC

3

-

1

Review of TC by I.A.

7.6 Cables Routine test Major Test One per BOM/spec. BOM/spec. Mfr's TC

3

-

1 Review of TC by I.A.

8 H ASSEMBLY OF CRANE (Before assembly of EOT crane all parts shall be inspected by TPIA/Purchaser. Supplier shall inform readiness of all parts) (HOLD)

8.1 Bridge Girder &

End carriage

assembly.

Overall Dimension s

Structural Alignment &

LT Wheel alignment.

Span measurement

Diagonal Checks

Major Measurement/

visual

inspection

100% Approved

General

Arrangement

drawing /

Specifications

Approved

General

Arrangement

drawing /

Specifications

Supplier's IR

2

1

-

Measured Dimensions /

alignment values shall be

marked on GA

/component drawings with allowed

dimensional variations.

8.2 Crab assembly with Main Hoist & CT machinery

Dimensional & CT

Wheel alignment

Couplings’ alignment

Major Measurement 100% Approved

drawing /

Specifications

Approved

drawing /

Specifications

Supplier's IR

2

1

-

Measured Dimensions /

alignment values shall be

marked on GA

/component drawings with



Legend




(TPIA) Place:

Date:


with Designation

Annexure - 3

58

Sl.

No

Components/

Operations

Characteristic

to be checked

Category

Type /

Method of

check

Extent

of

check

Ref. Document

Acceptance

Norm

Format of

record

Agency

Remark

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9 H LOAD TESTING AT WORKS (HOLD)

9.1 NO LOAD TEST

(MH ,AH , CT & LT

mechanisms)

NO Load test/

Performance & Safety

systems verification

speed, Current etc.,

Major NO Load test/

Measurement

of parameters

100% Approved dwg /

IS807/ IS 3177

/Specification

Approved dwg /

IS807/ IS 3177

/Specification

Supplier's IR &

Load test

Format

2

1

-

Measure Gear Box Noise. (Noise

Level should be <80dBA).

9.2 FULL LOAD (SWL) TEST AT WORKS FOR HOIST & CT MOTIONS

9.2.1 DEFLECTION TEST

With Safe Working Load Deflection Major Measurement

as per approved

procedure.

100% Specifications/

IS807/ IS 3177 Specifications/

IS807/ IS 3177 Supplier's IR &

Load test

Format

2

1

-

Deflection < Span/1000 . Record

procedure of test & measurement

with sketch.

9.2.2 Main Hoist and Auxiliary

Hoist With Safe Working

Load

Performance, duty cycle,

Speeds, Current, , Safety

systems etc.,

Major Full Load test/

Measurement

of parameters

100% Approved dwg /

IS807/ IS 3177

/Specification

Approved dwg /

IS807/ IS 3177

/Specification

Load test

report

/Supplier's IR

2

1

-


Level should be <85dBA) .

9.2.3 CT Mechanism With Safe

Working Load Performance, duty cycle,


systems etc.,


Measurement

of parameters

100% Approved dwg /

IS807/ IS 3177

/Specification

Approved dwg /

IS807/ IS 3177

/Specification

Load test

report

/Supplier's IR

2

1

-


Level should be <85dBA) .

9.2.4

OVER LOAD (125% SWL)

TEST

(MH, AH & CT)

Static test/ Capability of

all motions/ Permanent

set

Major Capability of CT

&Hoist motion/

Measurement

100% Approved dwg /

IS807/ IS 3177

/Specification

Approved dwg /

IS807/ IS 3177

/Specification

Supplier's IR &

Load test

report

2

1

-

Record procedure followed for test

& measurement with sketch. After

testing check for any damage,

cracks/paint flaking in load bearing

members. 10 PAINTING

10.1 Sand/ Grit Blasting &

Surface Cleaning Surface Cleanliness/

texture visual inspection

Major Visual Random Specification /

SSPC SA2 1/2 Specification /

SSPC SA2 1/2 Supplier's IR

2

-

1

10.2

Primer Coat Painting DFT Thickness/ visual

inspection Major Measurement

in µm / Visual Random Specification /

DFT ≥75µm Specification /

DFT ≥75 µm Supplier's IR

2

-

1 Paint thickness shall be measured

with paint thickness gauge/

elcometer.


Legend




(TPIA) Place:

Date:


with Designation

Annexure - 3

59

Sl.

No

Components/

Operations

Characteristic

to be checked

Category

Type /

Method of

check

Extent

of

check

Ref. Document

Acceptance

Norm

Format of

record

Agency

Remarks

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10.3 Epoxy paint Painting

(Two coats of 80 µm &

40 µm)

DFT Thickness/ visual

inspection Major Measurement/

Visual Random Specification /

DFT ≥195 µm Specification /

DFT ≥195 µm Supplier's IR

2

-

1

Paint thickness shall be measured with

paint thickness gauge/ elcometer . Final

DFT measured in presence of TPIA.

11 ERECTION AT SITE

11.1 GANTRY GIRDER RAIL

ALIGNMENT

Gantry rail Span, Level,

straightness, rail Joints

and Rail clamp distance.

Major Measurement

of parameters 100% Approved

drawing / IS 807

Specification /

IS3177

Approved

drawing / IS 807

Specification /

IS3177

Supplier's IR

2

-

1

Tolerances:

Rail span : ±5mm; Slope of rail : 1/1000

at 2m interval; Height diff : ±10mm

between LH & RH rails; Rail Gap :2mm;

Straightness of rails: ±5mm

12 LOAD TESTING AFTER ERECTION AT SITE.

12.1 NO LOAD TEST

(MH ,AH , CT & LT

mechanisms)

NO Load test/

Performance & Safety

systems verification

speed, Current etc.,

Major NO Load test/

Measurement

of parameters

100% Approved dwg /

IS807/ IS 3177

/Specification

Approved dwg /

IS807/ IS 3177

/Specification

Supplier's IR &

Load test

Format

2

1

-

Measure Gear Box Noise. (Noise Level

should be <80dBA).

12.2 DEFLECTION TEST

With Safe Working Load Deflection Major Measurement

as per approved

procedure.


IS807/ IS 3177 Specifications/

IS807/ IS 3177 Supplier's IR &

Load test

Format

2

1

-

Deflection < Span/1000 . Record

procedure of test & measurement with

sketch.

12.3 Main Hoist and Auxiliary

Hoist With Safe Working

Load

Performance, duty cycle,


systems etc.,


Measurement

of parameters

100% Approved dwg /

IS807/ IS 3177

/Specification

Approved dwg /

IS807/ IS 3177

/Specification

Load test

report

/Supplier's IR

2

1

-


should be <85dBA) .

12.4 CT Mechanism With Safe

Working Load Performance, duty cycle,


systems etc.,


Measurement

of parameters

100% Approved dwg /

IS807/ IS 3177

/Specification

Approved dwg /

IS807/ IS 3177

/Specification

Load test

report

/Supplier's IR

2

1

-


should be <85dBA) .


Legend




(TPIA) Place:

Date:


with Designation

Annexure - 3

60

Sl.

No

Components/

Operations

Characteristic

to be checked

Category

Type /

Method of

check

Extent

of

check

Ref. Document

Acceptance

Norm

Format of

record

Agency

Remarks

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12.5 LT Mechanism With

Safe Working Load Performance, duty cycle,


systems etc.,


Measurement

of parameters

100% Approved dwg /

IS807/ IS 3177

/Specification

Approved dwg /

IS807/ IS 3177

/Specification

Load test

report

/Supplier's IR

2

1

-


should be <85dBA) .

12.6 Brake Path Test/

Brakes Effectiveness

testing for all motions

Each Brake holding

Brake path / Delay

between two brakes

Major Measurement

of path &

Brake currents


Brake path

≤17mm for Hoist

Specifications/

Brake path

≤17mm for Hoist

Load test

report

/Supplier's IR

2

1

-

12.7

OVER LOAD (125%

SWL)

TEST (MH, AH , CT and

LT motions)

Static test/ Capability of

all motions/ Permanent

set

Major Capability of CT

&Hoist motion/

Measurement

100% Approved dwg /

IS807/ IS 3177

/Specification

Approved dwg /

IS807/ IS 3177

/Specification

Supplier's IR &

Load test

report

2

1

-

Record procedure followed for test &

measurement with sketch. After testing

check for any damage, cracks/paint

flaking in load bearing members.

13.

Final Painting & touch up

Aesthetic look of crane/

DFT measurement

Major

Thickness

measurement

Random

Tech .

Specifications.

Tech .

Specifications.

Supplier's IR

2

1

-

Final DFT measured in presence of

TPIA.

14

Safety features like limit

switches, overload relays,

buffers, stoppers etc.,

Performance, interlocks

Minor

Performance

100%

Tech .

Specifications./

IS3177

Tech .

Specifications./

IS3177

Supplier’s IR

2

1

-

15

Spool limit switch

Performance

Major

No Load test

100%

As per

Specifications

As per

Specifications Load test

report

/Supplier's IR

2

1

-

16 Decoupling of main

hoist output shaft

coupling to rope drum

Ensuring the

decoupling of drive

system

Major Ensuring the

removal and

fixing of drive

system

100% As per

specifications As per

specifications Load test

report

/Supplier's IR

2

1

-

61

Annexure - 4

LIST OF OPTIONAL SPARE PARTS (LUMPSUM PRICE)

S.No Item Description Unit Qty

I Electrical

1 Main Hoist - CUVC card No 1

2 Semi conductor fuse (for each type) Nos. 3

3 Indication lamps Red, Yellow, Blue (Each) Nos. 2

4 Push buttons Nos. 6

5 Emergency push button with lock and key Nos. 1

6 Encoder for main hoist No. 1

II Mechanical

7 Brake liner for main hoist Set 2

8 Thruster assembly for Imported Main hoist Brake (flame proof) No. 1

9 Bearings for input shaft of MH gearbox. Nos. 2

10 Bearings for CT Wheel. Nos. 2

11 Bearings for LT wheel. Nos. 2

12 Oil seals for input shaft of MH gearbox. Nos. 2

13 Oil seals for input shaft of AH gearbox. Nos. 2

14 Sealing rings for geared coupling (each type - 1no.) Set 2

15 Main hoist thruster brake springs Nos. 2

16 LT rail clamps Sets 5

17 CT rail clamps Sets 5

18 Special grease nipples of different sizes (Each) No 10

TOTAL COST OF SPARE PARTS OPTIONAL TO BE MENTIONED IN THE PRICE BID (Rs.)

TENDER SPECIFICATIONS FOR 175t/25t FLAMEPROOF EOT CRANE · TENDER SPECIFICATIONS FOR 175t/25t...

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