भारत सरकार Government of India ... · Fire Protection system for the Vertical Mixer 1 Lot 07 SHAR SP 2018 00 8023 e-procurement ... DBR Location VVVF Drive panels,

1

भारत सरकार Government of India

अ तिरक्ष िवभाग Department of Space

सतीश धवन अतंिरक्ष के द्र Satish Dhawan Space Centre शार SHAR

ीहिरकोटा डा.घ.524124 आ.ंप्र. भारत SRIHARIKOTA P.O. 524124, AP, INDIA टेिलफोन:+91 8623 225023 Telephone: +91 8623 225023 फेक्स: +91 8623 225170 Fax: +91 8623 225170

GOVERNMENT OF INDIA :: DEPARTMENT OF SPACE SATISH DHAWAN SPACE CENTER SHAR :: SRIHARIKOTA – 524 124

SRI POTTI SREERAMULU.NELLORE DISTRICT (A.P)

TENDER NOTICE NO. SDSC SHAR/Sr.HPS/PT/23/2017-18

On behalf of President of India, Sr. Head Purchase and Stores, SDSC SHAR, SRIHARIKOTA invites on line quotations for the following.

Sl No

Ref. No. Description Qty.

01 SHAR SP 2017 00 6950 e-procurement [Two part basis]

Design, Manufacture, Supply, Erection, Testing and Commissioning of Medium Capacity EOT Cranes

1 LS

02 SHAR VAST 2017 00 7637 e-procurement [Two Part basis]

Supplying and Laying of Flow Applied heavy dutyPolyurethane based Cementitious/concrete floortopping system of 4mm thickness for SVAB

2200 SQ.MT

03 SHAR CMD 2018 00 7766 e-procurement [Two part basis]

Replacement of Pipelines and cooling coils

1 LS

04 SHAR RO 2018 00 7803 e-procurement [Single Part basis]

CCTV Work Contract for a period of 2 years at the rate of 8 launches per year.

LS Man days

05 SHAR CMD 2018 00 7880 e-procurement [Two part basis]

Supply of Contract Technical Assistants – Civil (Diploma Civil Engineer with minimum 3 years experience)

2880 Man days

06 SHAR SP 2018 00 8013 e-procurement [Two Part basis]

Supply, Erection, Testing & Commissioning of the Fire Protection system for the Vertical Mixer

1 Lot

07 SHAR SP 2018 00 8023 e-procurement [Two Part basis]

Supply, Erection, Testing & Commissioning of the Fire Protection system for the VFM

1 Lot

Last Date for downloading of tender documents : 10.04.2018 at 16:00 hrs. Due Date for submission of bids online : 10.04.2018 at 16:00 hrs. Due Date for Bid Sealing on : 10.04.2018 at 16:01 hrs. to 10.04.2018 at 17.30 hrs. Due Date for Open Authorization : 10.04.2018 at 17.31 hrs. to 12.04.2018 at 17:00 hrs. Due Date for opening of tenders : 13.04.2018 at 14:30 hrs.

Instructions to Tenderers:

No tender fee shall be applicable for tenders submitted through EGPS

01. For full details/scope of work and terms and conditions etc., please see the enclosed annexures.

02. Interested tenderers can download the e-tender from ISRO e-procurement website https://eprocure.isro.gov.in and submit the offer on line in the e-procurement portal. Offers sent physically by post/courier/in person will not be considered.

03. Tender documents are also available on ISRO website www.isro.org; ISRO e-procurement website https://eprocure.isro.gov.in and SDSC SHAR, Sriharikota website www.shar.gov.in. The same can be down loaded and offer submitted on line in the e-procurement portal.

04. Quotations received after the due date/time will not be considered.

05. The tender documents are available for download upto 10.04.2018 at 1600 hrs. and last date for submission of tenders on line 10.04.2018 at 1600 hrs. and Tender Opening on 13.04.2018 at 14:30 hrs.

06. Sr. Head, Purchase and Stores, SDSC-SHAR, Sriharikota reserves the right to accept or reject any/or all the quotations. DT: 19.03.2018 Sr. HEAD, PURCHASE AND STORES

ANNEXURE - I

SCOPE OF WORK

� Design, manufacture, supply, erection, testing and commissioning of 9 no’s of EOT Cranes:

� Flame proof EOT Cranes:

1. 25t Flame proof DG Top running with VVVF Dual Drive EOT Crane - 01 No






� Non Flame proof EOT Cranes:

7. 30t Normal, DG top running with VVVF Dual Drive system EOT crane - 01 No



(as per IS 3177 and as per IS:807 with latest amendments)

� Supply and erection of suitable crane rails for the above cranes.

� Supply and installation of down shop leads (Drag Chain system) and its accessories for the above cranes.

� Engaging third party agency like M/S Loyds register, M/S M.N. Dhastur, M/S BVQI and Det Norske Veritas (DNV) only, and its expenses towards the same.

� As the crane is intended to be used in hazardous area, the electrical motors, junction boxes, light

fittings etc., should be of flame proof in nature and pendent station shall be interfaced with intrinsic safe barrier.

� Party shall fulfil and submit questionnaire and bid evaluation criteria as per Annexure – A

� Party shall fulfil the commercial terms and conditions as per Annexure – B

� Party shall quote in prescribed price bid format as per Annexure – C1, C2, C3, C4, C5, C6, C7,

C8 & C9

� Main parameters are enclosed in Annexure – IIA, IIB, IIC, IID, IIE, IIF, IIG, IIH & II-I

� Power cable length of each crane shall be considered as per layout mentioned in the annexures-III A, IIIB, IIIC, IIID, IIIE, IIIF, IIIG, IIIH & I II-I.

� The list of approved make of items are as detailed in Annexure – IV A & IV B.

� Party shall submit calculations &Drawing as per in Annexure- V.

� Code and standards that are to be followed are listed in Annexure- VI A & VI B.

� Party shall follow the detailed General and Technical specifications as in the specified Annexure- VII A & VII B.

� VVVF drives Specifications shall be provided as per in the Annexure- VIII.

� Party shall submit quality assurance plan(QAP) as per in the Annexure- IX.

� Party shall submit reports and test certificates as per in the Annexure- X A & X B.

� Key plan of facility enclosed in the Annexure – XI-A, XI-B, XI-C, XI-D, XI-E, XI-F, XI-G, XI-H & XI-I for party reference.

� Training is to be provided by the party for Two persons on Gear boxes conducted by standard

Gear box manufacturer.

ANNEXURE – IIA

Sl. No. 01: 25t Flame proof EOT Crane with VVVF Dual Drive:

MAIN PARAMETERS

Sl. No

Description Specification

01 Safe Working Load (t) 25 ton,

02 Type Flame proof Double girder VVVF Dual Drive EOT crane with Anti-collision system (Lever & Limit Switch type)

03 Duty

Class M5 (equivalent Class II) As per IS: 807-1976. IS: 3177-1999 with latest amendment for structure and mechanics. This crane is intended to handle hazardous and highly explosive rocket segments, So that duty factor(cdf)shall be taken as 1.7 while designing.

04 Location Indoor (Casting facility)

05 Ambient temperature 20-50 degree centigrade

06 Atmospheric condition Near sea shore

07 Area classification Hazardous area Zone 1, Gas group IIA, IIB as per IS: 5571, 5572, and IS: 8239,Temp ClassT4

08 Span 19000 mm (Distance between Centre of LT Rails.

09 Height of lift for MH 27000 mm (From FFL to Centre of hook 14000 mm + 13000 mm From pit to FFL

10 Bay length 55000mm

11

Vertical distance from top of the rail to nearest overhead obstruction (Head room)

5000mm

12 Distance from floor to top of the rail (mm)

15000 mm

13 Distance from center of the rail to nearest side obstruction (side room)

500 mm

14 Operating Hoist main

2.5 m/min

speed(m/min) LT

main 6.0m/min

CT main

6.0m/min

15

Operating speed(m/min)

Dual VVVF Drive system shall be opted.(one for main and one for redundant )

Hoist micro

0.25 m/min through VVVF Drive

LT micro

0.6m/min through VVVF Drive

CT micro


16 VVVF Drive panels, Control Panels and DBR Location

VVVF Drive panels, Control Panels and DBR shall be placed on the floor of the building

17 Nearest position of hook to the Centre of gantry rail (mm) CT

Not exceeding 1500 Left

Not Exceeding 2000 Right

(Left and Right with respective LT Drive)

18 Hook approach clearance (LT)

Not exceeding 2800 mm Non Drive End

Not exceeding 3200 mm Drive End

19 Bridge girder Fabricated out of rolled steel beam of plate box type construction

20 Type of hook Standard forged single point “C” hook with safety latch confirming to IS: 3815

21 Type of wheel

Double flanged wheels machined out of C55Mn75 forging, hardened as per IS: 3177 and mounted on ‘L” type bearings housings. LT wheel shall be selected suitable LT Rail of 75/25t existing EOT Crane. Because this 25t EOT Crane is moving on same track of 75/25t EOT Crane.

22

a)Wire rope Galvanized,6x36,RHO, IWRC, Usha Martin- Make, Tensile strength Min 1960Mpa

b) Factor of safety 6.0

23 Brakes (EHT)

The torque capacity of brakes shall be 2.0 times the rated full torque of the selected motor for main and for LT & CT the torque capacity of brakes shall be 1.5 times the rated full torque of the selected motor

2Nos of Imported brakes for main hoist and 1 no indigenous brake each for LT & CT operations of approved makes only.

24 Bearings Anti-friction ball roller bearings shall be provided

25 Lubrication Individual grease nipples shall be provided for grease lubrication points.

26 Gear box

Oil splash lubricated, fully enclosed type gear boxes with EN24/EN9 pinions and gears, and shall be duly hardened to 250-280 BHN. Main Hoist Gear box shall be Horizontal type.

The noise level shall not be more than 80dB when the Gear box operated alone, measured at 1m distance from the gear box. Note: if vertical gear box selected for CT, lubrication pump shall be provided. Input Power Transmissions, Elements, pinions and gears shall be inspected with UT/Suitable Radiography test. The Service factor of Gear Box shall be 2 over the motor kW rating. Own gear boxes are not acceptable.

27 Couplings Full gear couplings of make as per list

28 Motor

High starting torque, 60% CDF, S5 duty, IP 55, class F insulation, 300 starts / hour, Flame proof squirrel cage induction motors Inverter Duty in TEFC enclosure as per IS: 325 shall be provided for all the motors. The full load torque rating of the motor shall be 20% excess of the torque calculated as per IS: 3177. The pull out torque shall not be less than 2.75 times of full load torque. The motor shall not draw more than 80% of its rated current at full load. The motor shall be provided with minimum two sets of thermistor embedded in the winding with two numbers of winding temperature relays one for Alarm and other for trip at 135 Deg C and the WTR’s to be interfaced with VFD. The Voltage rise time, Insulation Strength, Bearing currents etc., as applicable towards compatibility with VFD to be considered.

29 Limit switches One number of Gravity type limit switch to trip entire control supply in case of activation during Hoisting up. One number of Rotary Type

(for up& down) for hoist system and shall have two additional NC points. Four Nos of Two way lever type for LT & CT operations.

30 Power supply 415 Volts +/- 10%, 50 Hz +/- 3%, 3 Phase supply.

31 Control supply Contactor circuit 110 V, AC, 230 VAC for lamps & socket, intrinsic safe supply for pendent control.

32 Pendent Control

Pendent station operation Requirements: Pendent station on trolley-1 Plug in pendent points at 3 locations

The EOT Crane is indented to get operated from two locations in the Bay. By plugging in pendent station on trolley to the pendent plug in interfacing points. The pendent station shall be provided with trolley arrangement to facilitate movement across Bay area. The pendent shall be mounted on the trolley in such a way to facilitate comfortable operation by standing on floor. The pendent male socket shall be mounted in a metallic box with a cap to close male socket when not in use. The pendent point box shall be mounted in well with suitable mounting arrangement. The vendor has to provide details pendent plug in male & female arrangement, control circuit, trolley arrangement for department approval. The plug & socket arrangement shall be with suitable mill connector or any other suitable & effective connector arrangement. The female plug in the trolley shall be proved with a cable length of 15mts attached to pendent with a suitable cable wounding & needing arrangement.

The cable length requirement is approximately 200mts for interconnecting pendent plug in points ( 3 Nos) and VFD panel.

33 Cable Drag Chain system and Cable tray

The LT and CT Movements shall be planned with Cable Drag chain system with necessary supporting system like beam/angles, cable tray etc., need to be considered The cables shall also be of IGUS make suitable for Drag chain application. Perforated cable trays need to be planned for routing the cables from panel to top of the crane. The tray shall be covered and Earthed to common grounding.

34 Cables PVC sheathed, flexible cables with multi strand copper conductors cable chain drag system shall be provided.

35 Power Supply at DSL The power available at 415 volts, 3 phase, 4wire, 50 Hz near by the crane panel.

36 Buffer Spring buffers for LT & CT with rubber lining.

37 Painting

The entire crane structure will be provided with one coat of zinc rich primer, one coat of golden yellow finish paint before dispatch at site and one more coat of golden yellow finish paint after crane erection at site.

38 Encoders for CT and LT movements

Positional information of Long travel & Cross travel Movements:

There shall be a provision for monitoring Long travel and Cross travel

positional information using an Intrinsic Safe Display units (two Nos)

at pendent station. In order to meet this requirement there shall be

two Encoders one shall be mounted on one wheel in LT System and

one on CT wheel for achieving positional information of Long travel

& cross travel movements.

The Encoder shall be flame proof (Ex-d) multiturn of P & F make.

The encoder shall be interfaced with SSI converter to be provided in a

FLP encoders on crab and 4-20A input from SSI converter shall be

interfaced with Intrinsically safe DPMs of Beka make mounted in the

pendent. The cable for encoder system shall be shielded cable and to

be routed through cable any chain system.

Vendor has to provide measurement & monitoring scheme for

approval.

39 Other points

1. Parties shall submit test certificates for all the bought out items as per Annexure.

2. The crane shall be load tested for no load, full load and 125% over load test prior to dispatch.

3. The noise level: shall not be more than 85 dB when the crane is operated at full load – measured at 1m distance from the crane gear box

ANNEXURE – II B


MAIN PARAMETERS

Sl. No



02 Type Flame proof Double girder VVVF Dual Drive EOT crane.

03 Duty


04 Location Indoor (Assembly and Decoring facility)





09 Height of lift for MH 9100 mm


11


2900mm


10100 mm


500 mm

14

Operating

speed(m/min)

Hoist main

2.5 m/min

LT 6.0m/min

main

CT

main

6.0m/min

15

Operating

speed(m/min)


Hoist micro


LT micro


CT

micro 0.6m/min through VVVF Drive












21 Type of wheel Double flanged wheels machined out of C55Mn75 forging, hardened as per IS: 3177 and mounted on ‘L” type bearings housings.

22 a)Wire rope

Galvanized,6x36,RHO, IWRC, Usha Martin- Make, Tensile strength Min 1960Mpa


23 Brakes (EHT) The torque capacity of brakes shall be 2.0 times the rated full torque of the selected motor for main and for LT & CT the

torque capacity of brakes shall be 1.5 times the rated full torque of the selected motor




26 Gear box


The noise level shall not be more than 80dB when the Gear box operated alone, measured at 1m distance from the gear box. Note: if vertical gear box selected for CT, lubrication pump shall be provided. Input Power Transmissions, Elements, pinions and gears shall be inspected with UT/Suitable Radiography test. The Service factor of Gear Box shall be 2 over the motor kW rating. Own gear boxes are not acceptable.


28 Motor


29 Limit switches One number of Gravity type limit switch to trip entire control supply in case of activation during Hoisting up. One number of Rotary Type (for up& down) for hoist system and shall have two additional NC

points. Four Nos of Two way lever type for LT & CT operations.



32 Pendent Control

Operation from floor through light weight pendent push button station moveable along the bridge girder on four wheeled cable trolleys with anti-friction ball bearing running on a separate track with Intrinsic Safe Control confirming to IS: 5780





36 Pendent Pendent cable shall be on independent “T” track.


38 Painting


39 Other points




ANNEXURE – II C


MAIN PARAMETERS

Sl. No




03 Duty


04 Location Indoor (4.5t Mixer facility)




08 Span 10100 mm (Distance between Centre of LT Rails.)

09 Height of lift for MH 10000mm

10 Bay length 19500 mm

11


3000mm

12 Distance from Floor level to top of the rail

11000 mm


450 mm

14 Operating

speed(m/min)

Hoist main

2.5 m/min

LT 6.0m/min

main

CT

main

6.0m/min

15

Operating

speed(m/min)


Hoist micro


LT micro


CT









Not exceeding 2200mm Non Drive End

Not exceeding 2500mm Drive End




22 a)Wire rope








26 Gear box


The noise level shall not be more than 80dB when the Gear box operated alone, measured at 1m distance from the gear box. Input Power Transmissions, Elements, pinions and gears shall be inspected with UT/Suitable Radiography test. The Service factor of Gear Box shall be 2 over the motor kW rating. Note: if vertical gear box selected for CT, lubrication pump shall be provided. Own gear boxes are not acceptable.


28 Motor






32 Pendent Control








38 Painting


39 Other points




ANNEXURE – II D


MAIN PARAMETERS

Sl. No




03 Duty


04 Location Indoor (Bowl Cleaning facility)







11


3000mm

12 Distance from floor level to top of the rail

9000 mm


350 mm

14 Operating

speed(m/min)

Hoist main

2.5 m/min

LT 6.0m/min

main

CT

main

6.0m/min

15

Operating

speed(m/min)


Hoist micro


LT micro


CT














22 a)Wire rope





2Nos of Imported brakes for main hoistand 1 no indigenous brake each for LT & CT operations of approved makes only.



26 Gear box




28 Motor






32 Pendent Control








38 Painting


39 Other points




ANNEXURE – II E


MAIN PARAMETERS

Sl. No




03 Duty


04 Location Indoor (Premix Storage facility)







11


3000mm


9000 mm


350 mm

14 Operating

speed(m/min)

Hoist main

2.5 m/min

LT 6.0m/min

main

CT

main

6.0m/min

15

Operating

speed(m/min)


Hoist micro


LT micro


CT














22 a)Wire rope








26 Gear box




28 Motor






32 Pendent Control








38 Painting


39 Other points




ANNEXURE – II F


MAIN PARAMETERS

Sl. No




03 Duty


04 Location Indoor (2.5t Mixer facility)







11


3000mm


7750 mm


400 mm

14 Operating

speed(m/min)

Hoist main

2.5 m/min

LT 6.0m/min

main

CT

main

6.0m/min

15

Operating

speed(m/min)


Hoist micro


LT micro


CT














22 a)Wire rope








26 Gear box




28 Motor






32 Pendent Control








38 Painting


39 Other points




B. Non Flame proof EOT Cranes:

ANNEXURE – II G

Sl. No. 07: 30t Normal, DG top running with VVVF Dual Drive system EOT crane:

MAIN PARAMETERS

Sl. No



02 Type Non Flame proof Double girder VVVF Dual Drive EOT crane.

03 Duty Class M5 (equivalent Class II) As per IS: 807-1976. IS: 3177-1999 with latest amendment for structure and mechanics.

04 Location Indoor (Insulation Machining facility)



07 Area classification Non Hazardous area.


09 Height of lift for MH 12000 mm (From FFL to Centre of hook 14000 mm + 13000 mm From pit to FFL


11


4000mm


13000 mm


450 mm

14 Operating

speed(m/min)

Hoist main

2.5 m/min

LT 6.0m/min

main

CT

main

6.0m/min

15

Operating

speed(m/min)


Hoist micro


LT micro


CT












21

22



Brakes (EHT)


2Nos of Imported brakes for main hoist and 1 no indigenous brake

each for LT & CT operations of approved makes only.



25 Gear box




27 Motor

High starting torque, 60% CDF, S5 duty, IP 55, class F insulation, 300 starts / hour, Squirrel cage induction motors Inverter Duty in TEFC enclosure as per IS: 325 shall be provided for all the motors. The full load torque rating of the motor shall be 20% excess of the capacity calculated as per IS: 3177.The pull out torque shall not be less than 2.75 times of full load torque. The motor shall not draw more than 80% of its rated current at full load. The motor shall be provided with thermistor embedded in the winding and to be interfaced with VFD. The Voltage rise time, Insulation Strength, Bearing currents etc., as applicable towards compatibility with VFD to be considered.

28 Limit switches

One number of Gravity type limit switch to trip entire control supply in case of activation during Hoisting up. One number of Rotary Type (for up & down) for hoist system and shall have two additional NC points. Four Nos of Two way lever type for LT & CT operations.


30 Control supply Contactor circuit 110 V, AC, 230 VAC for lamps & socket.

31 Pendent Control Operation from floor through light weight pendent push button station moveable along the bridge girder on four wheeled cable trolleys with anti-friction ball bearing running on a separate track with.







37 Painting


38 Other points




ANNEXURE – II H

Sl. No. 08: 25t Normal, DG top running with VVVF Dual Drive system EOT crane

MAIN PARAMETERS

Sl. No




03 Duty


04 Location Indoor (Hardware Preparation facility High Bay - I)







11


3500mm


11500 mm


350 mm


2.5 m/min

speed(m/min) LT

main 6.0m/min

CT

main

6.0m/min

15

Operating

speed(m/min)


Hoist micro


LT micro


CT












21

22



Brakes (EHT)





25 Gear box




27 Motor


28 Limit switches

One number of Gravity type limit switch to trip entire control supply in case of activation during Hoisting up. One number of Rotary Type (for up& down) for hoist system and shall have two additional NC points. Four Nos of Two way lever type for LT & CT operations.



31 Pendent Control








37 Painting


38 Other points




ANNEXURE – II-I

Sl. No. 09: 25t Normal, DG top running with VVVF Dual Drive system EOT crane

MAIN PARAMETERS

Sl. No




03 Duty


04 Location Indoor (Hardware Preparation facility High Bay - II)







11


3500mm


11500 mm


350 mm


2.5 m/min

speed(m/min) LT

main 6.0m/min

CT

main

6.0m/min

15

Operating

speed(m/min)


Hoist micro


LT micro


CT












21

22



Brakes (EHT)





25 Gear box




27 Motor


28 Limit switches

One number of Gravity type limit switch to trip entire control supply in case of activation during Hoisting up. One number of Rotary Type (for up& down) for hoist system and shall have two additional NC points. Four Nos of Two way lever type for LT & CT operations.



31 Pendent Control








37 Painting


38 Other points




ANNEXURE – IV A

LIST OF MANUFACTURERS / SPECIFIC BRANDS FOR BOUGHTOUT ITEMS. Flame Proof EOT Cranes 1. Gear boxes : Elecon / Premium /Flenda-Siemens Shanti/GREAVE 2. Wire ropes (All galvanized) : Usha Martin/ CASAR Germany/ BRIDON USA,Kiswire – KOREA/MALAYSIA 3. Flame proof Panels, Light fittngs : Baliga/FCG/Flameproof equipment Pvt Ltd/Stahl Glands, Junction Boxes etc., 4. Power & control cables. : IGUS/LAPP make cables as applicable shall be used

in cable drag chain system. The cable drag chain & cable shall be of same make.

Incab/ cable corpn of India, Universal/ Asian/ Finolex/ Polycab/ Lapp/RPG/ HAVELLS – Pendent/ fixed power & control cables.

5. Flame proof electric motors: : Kirloskar, Crompton Greaves,Bharat Bijilee. Alstom. 6. Thrustor brake for hoist : M/S Witton cramer,M/S Bubenzer Bremzen,M/S SIBRE 7. Thrustor brake for CT & LT : M/S Electromag methods (EMM)/Kateel/Sterling

Control 8 Power supply unit : M/S SIEMENS only

9. Limit switches : Speed-o-Control, EMM, Sterling control 10. Contactors, Over load Relays, : M/S SIEMENS only 11. Intrinsic Safe relays : P & F 12. VVVF Drive : M/s. Siemens / M/s. ABB 13. Electrical Switch gears : M/s. Siemens 13. Bearings : SKF, FAG, TIMKEN 14. Couplings : Fenner, Love-joy 15. Paints : Berger, Asian paints, Jenson& Nicholson, Nerolac, Dulex, Poly coat 16. Cable chain drag system : M/S IGUS/LAPP 17. Electrical Drive Panel : M/S Rittal /Siemens 18. Encoder : P&F/ Hengstler/ Hubner/ Kubler/ Schnider/Baumer

ANNEXURE – IVB

LIST OF MANUFACTURERS / SPECIFIC BRANDS FOR BOUGHTOUT ITEMS. NON-Flame Proof EOT Cranes 1. Gear boxes : Elecon / Premium /Flenda-Siemens Shanti/GREAVE 2. Wire ropes (All galvanised) : Usha Martin/ CASAR Germany/ BRIDON USA Kiswire – KOREA/MALAYSIA 3. Non Flame proof Panels, Light fittngs : FCG/Non Flameproof equipment Pvt Ltd Glands, Junction Boxes etc., 4. Power & control cables. : IGUS/LAPP make cables as applicable shall be used

in cable drag chain system. The cable drag chain & cable shall be of same make.

Incab/ cable corpn of India, Universal/ Asian/ Finolex/ Polycab/ Lapp/RPG/ HAVELLS – Pendent/ fixed power & control cables.

5. Non Flame proof electric motors: : Kirloskar, Crompton Greaves,Bharat Bijilee. Alstom. 6. Thrustor brake for hoist : M/S Witton cramer,M/s. Bubenzer Bremzen,M/s. SIBRE, M/s. GALVI 7. Thrustor brake for CT & LT : M/S Electromag methods, Kateel (EMM),Sterling Control 8 Power supply unit : M/S SIEMENS only

9. Limit switches : Speed-o-Control, EMM, Sterling control 10. Switch gear, Contactors, MCB etc., : M/S SIEMENS only 11. Intrinsic Safe relays : P & F 12. VVVF Drive : M/s. Siemens / M/s. ABB 13. Bearings : SKF, FAG, TIMKEN 14. Couplings : Fenner, Love-joy 15. Paints : Berger, Asian paints, Jenson & Nicholson, Nerolac, Dulex, Poly coat 16. Cable chain drag system : M/S IGUS/LAPP 17.Electrical Drive Panel : M/s. Rittal/ Ms. Siemens 18. Encoder : P&F, Hengstler, Hubner, Kubler, Schnider.

ANNEXURE – V

THE PARTY SHALL SUBMIT THE FOLLOWING CALCULATIONS ALONG WITH DRAWINGS (within 4 weeks) I. SIZING CALCULATIONS

1. Motor Selection – i) Main Hoist

ii) Travel Motion for CT & LT 2. Brake Selection – i) ) Main Hoist

ii) LT iii) CT

3. Wire ropes - Main Hoist

4. Sheaves

5. Rope drum – i) Thickness ii) Diameter

iii) Length 6. Gear box selection – (M.H, CT &LT )

7. Gear box calculations –

8. Coupling selection – i) Input, ii) Output iii) Hoist, CT& LT

9. Bearing life & Selection –

10. Angular twist for shaft – i) CT ii) LT iii) Rigid shaft

11. Wheel selection & spacing – i) Load

ii) Diameter selection for CT & LT 12. Rail selection – CT & LT, Contact Stresses 13. Braking path calculations for – i) Main Hoist

ii) CT iii) LT

14. Calculation of fleet angle for pulleys

II. STRUCTURAL & DESIGN CALCULATIONS :

1) Main Girder calculations

2) Camber calculations

3) Deflection of Girder < L/1000

4) Welding design of Main girder and end carriage

5) Collision effects

6) End carriage calculations

7) Goose neck calculations

8) Diaphragm calculations – I) Main Girder, II) End Carriage

9) Connection of the main girder to the end carriage& splice joints etc.,

10) Crab calculations

III. Electrical:

1. Cable sizes & type selected for different current values with voltage drop.

2. Torque speed curves of individual motors.

3. VVVF Drive selection

4. DBR sizing calculations

IV. Drawings:

MECHNICAL:

1) G.A drawings

2) Main Girder drawings

3) Crab drawings

4) End carriage drawings

5) Hook approaches drawings

6) LT arrangement

7) Snatch Block assembly.

8) Gear boxes

9) Rope drum

10) Sub assembly of wheels

ELECTRICAL :

1. Power Circuit Diagram

2. Control Circuit Diagram

3. Cable Schedule

4. VFD ratings, configuration, Model Number etc., (for VVVF Drive system only)

5. General Arrangement Drawing of panel with layout of all components.

6. Pendent schematic drawing.

ANNEXURE – VI A

CODES AND STANDARDS:

The design, manufacture and testing of flame proof cranes shall conform to the latest editions of the following codes and standards wherever applicable: IS: 3177 Code of Practice for Design of Overhead Traveling Cranes and Gantry Cranes other than Steel Works Cranes. IS: 800 Code of practice for use of structural steel in general building construction.

IS: 807 Code of Practice for Design, Manufacture, Erection and Testing (Structural Portion) of Cranes and Hoists. 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:3973 Selection, installation, maintenance and technical supply conditions of wire ropes

IS: 3443 Crane Rail Sections

IS: 325 Three Phase induction Motors.

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 5780 : 1980Specification for Intrinsically Safe Electrical Apparatus and Circuits. IS:4237 : General requirements of switch gears and control gears for voltages not exceeding 1000V AC.

IS 13947 : Part 4 : Sec 1 : 1993 /IEC Pub 947-4-1 : 1990 Specification for Low-Voltage Switchgear and Controlgear - Part 1 to Part 5 : Contractors and Motor-Starters - Section 1 : Electromechanical Contactors and Motor Starters

IS:2062 : Steel for general structural purpose.

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

ANSI/AWS D14.1 Structural Welding code: Code of welding practice for Mill cranes and other material handling equipment

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

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 8610 : 1977 Specification for Point Hooks with Shank Capacity Up to 25 Tonnes-Trapezoidal Section

IS 3815/ IS 15560: Specification for point hooks with shank for general engineering purposes

ANNEXURE – VIB

CODES AND STANDARDS:

The design, manufacture and testing of the Non flame proof crane shall conform to the latest editions of the following codes and standards wherever applicable: IS:3177 Code of Practice for Design of Overhead Traveling Cranes and Gantry Cranes other than Steel Works Cranes.

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

IS:807 Code of Practice for Design, Manufacture, Erection and Testing (Structural Portion) of Cranes and Hoists. 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:3973 Selection, installation, maintenance and technical supply conditions of wire ropes

IS: 3443 Crane Rail Sections

IS: 325 Three Phase induction Motors.

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

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

IS 13947 : Part 4 : Sec 1 : 1993 /IEC Pub 947-4-1 : 1990 Specification for Low-Voltage

Switchgear and Controlgear - Part 1 to Part 5 : Contractors and Motor-Starters - Section 1 : Electromechanical Contactors and Motor Starters

IS:2062 Steel for general structural purpose.

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 ANSI/AWS D14.1 Structural Welding code : Code of welding practice for Mill cranes and other

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

Practice

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 8610 : 1977 Specification for Point Hooks with Shank Capacity Up to 25 Tonnes-Trapezoidal

Section IS 3815/ IS 15560: Specification for point hooks with shank for general engineering purposes

ANNEXURE - XII

List of Spare Parts

Sl. No Item Description Capacity Qty

1.

Main Hoist EHT Brake Thruster (Imported Thruster)

30t (FLP) 1

2. 30t (Non FLP) 1

3. 25t (FLP) 1

4. 25t(NFLP) 1

5. 20t (FLP) 1

6.

LT EHT Brake Thruster

30t (FLP) 1

7. 30t (Non FLP) 1

8. 25t (FLP) 1

9. 25t(NFLP) 1

10. 20t (FLP) 1

11.

CT EHT Brake Thruster

30t (FLP) 1

12. 30t (Non FLP) 1

13. 25t (FLP) 1

14. 25t(NFLP) 1

15. 20t (FLP) 1

16.

Rotary Limit Switch

30t (FLP) 1

17. 30t (Non FLP) 1

18. 25t (FLP) 1

19. 25t(NFLP) 1

20. 20t (FLP) 1

21.

MPCB for Main Hoist Brake

30t (FLP) 1

22. 30t (Non FLP) 1

23. 25t (FLP) 1

24. 25t(NFLP) 1

25. 20t (FLP) 1

26.

MPCB for LT Brake

30t (FLP) 1

27. 30t (Non FLP) 1

28. 25t (FLP) 1

29. 25t(NFLP) 1

30. 20t (FLP) 1

31.

MPCB for CT Brake

30t (FLP) 1

32. 30t (Non FLP) 1

33. 25t (FLP) 1

34. 25t(NFLP) 1

35. 20t (FLP) 1

ANNEXURE – VII A

General & Technical Specifications

A) Flame Proof EOT Cranes

I. General Specifications: 1.0 SCOPE OF WORK

Scope of work shall include design, detail engineering, manufacture, inspection, shop testing,

supply, erection, site testing & commissioning of EOT Crane required for Solid Propellant Space

Booster Plant of SDSC SHAR, ISRO, SRIHARIKOTA including importation of equipment/

components (if any), in full & good condition as per the specifications, procedure, completion

schedule and the terms & conditions furnished in this document. The scope of work shall also

include procurement of all materials including components required for completion of the work,

coordinated planning for manufacture, testing, painting, inspection, packing, marking, loading on

Trucks/ Trailers, safe transportation to site, unloading and handling of the work fully erected,

tested, commissioned as per Technical Specifications.

a. The place “Sriharikota” is located 20 km east of Sullurupeta (nearest town) which is 80 km north of Chennai Tamilnadu and 95km South of Nellore, District head quarter of SPSR Nellore District.

b. SDSC SHAR, Sriharikota is a prohibited place. Hence, no contractor, working personnel will be allowed to stay and they have to be accommodated in Sullurupeta by their own arrangements.

c. The Contractor may have to transport working personnel on day to day basis by his own arrangement. Location of the site is worked out to be 30 km from Sullurupeta. The contractor personnel have to undergo security checks by security force is CISF as per the prevailing guidelines.

d. All the working personnel shall comply with code of conduct during their stay inside the SDSC SHAR campus.

Arranging the third party inspection is in the scope of supplier for the entire scope of Work as given above.

2.0 GENERAL CONDITIONS: 2.1 Tender shall be accompanied with general arrangement drawing showing to scale the

elevation, cross section and plan of the EOT crane which shall indicate the information viz., clearances, construction of bridge structure, hook approaches, lift, wheel base, wheel loads and wheel diameters, motor ratings, speeds, arrangement of all the drives and other equipment installed on the crane. Also the tender shall contain Annexure duly filled up to enable the purchaser to assess the important technical features of the equipment offered. Tenders may be rejected, if compliance with this clause is not ensured. The tenderer shall also clearly specify any request for deviation from technical specification on particular items. Generalized statements like crane shall be manufactured as per IS standard and our specification etc. are not adequate. The reference number of applicable, standards shall be clearly mentioned.

2.2 After receiving the order, the contractor shall submit design details, calculations and drawings (four copies each) as mentioned in Annexure-V to the purchaser and third party inspection agency for review, comments and approval prior to commencement of fabrication.

a) The general arrangement drawings containing all information as described in para 2.1.

In addition to this, the GA drawing shall clearly show the layout of electrical panels, DBR, etc. All the dimensions and clearances shall be clearly marked on the drawing.

b) Electrical schematic diagrams containing details of components such as make, type,

rating/range, settings etc., are to be marked on the schematic diagram. All contacts and coils of contact shall be numbered/ designated.

c) Detailed structural drawings for the bridge girders, end carriages, repair cages,

inspection platforms, trolley frame etc., with Bill of quantities and material specifications.

2.3.1 All the drawings and calculations required for the approval shall be submitted in stages

within 4 weeks of placement of order to the purchaser and third party inspection agency. 2.3.2 If the drawings and other particulars are returned by the purchaser, because they are

incomplete or faulty, the contractor shall make the necessary correction / modifications and resubmit the drawings and calculations within a reasonable time but in any case should not exceed two weeks from the date of receipt of purchase’s/third party inspection agencies comments.

2.3.3 Tendered shall give the break-up of weights of the cranes as mentioned below during

final design. a. Total weight of crane including electrical equipment. b. Total weight of trolley including electrical equipment. c. Weight of each bridge girder as assembled and ready for erection, with and

without mechanical and electrical components. d. Weight of each end carriage as assembled and ready for erection. e. Weight and name of individual heaviest mechanical components. f. Total weight of structural, mechanical and electrical components separately.

2.3.4 The granting of any approval by SDSC, SHAR shall not absolve the CONTRACTOR

of his responsibilities for the design or the correctness of drawings and specifications. Any such approval by SDSC, SHAR shall not constitute a waiver by SDSC, SHAR of any right.

2.3.5 The following information shall be supplied prior to commissioning of the crane:

a) Four copies of all drawings and data, which have been approved by the purchaser. b) Four copies of the following manuals/ drawings shall be submitted.

2.4 THIRD PARTY INSPECTION:

i. The supplier should engage Third Party Inspection Agency (INSPECTORATE) for carrying out design verification/stage inspection/ final inspection for supply items and for construction, erection and testing at supplier’s works and at SHAR site. Contractor shall extend all necessary help/ equipment/ tools/ measuring instruments as required for

carrying out necessary tests/ inspection at works/ site to the representatives of SDSC, SHAR/ INSPECTORATE.

ii. SDSC, SHAR/INSPECTORATE shall have the right of inspection and supervision of

the manufacturing process adopted by the Contractor 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 Contractor will be advised to adopt the correct manufacturing process which will be binding on the Contractor. SDSC, SHAR’s decision regarding the quality of work and its acceptability shall be final and binding on the Contractor.

iii. The Supplier shall give mutually agreeable reasonable time in advance to SDSC,

SHAR/INSPECTORATE for inspection and testing of any equipment on its being ready specifying the period likely to be required for such inspection and testing.

iv. The supplier should engage third party inspection agencies like M/S Loyds register, M/S

M.N.Dhastur, M/S BVQI and DET NORSKE VERITAS (DNV) only.

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

crane during different stages of its manufacture starting from the raw materials till the

completion of the crane by the SDSC, SHAR and INSPECTORATE at the suppliers site as per the following schedule.

a) Design verification b) Raw material identification, components like gears, shafts, keys, keyways sub-

assemblies of drive mechanism mechanical and electrical. c) Motor shaft, gear box shaft, brake unit, etc., proper alignment. d) Proper adjustment of brake shoes for optimum braking. Hoisting motion twin brakes –

each should be adjusted independently to take the full load. e) Measurement of noise level in dBA. f) Paint thickness measurements at various stages like primer, intermediate and final

coats. g) Radiographic / ultrasonic inspections of the critical weld joints of the girders, ropes

drums, end carriages etc. h) Testing and inspection of crane at the works prior to the dispatch. The test shall include

full load, no load, overload, insulation test, speed test, deflection test, etc. The crane shall be tested in all respects in conformity with section 4 of IS 3177-1999 in the presence of the purchaser or his representative before dispatch. The manufacturer shall submit detailed list on the item/tests to inspection agency and shall provide the necessary testing facility for the inspecting engineers during the test.

i) The crane is to be erected, tested and commissioning as per the approved specification

code at our site at Sriharikota in addition to the tests at manufactures’ works. j) Necessary test loads will be identified by the department in existing buildings where

EOT crane is available. Supplier shall make arrangements for loading and transporting these loads on trucks and trailers to building in which crane is being commissioned, and after completion of satisfactory load testing these loads shall be transported back

to respective original location. Trucks and trailers will be provided by department for the transportation of test loads at site. But necessary manpower, tools and tackles shall be arranged by the supplier at his own cost.

2.5 The contractor shall ensure that the cranes shall be manufactured as per the tolerances specified below. a) Span over L.T wheel : ± 4mm upto 19.5 meters maximum b) Diagonal on wheels : ± 5mm maximum. c) Long travel wheel alignment : ± 1mm maximum d) Tilt of wheels or balancer : ± 1mm / 100mm maximum (horizontal & vertical) e) Trolley wheel guage : ± 2mm for gauge up to 2.5m} max ± 3mm for gauge over 2.5m}

f) Difference in height between trolley rails. (H) in relation to the trolley track gauge (S) shall be within the following tolerances. “S” (mm) “H” mm up to 2500 3 above 2500 5

g) Speeds at full rated load, voltage, and frequency shall be as follows: I) Travelling & traversing : +10% -5% of specified speed. II) Hoisting : +10% -5% of specified speed. III) Lowering : +20%-5% of specified speed.

2.6 The contractor shall ensure that only minimum amount of assembly at site is necessary for early commissioning of the crane after delivery. Site welding shall be avoided. The contractor before proceeding with design details shall satisfy him self about the site condition so as to avoid any difficulty in erection due to peculiarity of site condition.

2.7 The tenderer shall also quote separately for erection, transport and unloading at site by

their own men, material, tools and tackles. The crane shall be transported at contractors risk and cost. The purchaser will not pay for any insurance.

2.8 The crane shall be completely assembled including wiring and other fittings in the

contractor’s shop before load testing of the crane. The crane hoist and traverse shall be tested to its rated load and over load at the supplier’s workshop before dispatch to site for erection.

2.9 The crane after erection shall be tested as given below: -

a) No load test: After completion of erection, crane shall be tested with no load to check the

performance of crane speeds, end clearance, hook approaches, height of lift, limit switch operations, no load current of motors, contacts, relays, inter locks etc.,

b) Deflection test:

The deflection of the bridge girders shall not exceed 1/1000 of span with the fully loaded trolley stationed at mid-span and the safe working load at rest. The measurement shall not be taken on the first application of load. The datum line for measuring the deflection should be obtained by placing the unloaded trolley on the extreme end of the crane span with smaller hook approach of the largest capacity hook.

c) Speed tests:

1) All the motions of the crane shall be tested with rated load and the rated speeds shall be attained within the tolerance limits indicated under clause 2.5(g).

2) All the motions of the crane shall be tested with 25% overload in which case the

rated speeds may not be attained but the crane shall show itself capable of dealing with the over load without difficulty.

d) Brake Tests:

� The hoists brakes shall be capable of braking the movement under conditions (1) & (2) of speed tests, however the braking path with rated load shall not exceed value given in the table No.1 under brakes (clause 13 of section IV: Mechanical details).

� The long travel and cross travel brakes shall be capable of arresting the motion within a distance in meters equal to 10% of the speed in metres/min and the retardation due to braking shall not exceed the values as given in the Table No.2 under brakes (clause 13 of section IV: Mechanical details)

e) Insulation and other tests shall also be carried out.

2.10 Dimensions of all parts used on crane shall confirm to metric standards. 2.11 All the electrical equipment shall be of proven quality as regards to their performance. 2.12 The transfer of title to the purchaser will take place only after satisfactory erection, testing

and commissioning of the crane by the contractor and acceptance by the purchaser. Hence, any insurance charges are to be borne by the contractor.

2.13 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. If the loads are not in acceptable limits of civil structure, supplier shall plan different arrangement.

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

contractor

has to make his own arrangements for boarding, lodging, transportation of his men and materials. However, hostel accommodation may be provided by the purchaser on chargeable basis, if available.

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

Commissioning of the crane at the site. 2.16 Initial filling of lubricants required for commissioning at site shall be provided by the

supplier. 2.17 Before starting the site work, the contractor has to insure all his personnel working at site

in Sriharikota against accidents.

II ) TECHNICAL SPECIFICATIONS :

II A. DESIGN STANDARDS & OTHER DETAILS:

01. The crane shall be designed in accordance with the latest editions of IS:3177-1999 for class M5 duty and any other standards referred to therein and subject to any modification and requirement specified herein after. 02. All the Electrical equipment in flame proof cranes shall be of flame proof type suitable to

use in hazardous area Zone1, Group IIA/IIB, T4 as per IS5572 / IEC60079. The control for pendent push button station and limit switches shall be intrinsically safe as per IS: 5780

03. Safe access for maintenance and removal of all mechanical and electrical parts must be

ensured without any additional scaffolding. All parts requiring replacement or inspection or lubrication shall be easily accessible without the need for dismantling of other equipments or structures. All electrical cables shall be so laid that they are not liable to be damaged and can be easily inspected and maintained.

04. For welded construction such as that of bridge girders and carriages, trolley frames, rope

drums, gearboxes etc., all steel plates shall conform to IS-2062 or its equivalent. 05. No cast iron parts shall be used on cranes except for electrical equipments. Similarly, no

wood or other combustible material shall be used in any part of the crane.

06. Full length chequered plate platform shall be provided for both the bridge girders in order to have access to long travel drive, current collectors, trolley etc., The chequered plate platform shall cover the full width between main and auxiliary girders. Where the platforms are bracketed out from the bridge girders, the width of the chequered plate covering shall not be less than 750 mm. The walkway platforms both the top and bottom chord levels shall be so arranged that there is a minimum clearance of 2000mm between the top of the platform and the lowest overhead obstruction.

07. Foot walks shall be of sufficient width to give at least 750mm clear passage at all points, except between railing and bridge drive where this clearance may be reduced to not less than 400mm.

08. All opening in foot walk flooring for access to bottom chord platforms and inspecting

platforms, shall be provided with strong hinged covers. Minimum size of hatch openings shall be 600 X 600mm. Any other opening in foot walk or end carriage shall be provided with bolted removable plate covers.

09. Guards of an approved design, which will push forward or off the track any object placed

across it, such as a person’s foot or arm, shall be attached to each end of the end carriage. 10. All wheels, couplings, line shafts etc, shall be provided with covers opening on strong

hinges. These covers shall preferably be made of minimum 5mm thick plates. All heavy covers shall be provided with inspection windows.

11. a) All bolts except those with nylon nuts shall be provided with grip lock nuts or

spring washers.

b) For side alignment of motors strong adjustable screws with lock nuts shall be provided. c) Welded snugs hall be fitted against the feet of all pedestals, gear boxes, etc.,

except motors. Motors shall be provided with alignment screws for side alignment.

d) 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.

e) All bolts, studs, nuts, washers, etc., shall be heavy duty galvanized. All bolts

shall be designed assuring the material as mild steel. High strength bolts can be used only where they cannot be avoided. In case of electro-galvanizing, suitable baking of galvanized bolts as per standards shall be carried out to drive out the Hydrogen in order to avoid hydrogen embrittlement.

12. a) Safety hand railings preferably of tubular construction shall be provided on

bridge foot walks, end carriages, ladders, staircases, trolley and in any other places where access has been provided. Railings shall not be less than 1000mm high with an intermediate member at a height of 500mm

. b) All edges or openings shall be provided with toe guards. Toe angles or bent plates

wherever required shall be 100mm high minimum.

13. Defects in the material like fractures, cracks, blow holes, laminations, pitting, etc., are not allowed. Rectification of any such flaw is permissible only with the approval of the purchaser or inspection agency Engineer.

14. a) All parts of the crane shall be sand blasted to SA 2 ½ cleaned of all loose mill scales, rust or foreign matter and then painted as specified. All parts inaccessible after assembly shall be painted before the assembly. Inner surfaces of box sections shall be painted before closing them.

b) All parts except motors, gears, thrusters, etc., shall be painted with a primer coat of

zinc rich epoxy as per IS and two finishing coats of approved color as described below.

c) Sand blasting: The entire surface of all the fabricated materials is to be sand blasted as per

second quality of BS 4232 or near white quality of Steel Structures Painting Council

(SSPC) standard or SA 2½ of SIS 055900. The surface shall be completely free from contamination by oil, grease, dirt or other mater except that tightly bonded residues

or mill scale rust shall be permissible subject to limit of not more than 5% of whole area.

Surface should be free from girt/sand just before application of primer paint. d) Painting: Immediately after sand blasting, one coat of zinc rich epoxy primer shall be

applied to a Dry Film Thickness (DFT) of 75 microns. An intermediate coat of 80 micron

(DFT) of polyurethane/epoxy painting has to be given. A final coat of polyurethane enamel paint of 40 microns DFT has to be given. 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.

All paint and primer shall be of standard quality and procured from approved manufacturers as prescribed in the list furnished. The contractor shall provide “ Elicometer” to the representative of the purchaser for measurements of thickness

of paint at random locations selected by him to confirm the required minimum DFT.

While painting the new structures, the existing floors and structure shall not be spoiled.

If there is any spillage of paint on the floors or members on the existing structure, the

contractor has to clean and provide the painting on the spoiled areas.

e) Interior of all gear box housings shall be sand blasted and painted with two coats of oil resisting enamel paint.

f) All machine pads, bearing surface on structures or housings shall be painted with white lead.

II B. STRUCTURAL DETAILS 01. GENERAL Crane structures shall be designed in accordance with the latest edition of I.S.807 taking the following additions / deviations as applicable into account: a) Unless otherwise specified, only bolted or welded joints shall be used. b) Not less than two turned fitted bolts or equivalent length of welding at each joint shall be

used for connections. c) Black bolts shall not be used in the main structures of the crane and high tensile steel bolts

shall not be used unless approved by the purchaser. All the bolts, nuts, washers etc., shall be heavy duty galvanized.

d) The calculated strength of riveted joint or joints made by friction grip bolts in structural

members shall be not less than calculated net strength of the member. e) Bolts used in shear shall be fitted into reamed holes. f) Where bolts pass through sections having tapered flanges taper pad shall be welded to the

tapered flange. Taper washers shall not be used. g) Transverse fillet welding on load carrying members shall be avoided. h) All but welds on structural members subject to tensile stress shall be x-rayed. i) Plates, bars, angles and where practicable, other rolled sections used in the load bearing

members of the structure shall be not less than 8 mm thick. Steel tubes, if sealed at the ends shall be not less than 4.9-mm (6 SG) thick and if unsealed, not less than 8 mm thick.

Minimum thickness of checkered plates for platforms shall be 6mm over plain for indoor cranes. Checkered plates shall not be considered for strength calculations of load carrying members.

j) The ratio of the effective length ‘l’ to the least radius of gyration ‘r’ for compression

members shall not exceed 120 for all main members i.e., for both the main and auxiliary girder members and top and bottom plan bracings and 180 for secondary members.

k) No splice joints allow for these cranes.

02. BRIDGE GIRDERS:

The bridge girders shall be of construction with double web plate girders. Girders shall be sufficiently strong and rigid to withstand the most severe combination of loads that may develop under different working conditions. The design of the bridge girder shall be in accordance with the latest edition of IS:807 taking following additions / deviations as applicable, into account.

a) For plate girders, span to depth ratio shall not exceed 18

b) For plate box girders, full length diaphragms shall be provided at bridge drive supports and line shaft bearing pedestals.

c) Equal to that at the end of bridge girder. Gusset plates shall be provided to assist the cranes remain square.

d) Squaring marks shall be provided on each girder to facilitate erection and squaring of the bridge.

03. END CARRIAGES:

End carriage shall be fabricated from rolled steel plates, welded together to form as box, a solid box, except for essential openings which shall be reinforced. If more than two wheels are required per bogie, articulated end carriages shall be used. Wherever possible, the end carriages shall be in two halves. Each half shall be rigidly connected to the respective bridge girder in the fabrication shop. End carriages shall be of ample strength to resist all stresses likely to be imposed on them under service conditions, including collision with other cranes or stops. The length of the end carriages shall be such that no other part of the crane is damaged in collision.

The wheel base shall not be less than 1/5th of span. On the end carriages with more than two wheels, the wheel base shall be taken as the distance between the centers of the outside wheels. The end carriages shall be fitted with substantial safety stops to prevent the crane from falling more than 25mm in the event of breakage of a track wheel, bogie, or axle. These safety stops shall not interfere with the removal of wheels. Suitable jacking pads at a height of 300mm from rail level shall be provided on each end carriage for jacking up the crane when changing track wheels. Jacking pads shall not interfere with the replacement of track wheels.

04. TROLLEY FRAME:

Trolley frame shall be produced in one piece unless there are transport limitations. In the case of splicing of the frame; the design shall be such that one unit of a mechanism mounted on one part of the trolley does not come over the other part. Connection between the two parts of the trolley shall be done by machined bolts. Drum bearings and supports for upper sheaves shall be located so as to equalize the load on the trolley wheels as nearly as possible.

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

capable of withstanding all stresses that will develop during the working of the crane and shall be arranged to afford maximum accessibility to mechanical and electrical parts place on it. It 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. Deviations shall be made only with specific approval of the purchaser.

The top of the trolley frame shall be plated all over except for openings required for the

ropes and flexible cables for bottom block etc., to pass. The openings in the trolley frame shall be such as to keep the ropes of cables at least 75 mm away from any part of the trolley frame or equipment to prevent damages for all positions of the bottom blocks. All the mechanical and electrical equipment shall be placed above trolley top plate as far as practicable. For any parts placed below the trolley top plate, access for maintenance, repair and replacement shall be provided. Handrails shall be provided on all the four sides of the trolley.

The trolley shall be fitted with substantial safety stops to prevent the trolley from falling more than 25 mm in the event of breakage of a track wheel, bogie or an axle. This safety stops shall not interfere with the removal of wheel. The trolley shall be provided with lifting pads for jacking up the trolley in case of wheel removal. The jacking pads shall be at a height of about 300mm from the rail level and shall not interfere with the removal of wheels.

05. TROLLEY RAIL:

Trolley track rails made of rail steel shall be clamped to the girders with double bolt clamping plates spaced not more than 900 mm apart with welded alignment blocks between every two clamps such that the distance of a clamp from any adjacent alignment block shall not be more than 450 mm. Rails shall be prevented from creeping in the longitudinal direction by rail stops, welded. Rails shall be made continuous by welding standard lengths. At splice joints, rails shall be welded at site and as such, edge preparation of the rails shall be done in the shop as per standard practice. For double web box girders, rails shall be fastened by clamps held by studs welded to cover plates, spacing of clamps and alignment blocks being as stated earlier.

06. REPAIR CAGES.

Repair cage shall be provided on the inside of the end carriage for attending to the Drag Chain system and trolleys. Repair cages shall also be provided at the corners of the crane, if required, to facilitate removal of long travel wheels. The repair cages shall be minimum 1000 mm wide and shall be such that two persons can work comfortably in the space provided. The floor of the repair cages shall be about 1500 mm below the L. T wheel centres except the one on which the Drag chain system & pendent cable trolleys are mounted, where it shall be suitably adjusted. The cages shall be of structural steel and shall be made substantially rigid by gusset plates and braces welded or bolted. Repair cages shall be provided with railings on all sides except for the repair cages on the down shop lead side, which shall be provided with easily removable type protection guards on three sides for safety reasons.

II C. MECHANICAL DETAILS 01. DESIGN OF MECHANISMS.

In the design of components on the basis of ultimate strength the value of stress factor used shall be the product of the basic factors and the duty factor for the appropriate mechanism class. The basic stress factor shall not be less than 5 and the duty factor, impact factor, basic stress factor, safety factor etc. shall be in accordance with provisions given in section 20 of IS 3177 – 1999 for group classification M5.

02. ROPE DRUMS:

Rope drums shall be fabricated or of cast steel. All fabricated rope drums shall be stress relieved. The length of the drum shall be sufficient to accommodate in one layer the length of rope requisite for the specified lift and in addition, not fewer than three dead turns at each anchored end and at least one spare groove at the other end. Each rope end shall be clamped with minimum two clamping wedges with at least two numbers of bolts on each clamping. Rope drum shall be designed as specified in section 8.4 of IS 3177 – 1999 in general.

03. STEEL WIRE ROPES

i) The ropes will be regular lay, right hand, as specified in IS: 2266 & IS 3973. .

ii). The wires shall be made of steel with tensile designation 1960 (minimum tensile strength 1960 MPa).

Size selections of wire ropes in general shall be as per section 8.3 of IS: 3177 – 1999 and as per IS 13870: Part 1: 1993 /ISO 4308-1: 1986 Cranes and Lifting Appliances - Selection of Wire Ropes - Part 1: General

iii). The factor of safety shall be 6.0, Core shall be IWRC. 04. ROPE SHEAVES:

All sheaves shall be of forged steel or cast steel. All sheaves shall be identical; however, exception may be made for equalizer sheave. The equalizer sheave / bar shall be mounted where feasible above the trolley floor and shall be easily accessible and removable from the floor of the trolley. Equalizer sheave / bar shall be arranged to turn and swivel in order to maintain proper alignment under all circumstances. 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. Equalizer sheave / bar shall be mounted on roller bearings and not on ball bearings. Design of sheaves in general shall be as per section 8.5 of IS:3177 – 1999.

05. RAIL WHEELS:

Rail wheel shall be double flanged with straight tread unless guide rollers on sides, to take up horizontal thrust, are provided. The wheels shall be capable of taking up misalignments in span as specified. Wheels shall be of forged steel. Minimum diameter of wheels for cross travel shall be 250 mm. minimum dia. of long travel wheels for class M5 cranes shall

be 315 mm. Minimum hardness of wheel tread shall be 300 BHN. General design of wheels shall be as per section 8.6 of IS:3177 – 1999.

06. BUFFERS:

Spring loaded case or any other better type buffers shall be fitted on the four corners of the crane and also on the four ends of the bridge girders (and not on the trolley frame) for soft dashing of crane and trolley respectively. 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. If the buffers are so located as to required removal when changing wheels or bogies, means shall be provided on the crane itself either by hinges or otherwise for handling the buffers. Buffers shall be designed to absorb the kinetic energy released at 50% of the full load rated travelling sped, the average rate of deceleration not exceeding 5.0m/sec2 at 50% of the rated travelling speed (freely oscillating loads suspended on the load suspension system shall not be taken into consideration) Refer sec. 8.11 of IS: 3177 – 1999.

07. DRIVES:

For class 2 duty cranes not less than 50% of the long travel wheels shall be positively driven unless agreed otherwise by the purchaser. The long travel shafts shall be supported on bearings at approximately 3 m Centre or less. Shaft couplings shall be as near as possible to the bearings. Shafts shall be easily accessible throughout their length and shall be designed as far as practicable inter-changeable lengths, the end and centre sections being as short as possible. Where applicable the driving pinions shall not interfere with the removal of wheels. Angular deflection of the line shaft at torque corresponding to 1.33 motor rated torque during acceleration shall not exceed 0.10 deg./m of shaft length. In case of L.T. drive located at the span Centre, half the above torque, i.e. 2/3 of motor torque shall be taken for each half of the shaft. The L.T. drive shaft minimum diameter shall be not less than 100mm. The offer will be rejected if the L.T. shaft minimum diameter is less than 100mm. All parts of the long travel drive shall preferably be located above the top platform. No part of cross travel drive shall be located below the trolley platform. Refer section 8.2 of IS: 3177 – 1999. Wheel mounted drives can be provided LT drive of cranes that are having spans more than 20meters.

08. GEARING: (Standard make gear boxes shall be used in EOT cranes for all drives)

Straight and helical spur gearing shall normally be used for all motions. Worm and bevel gears shall not be used without specific permission from purchaser. First and high-speed reductions shall be through helical gears. All first reduction pinions and also other pinions if feasible shall be integral with shafts. All gears shall be of hardened and tempered alloy or carbon steel with machine cut teeth. Gear teeth shell is preferably cut in metric module system. All gear teeth shall be ground smooth to give less noise while running.

09. GEAR BOXES: (Standard make gear boxes shall be used in EOT cranes for all drives):

All gears shall be completely covered or guarded by covers firmly attached to brackets. All gears shall be enclosed in oil tight casings except where not possible. All gear shafts

shall be supported on bearings mounted in gear box unless specifically agreed otherwise. In case of totally enclosed gear boxes splash or automatic lubrication system shall be used. The gearboxes shall be fabricated or of cast steel. Fabricated gearboxes shall be made of minimum 8 mm thick steel plate. All fabricated gearboxes shall be stress relieved. Covered shall be split horizontally at each shaft centre line and fastened and arranged so that the top half can be removed for inspection and repair without disturbing the bottom half. Directly above the mesh line of teeth, there shall be hand-holes with oil tight bolted covers. The gear box shall be provided with breather vents, oil level indicator, dipsticks and easily accessible drain plugs. If the sound level is more than the specified, they are to be replaced with better ones. This is very important for all the gearboxes and any gearbox making more noise is liable to be rejected. No oil leakage is allowed from gearboxes. Standard Gearboxes from reputed manufacturers shall be used in all drives of cranes.

10. BEARINGS:

Ball and roller antifriction bearings of FAG, SKF, TIMKEN make shall be used throughout the drives except where specified otherwise. Rated life of ball and roller bearings shall be not less than total life in working hours given under “01. Design of Mechanism”. Life of bearing shall be calculated in accordance with manufacturer’s recommendations. All bearings housings shall be made of cast or wrought steel bolted to a rigid portion of crane structure by at least 4 bolts except for intermediate line shaft bearing housings which may be bolted by at least 2 bolts. Housings shall be split on the shaft centre line to permit removal of the shafts. The underside of the base of each bearing pedestal shall be machined and shall bear upon a machined surface. Refer section 8.7 of IS – 3177 – 1999.

11. COUPLINGS: Motor shafts shall be connected to gear extension shafts through flexible shock absorbing couplings. For driving hoist drum, geared couplings shall be used between hoist rope drum and hoist gearbox out-put shafts. Geared couplings shall be used for connecting intermediate lengths of long travel and cross travel shafts. Geared or universal couplings shall be used between gearbox output shaft and intermediate shaft or end shaft. 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. Refer section 8.9 of IS: 3177 – 1999.

12. LIFTING HOOKS:

Standard single shank point hooks shall be used unless otherwise specified. These hooks shall confirm the latest edition of IS. Safety latch should be provided to the hook such that the rope does not slip out of the hook. Refer section 8.1 of IS: 3177 – 1999.

13. BRAKES:

Electro hydraulic thruster brakes shall be used for all drives in crane. Flame proof brakes shall be provided for all drives of flame proof cranes. Brake shall be mounted on the input pinion shaft of the gear train. The brake shoes shall be of hinged type. Brake levers shall be forged or fabricated or cast steel. Hinge pins shall be of hardened alloy steel and shall be lubricated. These hinge pins shall be provided with steel bushes at bearing point. Brake drums shall be forged or of cast steel. Drums shall be completely machined and dynamically balance. Width of the brake drum shall be 5 to10mm more than the width of the brake shoes. Hardness of brake drum shall be 38 – 43 Rc. No oil leakage is allowed from thruster brakes. Braking path shall be calculated as per is 3177.

i. Hoist mechanism shall be provided with two brakes. Each brake shall be designed for a minimum of 200% static moment considering that the full load can be held by one brake alone. This shall also apply to single drive with two brakes. ii. The brakes for long and cross travel motions shall be designed from the following consideration:

a) Braking against travelling shall be capable of arresting the motion within a distance in meters equal to 10% of the speed in m/min. When travelling at rated speed with rated load.

b) The retardation due to braking shall not exceed the values given in the table below to avoid skidding wheels.

Table –2

Retardation, according to percentage number of Working condition Driving wheels in ‘m/sec2 ‘

100% 50% 25%

Indoor (When = 0.1) 1.5 0.75 0.45 Refer section 8.12 of IS: 3177 – 1999. 14. BOLTS AND NUTS: All bolts, nuts, washers, etc. used in this crane shall be galvanized as per IS; 1367 part 13 Refer section 8.10 of IS: 3177 – 1999

II D. ELECTRICAL DETAILS

01. SCOPE OF SUPPLY

The scope of supply shall cover all items of electrical systems includes VFD panel consisting of VFD Drive system, switch gears, control transformer, DBR panel etc., motors, brakes, limit switches, power and control cables, encoder, socket outlets, lighting fittings with lamps, DSL, Cable drag chain system, Pendent, push button station and equipment earthing. All sundry erection material required for installation and connecting up of electrical equipment with cable laying and fixing accessories shall be included in the scope of supply by the tenderer.

02. HAZARDOUS OPERATING ENVIRONMENT:

The EOT cranes are intended to operate in Hazardous environment as per the hazardous area classification Zone 1 Gas group IIA/IIB, T4 as per IS5572. Hence all the electrical equipment, limit switches and controls offered shall be suitable to operate in the above environment as per relevant Indian standards (IS 5571, IS2148, IS 5780) and IEC standards (IEC 60079). The drive panel will be located in non-Hazardous area and hence, need not comply hazardous area requirements.

Motor lights, junction boxes shall be flame proof and pendent fuse button station & limit switches shall be Intrinsically safe system.

03. CLIMATIC CONDITONS:

The equipment offered shall be suitable for tropical and humid climate. For purpose of equipment selection and specially for derating the capacities of drive motors and power cables, the ambient temperature condition specified in salient features shall be taken as the basis. The design shall consider ambient temp of 500 C and saline atmosphere. The equipment on the crane shall be suitably protected against damage from radiant heat and shall be rendered proof against ingress of dust and vermin.

04. STANDARDS:

The equipment shall be selected, assembled and tested as per guide lines provided in the latest edition of Indian Standard Specification IS: 3177 - 1999 or class M5 duty cranes subject to any modification and requirements specified by the purchaser. Flame proof electrical fittings and controls in the cranes mentioned shall be selected, assembled and tested as per relevant Indian/ IEC standards like IS5571, IS2148, IS5780 and IEC 60079.

05. POWER SUPPLY CONDITIONS

The power, on the bay down-shop leads shall be available at 415 Volts, 3 phase, 4 wire, 50 HZ. The power and control equipment selected shall be suitable for operation on ± 10% variation in the voltage and ± 3% variation in supply frequency.

The following voltage shall be used in the cranes:

i) 415 volts, 3 phase, 50 HZ : For drive motors A.C (unearthed system) ii) 110V volts single phase, : Control circuit in VFD panel. 50 HZ, A.C ii) Intrinsically safe circuit : Pendent and limit switch interfacing.

06. CURRENT COLLECTION

a) CABLE DRAG CHAIN SYSTEM

Location of main switch is at VVVF Drive panel room at 1m height from the ground. Supply and routing of cable through cable drag chain system is included in the scope of supply. The power supply from VVVF Drive panel at adjacent room and from there it shall be brought to all motor brakes etc., Erected on EOT Crane Crab through suitable cable drag chain system. The power supply arrangement shall be provided through cable drag system of IGUS / LAPP make. The cables used in Drag chain system shall be of IGUS /LAPP make only suitable to Drag chain applications. The cable Drag chain system & cable Make shall be same. Party shall submit cable schedules & Drag chain selection criteria for approval by SDSC SHAR.

07. MOTORS

All crane motors shall be Flameproof (Ex-d, Temp classification T4) squirrel cage induction motors. Motors shall have S5 DUTY, 60% CDF, min of with 300 starts per hour. The motor shall be flameproof as per IS: 2148. The motor shall be inverter duty suitable for operation with VFD. The motors shall be provided with minimum 2 sets of thermistor embedded in the winding and interfaced with Drive through 2 Nos of winding temperature relay for tripping in case for Alarm & tripping when motor surface temperature exceeds 1350C. The motor shall address Voltage rise time, bearing currents, Insulation Strength etc., as applicable specific to operation by VFD. Motors shall have double side shaft to mount encoders. Encoder shall be flame proof / intrinsically safe and shall be of hallow shaft type

a) HORSE POWER

The service factors shall be taken for selection of motors for long and cross travel motions as per Annex-C of is 3177-1999. Motor selected are such that the maximum current drawn with full load should not exceed 80% of the full load rated current of the selected motor.

b) TORQUE The pull out torque of the motors at rated voltage and frequency shall not be less than

2.75 times the nominal torque.

c) CLASS OF INSULATION

All motors shall be class F or better insulated with temperature rise limited to class B insulation.

SWITCHING FREQUENCY AND DUTY CYCLE Motor rating shall take into account the operating frequency of 300starts/hour. Class of duty for all the motors shall be S5 as per IS 325. All motors shall be suitable for Operation with VFD (Inverter Duty)

08. CRANE CONTROL

Controls in FLP cranes shall be made suitable to operate in hazardous environment Zone1, Group IIA/IIB, T4. In order to control the speed during lowering, mechanical braking shall not be employed. On all motions, the circuit shall be so designed that brakes come into operation immediately in the event of tripping of main circuit breaker. Additionally, the control circuit shall be so designed that following functions are fulfilled.

Hoisting shall take place only when hoisting push button operated. Lowering shall take

place only when hoist lowering push button is operated. Both the push buttons should be interlocked such that only one direction operation is possible at a time. This type of control should be followed for all the motions of the crane.

09. PENDENT CONTROLLERS.

Non flame proof push button station with intrinsic safe barrier Isolation shall be used. The control ON push button shall be of lockable at OFF type (with key) so that power and control supply is cut off when the crane is not in use to prevent inadvertent operation. Selector switch C2 2 position shall be provided for lights ON/OFF. Indicating lamp for control ON shall be provided on the pendent. An emergency stop push button with mushroom Red knob latched type push button with 2 No & 2 Nc shall be provided to switch off Incoming MCCB/ A reset main contactor PB to be common for all drives provided to reset Drive fault. Push button for bell and two no’s of spare push buttons shall be provided. The drive fault indication lamp shall also be provided in pendent. The pendant station shall be suitably supported by means of a SS chain and it shall be ensured that no strain is caused to the pendant cable. A minimum of two spare cores shall be provided in the pendant cable. The pendant station shall move along the bridge girder on four wheeled cable trolleys with antifriction ball bearings running on a separate track. Each trolley shall be provided with buffers to avoid entanglement. Tension coming on the cable due to trolley movement shall be avoided by provided SS chain between trolleys.

The Push buttons and indication lamps in pendent to be interfaced with VFD panel through intrinsic safe isolators and solenoid drivers. The indication lamps make shall be Beka or any other make with approval and shall be intrinsically safe. All IS barriers shall be of P& F make only. In drive room itself DBR can be planned (by having panel A/C / DBR Room not required).

10. VFD Drive panel:

The drawings, Drive system, panel dimension etc., are to be approved by SDSC SHAR before fabrication. No add on blocks shall be used in power & control contactor and sufficient NO/NC shall be considered in the contactor itself or by providing auxiliary contactor.

All VFD Drives, power and control contactors, DBU, DBR, MPCB, MCCB etc., in Drive panel, shall be provided in adjacent service room where non flame proof equipments are permissible. The panels shall be of Rittal make or Siemens authorised panel builder/system house with approval of SDSC SHAR. In case of failure of VFD Drives operations shall be possible to carry out through Redundant VFD system with by changeover switch arrangement through control & power switch gear arrangement. Hazardous area chapter. The Under bridge lights, junction boxes etc., provided in bay shall be flame proof (Ex-d) ,150w LED Light Fittings of Baliga Make Complying requirements suitable for hazardous area classification zone 1, Gas Group IIA, IIB with Temp classification T4. Terminal strip shall be fixed inside the panel preferably in horizontal manner leaving enough space underneath the panel for termination of cables in a convenient manner. All equipment inside the panel shall have permanent identification labels in accordance with circuit diagram as also the power and control terminals. Suitable ferrules shall be provided inside the panels at the ends. The details are provided in Annexure-VIII.

11. CIRCUIT PROTECTIVE SWITCHGEAR

One triple pole MCCB Incomer , rated to carry at least combined full load currents of the two motions on the crane having largest power (KW) shall be provided.

12. LIMIT SWITCHES:

Limit switches shall be heavy duty type with protective enclosure of IP 55 as per IS 2147. limit switches shall be heavy-duty type and of shall be wired in the Intrinsic Safe circuit to operate in hazardous environment Zone 1, Gas group IIA/IIB as mentioned above.

All hoist motions shall be provided with limit switches to prevent the crane hook from over hoisting and over – lowering. Two limit switches shall be provided for proper back up protection. The first limit switch to act in the event of over hoisting and over lowering. This shall be screw type with self-resetting feature and be incorporated in the control circuit of the respective drive motor. The second one shall be of gravity operated hand resetting type switch

Connected in the trip circuit of the main incoming breaker. The second limit switch shall

act only to prevent over hoisting limit switch incorporated in the motor control circuit shall be made to act first but in case this limit switch fails to operate, the second limit switch connected in the main incoming circuit breaker’s control circuit shall operate and trip the breakers.

13. BRAKES:

All motions of the flame proof cranes shall be provided with Flame proof A.C Electro-

hydraulic thruster brakes to arrest the motion safely. This brake should be provided with brake release mechanism. The Brakes shall be protected with suitable MPCBs.

The torque capacity of brakes shall be 2.0 times the rated full torque of the selected motor for

hoist and for LT and CT the torque capacity of brakes shall be 1.5 times the rated full torque of the selected motor.

The brake logic shall be through VVVF Drives. There shall be Two brakes for Hoist one

will act as Main and other one will act as redundant brake. Each brake shall be operated with two numbers of contactors connected in series driven by two number of VFD output relays. This arrangement will prevent brake opening in case of drive relay/contactor welding and free fall of loads. All the Brakes shall be supplied with open/close limit switches and to be interlocked with control circuit.

14. LIGHTING:

Four numbers of under slung flame proof lamps of 250 W HPMV and with shock

absorbing & anti swing suspension shall be provided for uniform floor illumination. Screw cap type holders and lamps shall be used for crane lighting. These light fittings should be provided with wire mesh and glass to avoid free falling of lamp. Lighting transformers shall have 50% reserve capacity. Lighting control ON/OFF shall be possible from pendant station. The light fittings shall be so located that free access for maintenance is possible.

15. CABLING

All wiring for power control, lighting etc., shall be carried out with 1.1.K.V grade PVC flexible/Armored copper conductor cables as posible. All power cables shall be minimum 4sq.mm Cu and control cables minimum 2.5 sq. (cu). Cable cores shall be of stranded construction.

Cable selection and routing on the crane shall form part of the crane design. Selection of cable sizes shall take into account the following factors.

a) Ambient derating factors b) Group rating factor. c) Intermittent duty factor.

Suitable cable trays firmly secured to crane structure shall be provided with due regards to cable weight and vibration encountered. Cables shall be routed so that they do not constitute a safety hazard, pose any obstruction to free movement of personnel, and properly laid to present an orderly appearance. The cables shall have proper cable drag chain system of IGUS make cables & Drag chain except for pendent station.

16. IDENTIFICATION OF CIRCUITS, CABLES ETC.

Labels of permanent nature shall be provided on supports of all switches, fuses,

contactors, relays etc., to facilitate identification of circuits and replacement. All panels are to be properly marked for each motion. All power control cables, lighting and other cables are to be tagged at both ends as per cable number indicated in the supplier‘s drawing. All equipment terminals are also to be marked likewise.

17. EARTHING;

The Earth strip /Cable size shall be minimum 25 X 6 to be used for earthing purpose. The LT rail at both sides to be earthed. All electrical equipment mounted on crane including Mechanical structure to be earthed with double runs. Suitable Bridge Clamp provided on crane for tapping earth points. Along with pendent control cable an additional wire braided flexible copper strip of 12mm wide shall run as a special earth from the control panel up to the pendent station. SDSC will only provide ground riser at 1mtr height inside bay for grounding. Further connection from this riser to EOT system for earthing will be in bidder’s scope. Any specific grounding requirement other than the above power earth may be brought out in the offer.

ANNEXURE – VII B

General & Technical Specifications

Non Flame Proof EOT Cranes

I. General Specifications: 1 SCOPE OF WORK

Scope of work shall include design, detail engineering, manufacture, inspection, shop

testing, supply, erection, site testing & commissioning of EOT Crane required for Solid Propellant

Space Booster Plant of SDSC SHAR, ISRO, SRIHARIKOTA including importation of

equipment/ components (if any), in full & good condition as per the specifications, procedure,

completion schedule and the terms & conditions furnished in this document. The scope of work shall

also include procurement of all materials including components required for completion of the

work, coordinated planning for manufacture, testing, painting, inspection, packing, marking,

loading on Trucks/ Trailers, safe transportation to site, unloading and handling of the work fully

erected, tested, commissioned as per Technical Specifications.

a. The place “Sriharikota” is located 20 km east of Sullurupeta (nearest town) which is

80 km north of Chennai Tamil Nadu and 95km South of Nellore, District head quarter of SPSR Nellore District.

b. SDSC SHAR, Sriharikota is a prohibited place. Hence, no contractor, working personnel will be allowed to stay and they have to be accommodated in Sullurupeta by their own arrangements.

c. The Contractor may have to transport working personnel on day to day basis by his own arrangement. Location of the site is worked out to be 30 km from Sullurupeta. The contractor personnel have to undergo security checks by security force is CISF as per the prevailing guidelines.

d. All the working personnel shall comply with code of conduct during their stay inside the SDSC SHAR campus.

Arranging the third party inspection is in the scope of supplier for the entire scope of work as given above.

2 GENERAL CONDITIONS: 2.1 Tender shall be accompanied with general arrangement drawing showing to scale the

elevation, cross section and plan of the EOT crane which shall indicate the information viz., clearances, construction of bridge structure, hook approaches, lift, wheel base, wheel loads and wheel diameters, motor ratings, speeds, arrangement of all the drives and other equipment installed on the crane. Also the tender shall contain Annexure duly filled up to enable the purchaser to assess the important technical features of the equipment offered. Tenders may be rejected, if compliance with this clause is not ensured. The tenderer shall also clearly specify any request for deviation from technical specification on particular items. Generalized statements like crane shall be manufactured as per IS standard and our specification etc. are not adequate. The reference number of applicable, standards shall be clearly mentioned.

2.2 After receiving the order, the contractor shall submit design details, calculations and drawings (three copies each) as mentioned in annexure-V to the purchaser and third party inspection agency for review, comments and approval prior to commencement of fabrication. a) The general arrangement drawings containing all information as described in para 2.1.

In addition to this, the GA drawing shall clearly show the layout of electrical panels, DBR, etc. All the dimensions and clearances shall be clearly marked on the drawing.

b) Electrical schematic diagrams containing details of components such as make, type,

rating/range, settings etc., are to be marked on the schematic diagram. All contacts and coils of contact shall be numbered/ designated.

c) Detailed structural drawings for the bridge girders, end carriages, repair cages,

inspection platforms, trolley frame etc., with Bill of quantities and material specifications.

2.3.1 All the drawings and calculations required for the approval shall be submitted in stages

within 4 weeks of placement of order to the purchaser and third party inspection agency.

2.3.2 If the drawings and other particulars are returned by the purchaser, because they are

incomplete or faulty, the contractor shall make the necessary correction / modifications and resubmit the drawings and calculations within a reasonable time but in any case should not exceed two weeks from the date of receipt of purchase’s/third party inspection agencies comments.

2.3.3 Tendered shall give the break-up of weights of the cranes as mentioned below during

final design. a. Total weight of crane including electrical equipment. b. Total weight of trolley including electrical equipment. c. Weight of each bridge girder as assembled and ready for erection, with and without

mechanical and electrical components. d. Weight of each end carriage as assembled and ready for erection. e. Weight and name of individual heaviest mechanical components. f. Total weight of structural, mechanical and electrical components separately.

2.3.4 The granting of any approval by SDSC, SHAR shall not absolve the CONTRACTOR

of his responsibilities for the design or the correctness of drawings and specifications. Any such approval by SDSC, SHAR shall not constitute a waiver by SDSC, SHAR of any right.

2.3.5 The following information shall be supplied prior to commissioning of the crane:

a) Four copies of all drawings and data, which have been approved by the purchaser. b) Four copies of the following manuals/ drawings shall be submitted.

2.4 THIRD PARTY INSPECTION:

i. The supplier should engage Third Party Inspection Agency (INSPECTORATE) for carrying out design verification/stage inspection/ final inspection for supply items and for construction, erection and testing at supplier’s works and at SHAR site. Contractor shall extend all necessary help/ equipment/ tools/ measuring instruments as required for carrying out necessary tests/ inspection at works/ site to the representatives of SDSC, SHAR/ INSPECTORATE.

ii. SDSC, SHAR/INSPECTORATE shall have the right of inspection and supervision of

the manufacturing process adopted by the Contractor 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 Contractor will be advised to adopt the correct manufacturing process which will be binding on the Contractor. SDSC, SHAR’s decision regarding the quality of work and its acceptability shall be final and binding on the Contractor.

iii. The Supplier shall give mutually agreeable reasonable time in advance to SDSC,

SHAR/INSPECTORATE for inspection and testing of any equipment on its being ready specifying the period likely to be required for such inspection and testing.

Arrangements shall be made by the contractor for the inspection and testing of the crane during different stages of its manufacture starting from the raw materials till the

completion of the crane by the SDSC, SHAR and INSPECTORATE at the suppliers site as per the following schedule.

a) Design verification b) Raw material identification, components like gears, shafts, keys, keyways sub-

assemblies of drive mechanism mechanical and electrical. c) Motor shaft, gear box shaft, brake unit, etc., proper alignment. d) Proper adjustment of brake shoes for optimum braking. Hoisting motion twin brakes –

each should be adjusted independently to take the full load. e) Measurement of noise level in dBA. f) Paint thickness measurements at various stages like primer, intermediate and final

coats. g) Radiographic / ultrasonic inspections of the critical weld joints of the girders, ropes

drums, end carriages etc. h) Testing and inspection of crane at the works prior to the dispatch. The test shall include

full load, no load, overload, insulation test, speed test, deflection test, etc. The crane shall be tested in all respects in conformity with section 4 of IS 3177-1999 in the presence of the purchaser or his representative before dispatch. The manufacturer shall submit detailed list on the item/tests to inspection agency and shall provide the necessary testing facility for the inspecting engineers during the test.

i) The crane is to be erected, tested and commissioning as per the approved specification

code at our site at Sriharikota in addition to the tests at manufactures’ works. j) Necessary test loads will be identified by the department in existing buildings where

EOT crane is available. Supplier shall make arrangements for loading and transporting

these loads on trucks and trailers to building in which crane is being commissioned, and after completion of satisfactory load testing these loads shall be transported back to respective original location. Trucks and trailers will be provided by department for the transportation of test loads at site. But necessary manpower, tools and tackles shall be arranged by the supplier at his own cost.

2.5. The contractor shall ensure that the cranes shall be manufactured as per the tolerances specified below. a) Span over L.T wheel : ± 4mm upto 19.5 meters maximum b) Diagonal on wheels : ± 5mm maximum. c) Long travel wheel alignment : ± 1mm maximum d) Tilt of wheels or balancer : ± 1mm / 100mm maximum (horizontal & vertical) e) Trolley wheel guage : ± 2mm for gauge up to 2.5m} max ± 3mm for gauge over 2.5m}

f) Difference in height between trolley rails. (H) in relation to the trolley track gauge (S) shall be within the following tolerances. “S” (mm) “H” mm up to 2500 3 above 2500 5

g) Speeds at full rated load, voltage, and frequency shall be as follows: I) Travelling & traversing : +10% -5% of specified speed. II) Hoisting : +10% -5% of specified speed. III) Lowering : +20%-5% of specified speed.

2.6 The contractor shall ensure that only minimum amount of assembly at site is necessary for early commissioning of the crane after delivery. Site welding shall be avoided. The contractor before proceeding with design details shall satisfy him self about the site condition so as to avoid any difficulty in erection due to peculiarity of site condition.

2.7 The tenderer shall also quote separately for erection, transport and unloading at site by their

own men, material, tools and tackles. The crane shall be transported at contractors risk and cost. The purchaser will not pay for any insurance.

2.8 The crane shall be completely assembled including wiring and other fittings in the

contractor’s shop before load testing of the crane. The crane hoist and traverse shall be tested to its rated load and over load at the supplier’s workshop before dispatch to site for erection.

2.9 The crane after erection shall be tested as given below: -

a) No load test: After completion of erection, crane shall be tested with no load to check the

performance of crane speeds, end clearance, hook approaches, height of lift, limit switch operations, no load current of motors, contacts, relays, inter locks etc.,

b) Deflection test: The deflection of the bridge girders shall not exceed L/1000 of span with the fully

loaded trolley stationed at mid-span and the safe working load at rest. The measurement shall not be taken on the first application of load. The datum line for measuring the deflection should be obtained by placing the unloaded trolley on the extreme end of the crane span with smaller hook approach of the largest capacity hook.

c) Speed tests:

1) All the motions of the crane shall be tested with rated load and the rated speeds shall be attained within the tolerance limits indicated under clause 2.5(g).

2) All the motions of the crane shall be tested with 25% overload in which case the rated speeds may not be attained but the crane shall show itself capable of dealing with the over load without difficulty.

d) Brake Tests:

� The hoists brakes shall be capable of braking the movement under conditions (1) & (2) of speed tests, however the braking path with rated load shall not exceed value given in the table No.1 under brakes (clause 13 of section IV: Mechanical details).

� The long travel and cross travel brakes shall be capable of arresting the motion within a distance in meters equal to 10% of the speed in metres/min and the retardation due to braking shall not exceed the values as given in the Table No.2 under brakes (clause 13 of section IV: Mechanical details)

e) Insulation and other tests shall also be carried out.

2.10 Dimensions of all parts used on crane shall confirm to metric standards. 2.11 All the electrical equipment shall be of proven quality as regards to their performance. 2.12 Excise duty exemption will be availed by the purchaser for this crane. Hence the

quotation shall take this into account. 2.13 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. If the loads are not in acceptable limits of civil structure, supplier shall plan different arrangement.

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

contractor has to make his own arrangements for boarding, lodging, transportation of his men and materials. However, hostel accommodation may be provided by the purchaser on chargeable

basis, if available. 2.15 Free electricity and water will be provided by the purchaser for the erection, testing and

Commissioning of the crane at the site. 2.16 Initial filling of lubricants required for commissioning at site shall be provided by the

supplier. 2.17 Before starting the site work, the contractor has to insure all his personnel working at site

in Sriharikota against accidents.

II ) TECHNICAL SPECIFICATIONS :

II A. DESIGN STANDARDS & OTHER DETAILS:

01. The crane shall be designed in accordance with the latest editions of IS:3177-1999 for class M5 duty and any other standards referred to therein and subject to any modification and requirement specified herein after. 02. Safe access for maintenance and removal of all mechanical and electrical parts must be

ensured without any additional scaffolding. All parts requiring replacement or inspection or lubrication shall be easily accessible without the need for dismantling of other equipments or structures. All electrical cables shall be so laid that they are not liable to be damaged and can be easily inspected and maintained.

03. For welded construction such as that of bridge girders and carriages, trolley frames, rope drums, gearboxes etc., all steel plates shall conform to IS-2062 or its equivalent. 04. No cast iron parts shall be used on cranes except for electrical equipments. Similarly, no wood or other combustible material shall be used in any part of the crane.

05. Full length chequered plate platform shall be provided for both the bridge girders in order to have access to long travel drive, current collectors, trolley etc., The chequered plate platform shall cover the full width between main and auxiliary girders. Where the platforms are bracketed out from the bridge girders, the width of the chequered plate covering shall not be less than 750 mm. The walkway platforms both the top and bottom chord levels shall be so arranged that there is a minimum clearance of 2000mm between the top of the platform and the lowest overhead obstruction.

06. Foot walks shall be of sufficient width to give at least 750mm clear passage at all points, except between railing and bridge drive where this clearance may be reduced to not less than 400mm.

07. All opening in foot walk flooring for access to bottom chord platforms and inspecting

platforms, shall be provided with strong hinged covers. Minimum size of hatch openings shall be 600 X 600mm. Any other opening in foot walk or end carriage shall be provided with bolted removable plate covers.

08 Guards of an approved design, which will push forward or off the track any object placed

across it, such as a person’s foot or arm, shall be attached to each end of the end carriage. 09 All wheels, couplings, line shafts etc, shall be provided with covers opening on strong

hinges. These covers shall preferably be made of minimum 5mm thick plates. All heavy covers shall be provided with inspection windows.

10. a) All bolts except those with nylon nuts shall be provided with grip lock nuts or

spring washers.

b) For side alignment of motors strong adjustable screws with lock nuts shall be provided. c) Welded snugs hall be fitted against the feet of all pedestals, gear boxes, etc.,

except motors. Motors shall be provided with alignment screws for side alignment.

d) 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.

e) All bolts, studs, nuts, washers, etc., shall be heavy duty galvanized. All bolts

shall be designed assuring the material as mild steel. High strength bolts can be used only where they cannot be avoided. In case of eletro-galvanizing, suitable baking of galvanized bolts as per standards shall be carried out to drive out the Hydrogen in order to avoid hydrogen embrittlement.

11. a) Safety hand railings preferably of tubular construction shall be provided on

bridge foot walks, end carriages, ladders, staircases, trolley and in any other places where access has been provided. Railings shall not be less than 1000mm high with an intermediate member at a height of 500mm

.b) All edges or openings shall be provided with toe guards. Toe angles or bent plates wherever required shall be 100mm high minimum.

12. Defects in the material like fractures, cracks, blow holes, laminations, pitting, etc., are

not allowed. Rectification of any such flaw is permissible only with the approval of the purchaser or inspection agency Engineer.

13. a) All parts of the crane shall be sand blasted to SA 2 ½ cleaned of all loose mill

scales, rust or foreign matter and then painted as specified. All parts inaccessible after assembly shall be painted before the assembly. Inner surfaces of box sections shall be painted before closing them.

b) All parts except motors, gears, thrustors, etc., shall be painted with a primer coat of

zinc rich epoxy as per IS and two finishing coats of approved colour as described below.

14. Sand blasting:

The entire surface of all the fabricated materials is to be sand blasted as per second quality of BS 4232 or near white quality of Steel Structures Painting Council (SSPC) standard or SA 2½ of SIS 055900. The surface shall be completely free from contamination by oil, grease, dirt or other mater except that tightly bonded residues or

mill scale rust shall be permissible subject to limit of not more than 5% of whole area. Surface should be free from girt/sand just before application of primer paint.

15. Painting:

Immediately after sand blasting, one coat of zinc rich epoxy primer shall be applied to a Dry Film Thickness (DFT) of 75 microns. An intermediate coat of 80 micron (DFT) of polyurethane/epoxy painting has to be given. A final coat of polyurethane enamel paint of 40 microns DFT has to be given. 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.

All paint and primer shall be of standard quality and procured from approved manufacturers as prescribed in the list furnished. The contractor shall provide “ Elicometer” to the representative of the purchaser for measurements of thickness of paint at random locations selected by him to confirm the required minimum DFT. While painting the new structures, the existing floors and structure shall not be spoiled. If there is any spillage of paint on the floors or members on the existing structure, the contractor has to clean and provide the painting on the spoiled areas.

16. Interior of all gear box housings shall be sand blasted and painted with two coats of oil resisting enamel paint.

17. All machine pads, bearing surface on structures or housings shall be painted with white lead.

.

II B. STRUCTURAL DETAILS

01.GENERAL Crane structures shall be designed in accordance with the latest edition of I.S.807 taking the following additions / deviations as applicable into account: a) Unless otherwise specified, only bolted or welded joints shall be used. b) Not less than two turned fitted bolts or equivalent length of welding at each joint shall be used for connections.

c) Black bolts shall not be used in the main structures of the crane and high tensile steel bolts shall not be used unless approved by the purchaser. All the bolts, nuts, washers etc., shall be heavy duty galvanized.

d) The calculated strength of riveted joint or joints made by friction grip bolts in structural

members shall be not less than calculated net strength of the member.

e) Bolts used in shear shall be fitted into reamed holes.

f) Where bolts pass through sections having tapered flanges taper pad shall be welded to the tapered flange. Taper washers shall not be used.

g) Transverse fillet welding on load carrying members shall be avoided.

h) All but welds on structural members subject to tensile stress shall be x-rayed.

i) Plates, bars, angles and where practicable, other rolled sections used in the load bearing

members of the structure shall be not less than 8 mm thick. Steel tubes, if sealed at the ends shall be not less than 4.9-mm (6 SG) thick and if unsealed, not less than 8 mm thick.

Minimum thickness of checkered plates for platforms shall be 6mm over plain for indoor cranes. Checkered plates shall not be considered for strength calculations of load carrying members.

j) The ratio of the effective length ‘l’ to the least radius of gyration ‘r’ for compression

members shall not exceed 120 for all main members i.e., for both the main and auxiliary girder members and top and bottom plan bracings and 180 for secondary members.

k) No splice joints allow for these crane.

02. BRIDGE GIRDERS: The bridge girders shall be of construction with double web plate girders. Girders shall be sufficiently strong and rigid to withstand the most severe combination of loads that may develop under different working conditions. The design of the bridge girder shall be in accordance with the latest edition of IS:807 taking following additions / deviations as applicable, into account.

a) For plate girders, span to depth ratio shall not exceed 18 b) For plate box girders, full length diaphragms shall be provided at bridge drive supports and

line shaft bearing pedestals.

c) Equal to that at the end of bridge girder. Gusset plates shall be provided to assist the cranes remain square.

d) Squaring marks shall be provided on each girder to facilitate erection and squaring of the

bridge. 03 END CARRIAGES:

End carriage shall be fabricated from rolled steel plates, welded together to form as box, a solid box, except for essential openings which shall be reinforced. If more than two wheels are required per bogie, articulated end carriages shall be used. Wherever possible, the end carriages shall be in two halves. Each half shall be rigidly connected to the respective bridge girder in the fabrication shop. End carriages shall be of ample strength to resist all stresses likely to be imposed on them under service conditions, including collision with other cranes or stops. The length of the end carriages shall be such that no other part of the crane is damaged in collision.

The wheel base shall follow as per IS:807. On the end carriages with more than two wheels, the wheel base shall be taken as the distance between the centers of the outside wheels. The end carriages shall be fitted with substantial safety stops to prevent the crane from falling more than 25mm in the event of breakage of a track wheel, bogie, or axle. These safety stops shall not interfere with the removal of wheels. Suitable jacking pads at a height of 300mm from rail level shall be provided on each end carriage for jacking up the crane when changing track wheels. Jacking pads shall not interfere with the replacement of track wheels.

04 TROLLEY FRAME:

Trolley frame shall be produced in one piece unless there are transport limitations. In the case of splicing of the frame; the design shall be such that one unit of a mechanism mounted on one part of the trolley does not come over the other part. Connection between the two parts of the trolley shall be done by machined bolts.

Drum bearings and supports for upper sheaves shall be located so as to equalize the load on the trolley wheels as nearly as possible.

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

capable of withstanding all stresses that will develop during the working of the crane and shall be arranged to afford maximum accessibility to mechanical and electrical parts place on it. It 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. Deviations shall be made only with specific approval of the purchaser.

The top of the trolley frame shall be plated all over except for openings required for the

ropes and flexible cables for bottom block etc., to pass. The openings in the trolley frame shall be such as to keep the ropes of cables at least 75 mm away from any part of the trolley frame or equipment to prevent damages for all positions of the bottom blocks. All the mechanical and electrical equipment shall be placed above trolley top plate as far as practicable. For any parts placed below the trolley top plate, access for maintenance, repair and replacement shall be provided. Handrails shall be provided on all the four sides of the trolley.

The trolley shall be fitted with substantial safety stops to prevent the trolley from falling more than 25 mm in the event of breakage of a track wheel, bogie or an axle. This safety stops shall not interfere with the removal of wheel. The trolley shall be provided with lifting pads for jacking up the trolley in case of wheel removal. The jacking pads shall be at a height of about 300mm from the rail level and shall not interfere with the removal of wheels.

05 TROLLEY RAIL:

Trolley track rails made of rail steel shall be clamped to the girders with double bolt clamping plates spaced not more than 900 mm apart with welded alignment blocks between every two clamps such that the distance of a clamp from any adjacent alignment block shall not be more than 450 mm. Rails shall be prevented from creeping in the longitudinal direction by rail stops, welded. Rails shall be made continuous by welding standard lengths. At splice joints, rails shall be welded at site and as such, edge preparation of the rails shall be done in the shop as per standard practice. For double web box girders, rails shall be fastened by clamps held by studs welded to cover plates, spacing of clamps and alignment blocks being as stated earlier.

06 REPAIR CAGES.

Repair cage shall be provided on the inside of the end carriage for attending to the Drag Chain system and trolleys. Repair cages shall also be provided at the corners of the crane, if required, to facilitate removal of long travel wheels. The repair cages shall be minimum 1000 mm wide and shall be such that two persons can work comfortably in the space provided. The floor of the repair cages shall be about 1500 mm below the L. T wheel centers except the one on which the Drag chain system & pendent cable trolleys are mounted, where it shall be suitably adjusted.

The cages shall be of structural steel and shall be made substantially rigid by gusset plates and braces welded or bolted. Repair cages shall be provided with railings on all sides except for the repair cages on the down shop lead side, which shall be provided with easily removable type protection guards on three sides for safety reasons.

II C. MECHANICAL DETAILS 01 DESIGN OF MECHANISMS.

In the design of components on the basis of ultimate strength the value of stress factor used shall be the product of the basic factors and the duty factor for the appropriate mechanism class. The basic stress factor shall not be less than 5 and the duty factor, impact factor, basic stress factor, safety factor etc. shall be in accordance with provisions given in section 20 of IS 3177 – 1999 for group classification M5.

02. ROPE DRUMS:

Rope drums shall be fabricated or of cast steel. All fabricated rope drums shall be stress relieved. The length of the drum shall be sufficient to accommodate in one layer the length of rope requisite for the specified lift and in addition, not fewer than three dead turns at each anchored end and at least one spare groove at the other end. Each rope end shall be clamped with minimum two clamping wedges with at least two numbers of bolts on each clamping. Rope drum shall be designed as specified in section 8.4 of IS 3177 – 1999 in general.

03. STEEL WIRE ROPES

i) The ropes will be regular lay, right hand, as specified in IS: 2266 & IS 3973. . ii) The wires shall be made of steel with tensile designation 1960 (minimum tensile

strength 1960 MPa). Size selections of wire ropes in general shall be as per section 8.3 of IS: 3177 – 1999

and as per IS 13870: Part 1: 1993 /ISO 4308-1: 1986 Cranes and Lifting Appliances - Selection of Wire Ropes - Part 1: General

iii) The factor of safety shall be 6.0, Core shall be IWRC.

04. ROPE SHEAVES:

All sheaves shall be of forged steel or cast steel. All sheaves shall be identical; however, exception may be made for equalizer sheave. The equalizer sheave / bar shall be mounted where feasible above the trolley floor and shall be easily accessible and removable from the floor of the trolley. Equalizer sheave / bar shall be arranged to turn and swivel in order to maintain proper alignment under all circumstances. 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. Equalizer sheave / bar shall

be mounted on roller bearings and not on ball bearings. Design of sheaves in general shall be as per section 8.5 of IS:3177 – 1999.

05. RAIL WHEELS:

Rail wheel shall be double flanged with straight tread unless guide rollers on sides, to take up horizontal thrust, are provided. The wheels shall be capable of taking up misalignments in span as specified. Wheels shall be of forged steel. Minimum diameter of wheels for cross travel shall be 250 mm. minimum dia. of long travel wheels for class M5 cranes shall be 315 mm. Minimum hardness of wheel tread shall be 300 BHN. General design of wheels shall be as per section 8.6 of IS:3177 – 1999.

06 BUFFERS:

Rubber buffers shall be fitted on the four corners of the crane and also on the four ends of the bridge girders (and not on the trolley frame) for soft dashing of crane and trolley respectively. 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.

07 DRIVES:

For class 2 duty cranes not less than 50% of the long travel wheels shall be positively driven unless agreed otherwise by the purchaser. The long travel shafts shall be supported on bearings at approximately 3 m Centre or less. Shaft couplings shall be as near as possible to the bearings. Shafts shall be easily accessible throughout their length and shall be designed as far as practicable inter-changeable lengths, the end and centre sections being as short as possible. Where applicable the driving pinions shall not interfere with the removal of wheels. Angular deflection of the line shaft at torque corresponding to 1.33 motor rated torque during acceleration shall not exceed 0.10 deg./m of shaft length. In case of L.T. drive located at the span Centre, half the above torque, i.e. 2/3 of motor torque shall be taken for each half of the shaft. The L.T. drive shaft minimum diameter shall be not less than 100mm. The offer will be rejected if the L.T. shaft minimum diameter is less than 100mm. All parts of the long travel drive shall preferably be located above the top platform. No part of cross travel drive shall be located below the trolley platform. Refer section 8.2 of IS: 3177 – 1999. Wheel mounted drives can be provided LT drive of cranes that are having spans more than 20meters.

08 GEARING : (Standard make gear boxes shall be used in EOT cranes for all drives)

Straight and helical spur gearing shall normally be used for all motions. Worm and bevel gears shall not be used without specific permission from purchaser. First and high-speed reductions shall be through helical gears. All first reduction pinions and also other pinions if feasible shall be integral with shafts. All gears shall be of hardened and tempered alloy or carbon steel with machine cut teeth. Gear teeth shell is preferably cut in metric module system. All gear teeth shall be ground smooth to give less noise while running.

09 GEAR BOXES: (Standard make gear boxes shall be used in EOT cranes for all drives) All gears shall be completely covered or guarded by covers firmly attached to brackets. All gears shall be enclosed in oil tight casings except where not possible. All gear shafts shall be supported on bearings mounted in gear box unless specifically agreed otherwise. In case of totally enclosed gear boxes splash or automatic lubrication system shall be used. The gearboxes shall be fabricated or of cast steel. Fabricated gearboxes shall be made of minimum 8 mm thick steel plate. All fabricated gearboxes shall be stress relieved. Covered shall be split horizontally at each shaft centre line and fastened and arranged so that the top half can be removed for inspection and repair without disturbing the bottom half. Directly above the mesh line of teeth, there shall be hand-holes with oil tight bolted covers. The gear box shall be provided with breather vents, oil level indicator, dipsticks and easily accessible drain plugs. Radial clearance between the gear box inner surface and the outside diameter of the gears shall be at least 1¼ times the depth of the largest gear tooth inside the gear box or 20 mm whichever is higher. The physical clearance between the pinions shall be at least 20mm. No oil leakage is allowed from gearboxes. Standard gearboxes from reputed manufacturers shall be used in all drives of cranes.

10. BEARINGS:

Ball and roller antifriction bearings of FAG, SKF, TIMEN make shall be used throughout the drives except where specified otherwise. Rated life of ball and roller bearings shall be not less than total life in working hours given under “01. Design of Mechanism”. Life of bearing shall be calculated in accordance with manufacturer’s recommendations. All bearings housings shall be made of cast or wrought steel bolted to a rigid portion of crane structure by at least 4 bolts except for intermediate line shaft bearing housings which may be bolted by at least 2 bolts. Housings shall be split on the shaft centre line to permit removal of the shafts. The underside of the base of each bearing pedestal shall be machined and shall bear upon a machined surface. Refer section 8.7 of IS – 3177 – 1999.

11. COUPLINGS: As far as possible gear boxes directly mounted with motors (Geared motors) shall be used for all drive motions of cranes. Motor shafts shall be connected to gear extension shafts through flexible shock absorbing couplings. For driving hoist drum, geared couplings shall be used between hoist rope drum and hoist gearbox out-put shafts. Geared couplings shall be used for connecting intermediate lengths of long travel and cross travel shafts. Geared or universal couplings shall be used between gearbox output shaft and intermediate shaft or end shaft. 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. Refer section 8.9 of IS: 3177 – 1999.

12. LIFTING HOOKS:

Standard single shank point hooks shall be used unless otherwise specified. These hooks shall confirm the latest edition of IS:3815/15560 or to the relevant Indian standards

specification. Safety latch should be provided to the hook such that the rope does not slip out of the hook. Refer section 8.1 of IS: 3177 – 1999.

13. BRAKES:

Electro hydraulic thruster brakes shall be used for all drives in crane. Brakes shall be provided for all drives of cranes. Brake shall be mounted on the input pinion shaft of the gear train. The brake shoes shall be of hinged type. Brake levers shall be forged or fabricated or cast steel. Hinge pins shall be of hardened alloy steel and shall be lubricated. These hinge pins shall be provided with steel bushes at bearing point. Brake drums shall be forged or of cast steel. Drums shall be completely machined and dynamically balance. Width of the brake drum shall be 5 to10mm more than the width of the brake shoes. Hardness of brake drum shall be 38 – 43 Rc. No oil leakage is allowed from thruster brakes. Braking path shall be calculated as per is 3177.

i. Hoist mechanism shall be provided with two brakes. Each brake shall be designed for a minimum of 200% static moment considering that the full load can be held by one brake alone. This shall also apply to single drive with two brakes. ii. The brakes for long and cross travel motions shall be designed from the following consideration:

a) Braking against travelling shall be capable of arresting the motion within a distance in meters

equal to 10% of the speed in m/min. When travelling at rated speed with rated load.

b) The retardation due to braking shall not exceed the values given in the table below to avoid

skidding wheels. Table –2

Retardation, according to percentage number of

Working condition Driving wheels in ‘m/sec2 ‘

100% 50% 25%

Indoor (When = 0.1) 1.5 0.75 0.45 Refer section 8.12 of IS: 3177 – 1999. 14. BOLTS AND NUTS: All bolts, nuts, washers, etc. used in this crane shall be galvanized as per IS; 1367 part 13 Refer section 8.10 of IS: 3177 – 1999

II D. ELECTRICAL DETAILS

01. SCOPE OF SUPPLY

The scope of supply shall cover all items of electrical systems commencing from main cable. The crane electric includes VFD panel consisting of VFD Drive system, switch gears, control transformer, DBR panel etc., motors, brakes, limit switches, power and control cables, encoder, socket outlets, lighting fittings with lamps, DSL, Cable drag chain system, Pendent, push button station and equipment earthing. All sundry erection material required for installation and connecting up of electrical equipment with cable laying and fixing accessories shall be included in the scope of supply by the tenderer.

02. CLIMATIC CONDITONS:

The equipment offered shall be suitable for tropical and humid climate. For purpose of equipment selection and specially for derating the capacities of drive motors and power cables, the ambient temperature condition specified in salient features shall be taken as the basis. The design shall consider ambient temp of 500 C and saline atmosphere. The equipment on the crane shall be suitably protected against damage from radiant heat and shall be rendered proof against ingress of dust and vermin.

03. STANDARDS:

The equipment shall be selected, assembled and tested as per guide lines provided in the latest edition of Indian Standard Specification IS: 3177 - 1999 or class M5 duty cranes subject to any modification and requirements specified by the purchaser.

04. POWER SUPPLY CONDITIONS

The power, on the bay down-shop leads shall be available at 415 Volts, 3 phase, 4 wire, 50 HZ. The power and control equipment selected shall be suitable for operation on ± 10% variation in the voltage and ± 3% variation in supply frequency.

The following voltage shall be used in the cranes: i) 415 volts, 3 phase, 50 HZ : For drive motors A.C (unearthed system) ii) 110V volts single phase, : Control circuit in VFD panel. 50 HZ, A.C

05. CURRENT COLLECTION a). CABLE DRAG CHAIN SYSTEM

Location of main switch is at VVVF Drive panel room at 1m height from the ground. Supply and routing of cable through cable drag chain system is included in the scope of supply. The

power supply from VVVF Drive panel at adjacent room and from there it shall be brought to all motor brakes etc., Erected on EOT Crane Crab through suitable cable drag chain system. The power supply arrangement shall be provided through cable drag system of IGUS / LAPP make. The cables used in Drag chain system shall be of IGUS /LAPP make only suitable to drag chain applications. The cable Drag chain system & cable Make shall be same .party shall submit cable schedules & Drag chain selection criteria for approval by SDSC SHAR.

06. MOTORS

All crane motors shall be non-flameproof squirrel cage induction motors. Motors shall have S5 DUTY, 60% CDF, min of with 300 starts per hour. The motor shall be non-flameproof. The motor shall be inverter duty suitable for operation with VFD. The motors shall be provided with thermistor embedded in the winding and interfaced with Drive for tripping in case surface temperature exceeds designed safe limit of motor. The motor shall address Voltage rise time, bearing currents, Insulation Strength etc., as applicable specific to operation by VFD. Encoder shall be of hallow shaft type.

a) HORSE POWER

The service factors shall be taken for selection of motors for long and cross travel motions as per Annex-C of is 3177-1999. Motor selected are such that the maximum current drawn with full load should not exceed 80% of the full load rated current of the selected motor. Motors shall have 120% of torque rating over the calculated torque requirement.

b) TORQUE The pull out torque of the motors at rated voltage and frequency shall not be less than

2.75 times the nominal torque.

07. CRANE CONTROL

On all motions, the circuit shall be so designed that brakes come into operation immediately in the event of tripping of main circuit breaker. Additionally, the control circuit shall be so designed that following functions are fulfilled.

Hoisting shall take place only when hoisting push button is pressed in position up to rated

load, lowering shall take place only when hoist lowering push button is pressed in position. Both the push buttons should be interlocked such that only one direction

operation is possible at a time. This type of control should be followed for all the motions of the crane.

08. PENDENT CONTROLLERS. Normal push button station shall be provided with OFF push button shall be of lockable type (with key) so that power and control supply is cut off when the crane is not in use to prevent inadvertent operation. Push button shall be provided for lights. Indicating lamps for power and control ON, emergency switch shall also be provided on the pendant to cutoff control power supply. The pendant station shall be suitably supported by means of a SS chain and it shall be ensured that no strain is caused to the pendant cable. A minimum of two spare cores shall be provided in the pendant cable. The pendant station shall move along the bridge girder on four wheeled cable trolleys with antifriction ball bearings running on a separate track. Each trolley shall be provided with buffers to avoid entanglement. Tension coming on the cable due to trolley movement shall be avoided by provided SS chain between trolleys.

09.VFD Drive panel:

All VFD Drives, power and control contactors, DBU, DBR, MPCB, MCCB etc., in Drive panel, shall be provided in adjacent service room. The panels shall be of Rittal make or Siemens authorized panel builder/system house with approval of SDSC SHAR. In case of failure of VFD Drives operations shall be possible to carry out through Redundant VFD system with by changeover switch arrangement through control & power switch gear arrangement.

Terminal strip shall be fixed inside the panel preferably in horizontal manner leaving

enough space underneath the panel for termination of cables in a convenient manner.

All equipment inside the panel shall have permanent identification labels in accordance with circuit diagram as also the power and control terminals. Suitable ferrules shall be provided inside the panels at the ends. The details are provided in Annexure-VIII.

10. LIMIT SWITCHES: All hoist motions shall be provided with limit switches to prevent the crane hook from

over hoisting and over – lowering. Two limit switches shall be provided for proper back up protection. The first limit switch to act in the event of over hoisting and over lowering. This shall be screw type with self-resetting feature and be incorporated in the control circuit of the respective drive motor. The second one shall be of gravity operated hand resetting type switch connected in the trip circuit of the main incoming current breaker. The second limit switch shall act only to prevent over hoisting limit switch incorporated in the motor control circuit shall be made to act first but in case this limit switch fails to operate, the second limit switch connected in the main incoming circuit breaker’s control circuit shall operate and trip the breakers.

11. BRAKES:

All motions of the cranes shall be provided with non-Flame proof A.C Electro-hydraulic thruster brakes to arrest the motion safely. This brake should be provided with brake release mechanism. The Brakes shall be protected with suitable MPCBs. The torque capacity of brakes shall be 2.0 times the rated full torque of the selected motor

for hoist. The torque capacity of brakes for LT, CT shall be 1.5 times the rated full torque of the selected motor..

The brake logic shall be through VVVF Drives. There shall be Two brakes for Hoist one will act as Main and other one will act as redundant brake. Each brake shall operate two no’s of contactors connected in series driven by two number of VFD output relays. This arrangement will prevent brake opening in case of drive relay/contactor welding.

LIGHTING: Four numbers of under slung Non flame proof lamps of 250 W HPMV and with shock

absorbing & anti swing suspension shall be provided for uniform floor illumination. Screw cap type holders and lamps shall be used for crane lighting. These light fittings should be provided with wire mesh and glass to avoid free falling of lamp. Lighting transformers shall have 50% reserve capacity. Lighting control ON/OFF shall be possible from pendant station. The light fittings shall be so located that free access for maintenance is possible.

12. CABLING:

All wiring for power control, lighting etc., shall be carried out with 1.1.K.V grade PVC flexible armored copper conductor cables. All power cables shall be minimum 4sq.mm Cu and control cables minimum 2.5 sq. (cu). Cable cores shall be of stranded construction.

Cable selection and routing on the crane shall form part of the crane design. Selection of cable sizes shall take into account the following factors.

a) Ambient derating factors b) Group rating factor. c) Intermittent duty factor.

Suitable cable trays firmly secured to crane structure shall be provided with due regards

to cable weight and vibration encountered. Cables shall be routed so that they do not constitute a safety hazard, pose any obstruction to free movement of personnel, and properly laid to present an orderly appearance.

13. IDENTIFICATION OF CIRCUITS, CABLES ETC.

Labels of permanent nature shall be provided on supports of all switches, fuses, contactors, relays etc., to facilitate identification of circuits and replacement. All panels, are to be properly marked for each motion. All power control cables, lighting and other cables are to be tagged at both ends as per cable number indicated in the supplier ‘s drawing. All equipment terminals are also to be marked likewise.

14. EARTHING: The Earth strip /Cable size shall be minimum 25 X 6 to use for earthing purpose. The

LT Rail at both sides to be earthed. All electrical equipment mounted on crane including Mechanical structure to be earthed with double runs. Suitable Bridge Clamp provided on crane for tapping earth points. Along with pendent control cable an additional wire braided flexible copper strip of 12mm wide shall run as a special earth from the control panel up to the pendent station. SDSC will only provide ground riser at 1mtr height inside bay for grounding. Further connection from this riser to EOT system for earthing will be in bidder’s scope. Any specific grounding requirement other than the above power earth may be brought out in the offer.

ANNEXURE - VIII

VVVF DRIVES FOR ALL EOT CRANES

Equivalent A1 The Vendor has to furnish VVVF Drive configuration before procurement for approval from

the Department

Redundant Drive arrangement:

There shall be Redundant Drive arrangement for each Hoist/CT/LT movements.

The changeover main to Redundant Drive system through manual changeover switch with

necessary control & Power circuit inter locking to ensure only one drive system at a time

feeding each motion.

Drive Programming Unit :

A portable programming unit consisting necessary communication port with suitable

cable for communicating with VFDs shall be supplied. The drive software shall be preloaded

and Drive parameters shall be loaded into programming unit. The programming unit should be

preloaded with licensed windows software with intel i7 or higher processor. RAM minimum

4GB and memory 500 GB or more with suitable communication interface to communicate with

drive. Any other model with Department approval is allowed.

The drive parameters shall be set properly for allowable brake path by authorized

siemens service engineer having good experience in drives related to EOT cranes. The supplier

shall furnish total parameter list in CD. Hard copy of programming parameters shall also be

supplied.

VVVF DRIVE SPECIFICATION Make and Model: M/s SIEMENS: S120 M/S ABB: ACS880

1 Input Power Supply 415 V AC +/- 10%, 3 Ph, 50 HZ +/-3%

2 Drive Rating The continuous current rating of the VFD drive shall be 150% of the motor rated current. The power rating of VVVF drive shall be one step higher than power rating of motor.

3 Basic Design Particulars

Closed loop encoder feedback for Hoist. CT & LT without encoder feed back.

4 Over Load Capacity 150% of the rated current for 1min.

5 Speed Requirement

a) The hoisting and travel drives shall be provided with VVVFD for varying the speed to creep speed in inching mode through push button as Digital input to Drive control unit. b) There will be two levels of speed requirement (Main speed and creep speed) for each movement in inch mode by independent push button inputs. Each Hoisting/travel Movement will be provided with One set of push buttons for Main speed and one more set for creep speed. The speed control Logic to be executed with four digital inputs.

6 Ambient Temperature

The ambient temperature shall be minimum 500C.

7 Crane control

1. Motor and Brake Torque Proving: 1.1 Precise coordination between motor and brake to extends brake life and lower maintenance costs. 1.2 The drive shall completely control motor torque, a brake shall be required only for holding and emergency stopping in case of power outages or faults. 2. Dual Upper and Lower Limit Switch Inputs: 2.1 To accommodate limit-switch inputs on both the upper and lower travel of the hoist. Operation of the rotary limit switch in either direction shall stop the hook motion; operation of the counter weight limit switch will be considered as control of entire power supply.

8 System I/O

1.Digital inputs. 2.Digital outputs. 3.Relay O/P (programmable)

4.I/O are required as per logic requirement.

20% additional DI/DOs for future.

9

Panel for Drive

A) Sheet steel used for fabrication of metal cabinet for drive panel shall be of cold rolled type and of thickness not less than 2 mm. Non - load bearing side may be of 1.6 mm thick sheet. Base frame shall be ISMC 100 x 50 with Matt black B) The cabinet shall be Indoor,floor-mounting type and shall be provided with lockable - hinged door at front with handle. Hinges should be of stainless steel or alloy steel. C) Durable gasket shall be provided for all doors and covers and for all partitions between adjacent units. The gasket shall be of sponge rubber synthetic rubber and shall be adequately secured. Barrier shall be provided/between power equipment and control equipment. D) Internal control & power wiring shall be routed separately to have better noise immunity. E) The control and power terminals shall be such that each and individual terminal shall be accessible for maintenance without effecting the wiring at any other terminal.

F) Power &Control Supply: 415 v +/- 10%, 3Ph, 5 Hz +/-3% Fault Level 50KA for 1 sec, Control supply, 110V AC, 1Ph. G) Insulation level: With 1000V Megger. H) Painting : Powder Coating after seven tank process Paint shade - RAL 7032/7035 I) Control & Signal Wiring: Minimum 2.5 Sq.mm with copper Conductor for control cable and Maximum 0.5 Sq.mm for signal cable J) Power Wiring: Minimum 4.0 Sq.mm with copper conductor K) Main Plate Name Plate & Component label: Acylic Engrave with Black Back ground and White Lettering. L) Shrouding: Acylic Shrouded are provided for all live supply. M) Terminal Clearance: Terminals should be provided at min 250mm distance from bottom of panels. N) Component Clearance: Bottom row of components should be at min 350mm distance from bottom of panels. O) Cooling: To be designed as per std. P) Lifting arrangement: suitable lifting arrangement shall be provided for each panel on all four sides Q) Space heater and thermostat to be provided to avoid moisture condensation.

10 Choke

1. AC input choke of suitable rating shall be provided to limit THD 2. Suitable choke (with mH rating, 3 phase) at input side shall be provided and shall have following minimum requirement. i) Nominal operating voltage = Rated voltage of the drive. ii) Maximum current Imax= 2x I rated for 1 minute. iii) Grade of core material CRGO. iv) Temperature rise at I rated=95 deg C. v)Insulation class H Vi) Insulation resistance at 1100 V dc, between winding to core more than 100 M Ohms. Output side chokes to protect motor from dv/dt and voltage peaks.

11 Operating Panel

Advanced operating panel (AOP) Shall be mounted on the front door of the cubical. The same unit shall be used for programming, fault messaging and running status. Each panel for Hoist, CT, LT shall be provided. (03 No’s)

12 Dynamic Braking

Suitable rated Dynamic Braking unit need to be provided for individual drives.

13 Dynamic braking Resistors

1. Necessary calculations to be submitted before choosing of DBR rating. Full height lift, speed and rated load shall be considered in arriving DBR sizing. 2. Dynamic Braking Resistors shall be adequately protected to prevent contact with live parts. 3. Dynamic braking Resistors shall be mounted in pressed sheet steel and plates with drip proof and louvered side covered in separate units. All resistors shall be located on alongside and adjacent to control cabinet with provision of at least 100 mm clear space at front and rear of each panel. 4. Dynamic braking connecting resistor temperature of any exposed portion of the resistor enclosure shall not exceed the limits set by standards. 5. There shall be thermistor protection to trip DBR from drive for excessive temperature rise. 5. The braking resistor shall be thermally capable to absorb the re generative energy during successive drive cycles of the application. Tolerance in breaking resistor is +/- 10%. For cross traverse and long travel motions, the braking resistor shall be capable of absorbing the regenerative energy during deceleration of the motion also taking into account the possibility of a swinging load. 7. The braking resistor of a hoisting drive shall be selected considering the possible lowering height of the load being lowered at the maximum speed. 8. The sizing of the braking resistor shall take into consideration the regenerative energy due to overhauling load and the lowering time for full height of lift at full load. The peak/short time/continuous ratings shall be indicated. 9. Hoist DBR shall be sized for 150% of full load torque and shall not be less than the torque limit setting of VFD in Hoisting direction.

14 Compliance

1. VFD shall comply IEC-61800 standards towards VFD functional Safety and Electromagnetic compatibility.

15 Redundancy features

Each Hoist/ CT/LT shall be provided with Main & Redundant VVVF drives with changeover arrangements by manually actuating power & control switches. Necessary interlocking shall be provided such that only one Drive shall be in circuit.

16 Special feature All power components other than VFDs such as contactor’s etc shall be rated 150% of the nominal rating of the system.

17 Brake contactor Two brake contactors/brake in series shall be incorporated

18 Emergency stop Independent contactor shall be activated on the operation of emergency stop

19 Brake relay There shall be two independent drive relay to be assigned for operating two brake contactors connected in series.

QAP INSPECTION PLAN FOR EOT CRANES ANNEXUXE-IX

Legend 1 Inspection Agency 2 Vendor (Suppliers) Signature Date Place 3 Sub Vendor / Supplier Designation Page 1 of 11

# 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

Witn

esse

d

Ve

rifie

d

A B C D E F G H I J K 1 BRIDGE

GIRDER, END CARRIAGE, CRAB, FRAME ETC.

1.1 Materials - Plates

Chemical / Physical Major T.C. Correlation if not available then check test

One per heat Component drawing/ Specs./ IS 2062

Component drawing / Specs./ IS 2062

Material TC or Supplier's Test Report 3 2 1

For plate of thickness>=25mm,UT Red

Reports / TC review.

Lamination /Internal Major UT 100% ASTM A-435 ASTM A-435 IR 2 - 1

1.2 Welding Welding procedure & Welders qualification.

Critical Test piece visual & physical test.

One for each position

ASME Sec.IX ASME Sec.IX PQR format 2 1 1

1.2.1 Load Bearing Butt welds

a) Welding quality & Surface defects

Critical D.P.Test 100% IS:3658 IS:3658 Supplier's IR 2 - 1

Use weld gauges

b) Sub surface defects

Critical Radiography As per component drawing.

ASME Sec.VIII Div I

ASME Sec.VIII Div I

Supplier's IR 2 1 -

Review of radiography films by I.A.

1.2.2 Other than load Bearing Butt welds & fillet welds

Surface defects & Size Major Visual & DPT 100% Visual check DP test 10% random

2 - 1

Use weld gauges





Category Type /

Method of check

Extent of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

Per

form

ed

Witn

esse

d

Ver

ifie

d

A B C D E F G H I J K 1.2.3

Final Welding Inspection

Visual Inspection Major Inspection of Welding quality

100% Visual Visual Supplier's IR 2 1 -

Visual final stage.

1.2.4 Bridge Girder(inside) & End Carriage inspection

Visual, Welding Measurement

Major Visual & welding quality

Visual 100% DPT-random of 10%

Component drawing

Component drawing

Supplier's IR

2 1 -

1.2.5 Final Inspection of fabricated components

Dimensional conformity

Major Measurement 100% Component drawing

Component drawing

Supplier's IR 2 - 1

Review of reports at final stage

2 OTHER FABRICATED COMPONENTS

2.1 MH, LT & CT Gear box, Housings

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

Supplier's IR 2 - 1

SR chart will be reviewed by I.A.

Surface defects & dimensional check

Major Visual/DP Test/ Measurement

DPT 10% random & 100% visual

IS:3658/Component drawing

IS:3658/Component drawing

Supplier's IR 2 - 1

2.2 ROPE DRUM Welding Joint quality & Weldment defects

Critical Visual/DP Test/RT/ Measurement

100% Component drawing

ASME Sec.VIII Div I

Supplier's IR 3/2

2` 1 Examination of RT films by I.A.

ROPE DRUM

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

Supplier's IR 3/2

2 1





Category Type /

Method of check

Extent of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

Per

form

ed

Witn

esse

d

Ver

ifie

d

A B C D E F G H I J K 2.2.1 RT of rope drum

joints Sub surface defect Critical Radiography As per

component drawing

ASME Sec.VIII Div I

ASME Sec.VIII Div I

Supplier's IR/Vendor TC 2 - 1

Examination of RT films by I.A. For seamless pipes no RT.

2.3 a) Platform b) LT Frame c) Hand Rails

Dimensional Conformity

Minor Measurement Critical dimensions 100% others at random

Component drawing

Component drawing

Supplier's IR

2 1

3 MECHANICAL COMPONENTS

3.1 MH, CT & LT Gear box Gears , Pinions and axles

Mfr's TC with chemical composition & physical properties Dimensional conformity Checks & Inspection of Key way milling

Major Correlation with TC

100% Component drawing/ Specification IS:1570 / BS 970

Component drawing/ Specification IS:1570 / BS 970

Mfr's TC/ Supplier's IR

2 - 1

All the keys &keyways shall be checked by TPIA before assembly. Reports shall be furnished with tolerances & dimensions

3.1.1 LT & CT Shafts Straightness & Dimensional conformity Checks & Inspection of Key way milling

Major Correlation with TC

100% Component drawing/ Specification IS:1570 / BS 970

Component drawing/ Specification IS:1570 / BS 970

Mfr's TC/ Supplier's IR

2 1 1

All the keys &keyways shall be checked by TPIA before assembly. Reports shall be furnished with

tolerances & dimensions 3.2 Machined

components for MH, CT &LT Gear box

Hardness Dimensional conformity.


IS:2048

Component drawing

Supplier's IR

2 1





Category Type /

Method of check

Extent of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

Per

form

ed

Witn

esse

d

Ver

ifie

d

A B C D E F G H I J K 3.2.1 Gear box Dimensional

conformity/ Inspection of machine surface of gearbox base.


IS:2048

Component Drawing.

Supplier's IR

2 1

3.3

Gear box assembly (no load run test & load test)

Hardness of gear teeth and grinding of Contact surfaces Backlash,

Number of bearings. Oil seals, key way and keys.

Noise level & Bearing temperature.

Major Measurement & no load running

100% Component drawing / Specification

Component drawing / Specification Noise level of gear box < 80db

Supplier's IR

2 1 -

Review of reports/ Load Test witnessed by I.A.

3.4 Pulleys, Couplings, Buffers, Plummer blocks & other components

a) Material (Cast Steel and Steel)

Chemical & Physical as applicable

Major Correlation with TC / Check test


Component drawing / Specification Noise level of gear box < 80db

Mfr's TC

3 - 1,2

Review of Test certificates of all bought out components. by I.A. and issue Compliance certificate

b) Dimensional Inspection

Visual Inspection / Dimensional Inspection

Major Visual Inspection / Measurement

100% Component drawing

Component drawing

Supplier's IR 3 - 1,2

3.5 LT & CT Wheel





Category Type /

Method of check

Extent of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

Per

form

ed

Witn

esse

d

Ver

ifie

d

A B C D E F G H I J K

a) Matl. Forged

Mfr's TC with chemical composition & Tensile strength

Major TC correlation if not available then check test for chemical

one per heat Component drawing / Spec. IS:1578 /BS 970

Component drawing / Spec. IS:1578 / BS 970

Mfr's TC / Supplier's Report 3/

2 1

UT Major UT checking 100% ASTM A-388 ASM A-388 Supplier's IR 2 - 1

Reports/TC will review by I.A.

b) Machined



Component drawing

Supplier's IR

2 - 1

c)

Material

Hardness Major Measurement 100% Component drawing

Component drawing

Supplier's IR

3 2 1

3.6 Snatch block assembly


Major Measurement 100% Assembly Drawing

Assembly Drawing

Supplier's IR 2 - 1

Review of reports by I.A.

3.7 Hook

Physical & Chemical Composition and UT

Major Witnessing / Correlation with Test Certificate.

100% Component drawing / IS – 1875

Component drawing / IS - 1875

Mfr's TC 3 - 1

Proof load test from Govt. approved laboratory.

Proof Load Test Major Testing 100% Component drawing

Component drawing

Mfr's TC 3 - 1

Stress relieving Major Verification 100% Component drawing

Component drawing

Vendor TC 3 - 2/1





Category Type /

Method of check

Extent of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

Per

form

ed

Witn

esse

d

Ver

ifie

d

A B C D E F G H I J K

3.8 Brake drums

Chemical & Physical as applicable and Dynamic balancing. Key way and key.

Major Correlation with TC / Check test


Component drawing / Specification

Mfr's TC

3 - 1,2

All the keys &keyways shall be checked by TPIA before assembly. Reports shall be furnished with tolerances & dimensions

4 BOUGHT OUT ITEMS

4.1 Wire Rope

Dimensional,

Lay, core and stands.

Major Mfr's TC 100% Component drawing/ BOOM

Component drawing / BOOM

Mfr's TC 3 - 1

Review of Mfr's TC by I.A.

Breaking Load Major Mfr's TC 100% IS:1364

IS:1367

IS:1364

IS:1367

Mfr's TC 3 - 1

4.1.1 Bearings Specific brand conformity.

Mfr's TC

3 1

4.1.2 Machined Bolts & Nuts

Dimensional, visual, chemical/ physical

Major Mfg TC Random Drawing Drawing Supplier IR, MFG TC

3 1 Use No black bolts and taper washers

5 ELECTRICAL ITEMS

5.1 Electrical Control Panel

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





Category Type /

Method of check

Extent of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

Per

form

ed

Witn

esse

d

Ver

ifie

d

A B C D E F G H I J K 5.2 Motor Visual Major Name Plate

details 100% IS 325 IS 325 Mfr's TC

3 - 1 Review of TC by I.A.

Routine

No load test, Insulation resistance values, winding resistance values

Major Elec. test 100% IS 325 IS 325 Mfr's TC

3 - 1

5.3 Brakes and

Brake coil

Visual

Accessibility of parts.

Major Name plate details verification of TC

100% BOOM/Spec BOOM/Spec Mfr's TC

3 - 1

Review of TC by I.A.

5.4 Resistance box Megger test, Resistance value

Major Electrical test 100% BOOM/ drawing / Specifications.

BOOM/ drawing / Specifications.

Mfr's TC 3 - 1

Review of I.A.

5.5 Master controller Limit switch/Circuit breakers

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.

5.6 Cables Routine test Major Test One per size BOM/spec. BOM/spec. Mfr's TC 3 - 1 Review of TC by I.A.

6 ASSEMBLY OF CRANE





Category Type /

Method of check

Extent of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

Per

form

ed

Witn

esse

d

Ver

ifie

d

A B C D E F G H I J K 6.1 Bridge Girder &

End carriage assembly.

Overall Dimension s Structural Alignment & LT Wheel alignment. Span measurement

Diagonal Checks

Major Measurement 100% Approved General Arrangement drawing / Specifications

Approved General Arrangement drawing / Specifications

Supplier's IR

2 1 -

6.2 Crab assembly with Main Hoist & CT machinery

Dimensional & CT Wheel alignment

Major Measurement 100% Approved drawing / Specifications

Approved drawing / Specifications

Supplier's IR 2 1 -

7 NO LOAD TEST

7.1 Main Hoist and No Load test Major No Load test 100% Approved drawing / Specifications & IPSS

IS 3177 Supplier's IR

2 1 -

Measure Gear Box Noise. (Noise Level should be <80db) Follow format annexed for parameters to be measured etc.,

7.1 CT Mechanism No Load test Major No Load test 100% Approved drawing / Specifications & IPSS

IS 3177 Supplier's IR

2 1 -

Measure Gear Box Noise.

(Noise Level should be <80db)

7.2 LT Mechanism

No Load test Major No Load test 100% Approved

drawing / Specifications

IS 3177 Supplier's IR 2 1 - Measure Gear Box Noise.

(Noise Level should be <80db)

8 TESTING





Category Type /

Method of check

Extent of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

Per

form

ed

Witn

esse

d

Ver

ifie

d

A B C D E F G H I J K 8.1 DEFLECTION

TEST

With Safe Working Load

Load test Major Measurement 100% Approved drawing / Specification / IS 3177 as applicable.

Approved drawing / Specification / IS 3177 as applicable.

Supplier's IR & ISRO Format

2 1 -

Record Test procedure followed.

8.2 FULL LOAD TEST

SAFE WORKING LOAD (MH & CT)

Load test Major Measurement of speed, voltage & Current Measurement

100% Approved drawing / Specification / IS 3177 as applicable.



2 1 -

8.3 OVER LOAD TEST (MH & CT)

Load test Major Observation and manoeuvre ability of CT & Hoist motion




2 1 -

9 GANTRY GIRDER AND RAIL ALIGNMENT

Span, Level, Joints and Anchoring of girders

Major Measurement 100% Approved drawing / Specification / IS 3177 as applicable

Approved drawing / Specification / IS 3177 as applicable

2 1

10

LOAD TESTING AFTER ERECTION AT SITE.

10.1 No Load Test

Functional checks of all motions, limit switches and Safety Inter locks

Major 3/2 1





Category Type /

Method of check

Extent of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

Per

form

ed

Witn

esse

d

Ver

ifie

d

A B C D E F G H I J K 10.2

Deflection test with full load

Load test Major Measurement 100% Approved drawing / Specification / IS 3177 as applicable.



3/2 1 -

10.3 Full load test (MH, CT & LT) & Safety Mechanisms.

Load test Major Measurement of speed, voltage & current measurement




3/2 1 -

10.4

Brake Test

Brake holding Test

Brake path test, Brake current, winding resistance values, electrical test (IR with respect to body)

3 1

10.5 Hoist operation without encoder

In SLVC mode capability to be checked

1





Category Type /

Method of check

Extent of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

Per

form

ed

Witn

esse

d

Ver

ifie

d

A B C D E F G H I J K 10.6 VVVF Drives

output voltage, current, Torque curves (Graphs), Brake resistance during load test,

Braking resistor resistance value & IR, Braking resistor max temperature during load test

3 1

10.7

Over Load test 125% of Full Load (MH, CT & LT)

Load test

Major Observation and manoeuvre ability of CT & Hoist motion




3/2 1 -

Examine for weld cracks etc.,

11 Painting 3/2 1

12 Safety features 3/2 1

13 Special requirements

ANNEXURE – X A

THE PARTY SHALL SUBMIT THE FOLLOWING

TEST CERTIFICATES, INSPECTION REPORTS&MAINTANACE CA TALOGUES

A) Flame Proof EOT Cranes:

1. Raw Material Test Reports 2. Welding Procedure Specifications(WPS) 3. Welding Procedure qualification/Procedure qualification Records(PQR) 4. Girder and End Carriage Inspection Reports 5. DP Test Reports of fillet weld joints of girders 6. NDT Level II Certificates 7. Rope Drum SR Charts 8. Rope Drum fillet joint DP Test report 9. Gear Box Reports & lubrication charts. 10. Dimensional Reports including tolerances of Key & Key ways of Gear Box, MH, LT, CT & Wheels and shafts. 11. Key material Test certificates 12. CT/LT Wheel Physical /Chemical Reports 13. Wheel Hardness Test Reports 14. Wheel UT Report 15. Wheel Dimensional Report 16. Hook Test Report with twice its SWL at govt approval test house/dock labour board. 17. Coupling Test Certificates 18. Dimensional Reports of Couplings 19. Brake Drum Dynamic Balancing Reports 20. Material & Dimensional Report for Sheaves 21. Inspection Report for lower block assembly 22. Wire rope Test Certificates 23. Flame Proof Certificates of EHT Brakes, Thruster, Motors & Under bridge Light fittings. 24. VFD panel test report for HV & Dielectric strength test. 25. Motor Routine Test Certificate & Inverter suitability. 26. Test certificate for IGUS cable. 27. Brake Test Certificate 28. ATEX compliance certificate for FLP Imported Brakes. 29. Inspection Reports as Per ISRO Crane Test Procedure 30. Electrical wiring diagrams, control drawings. 31. Cable routing diagrams showing cross sectional details of clamping/fixing arrangement of cable etc., 32. Maintenance Catalogues of motors, Brakes, Gear Boxes and VVVF Drive systems. 33. Painting Inspection Report. 34. Inspection Release Note & Inspection Report 35. Load test report 36. Drive back up data in CD/DVD.

ANNEXURE – X B

THE PARTY SHALL SUBMIT THE FOLLOWING

TEST CERTIFICATES, INSPECTION REPORTS&MAINTANACE CA TALOGUES

B) Non Flame Proof EOT Cranes:

1. Raw Material Test Reports 2. Welding Procedure Specifications(WPS) 3. Welding Procedure qualification/Procedure qualification Records(PQR) 4. Girder and End Carriage Inspection Reports 5. DP Test Reports of fillet weld joints of girders 6. NDT Level II Certificates 7. Rope Drum SR Charts 8. Rope Drum fillet joint DP Test report 9. Gear Box Reports & lubrication charts. 10. Dimensional Reports including tolerances of Key & Key ways of Gear Box,

MH, LT, CT & Wheels and shafts. 11. Key material Test certificates 12. CT/LT Wheel Physical /Chemical Reports 13. Wheel Hardness Test Reports 14. Wheel UT Report 15. Wheel Dimensional Report 16. Hook Test Report with twice its SWL at govt approval test house/dock labour board. 17. Coupling Test Certificates 18. Dimensional Reports of Couplings 19. Brake Drum Dynamic Balancing Reports 20. Material & Dimensional Report for Sheaves 21. Inspection Report for lower block assembly 22. Wire rope Test Certificates 23. VFD panel test report for HV & Dielectric strength test. 24. Motor Routine Test Certificate 25. Test certificate for IGUS cable. 26. Brake Test Certificate 27. Inspection Reports as Per ISRO Crane Test Procedure 28. Electrical wiring diagrams, control drawings. 29. Cable routing diagrams showing cross sectional details of clamping/fixing arrangement

of cable etc., 30. Maintenance Catalogues of motors, Brakes, Gear Boxes and VVVF Drive systems. 31. Painting Inspection Report. 32. Inspection Release Note & Inspection Report 33. Load test report

ANNEXURE-A

QUESTIONNAIRE FOR DESIGN, MANUFACTURE, TESTING AND ERECTION

MEDIUM CAPACITY EOT CRANES (9No’s of 20t, 25t & 30t FLP and Non FLP DG

VVVF Dual Drive 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

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

2 Year of Establishment

3 Annual Turnover (In Rs.Lakhs) for last three years

year ending up to 31.03.2017 (Rs.

)

3.1 Turn over – 2016-2017 (Rs.

)

3.2 Turn over – 2015-2016 (Rs.

)

3.3 Turn over – 2014-2015 (Rs.

)

4 Orders executed during last 03 years capacity of

EOT Cranes, references are is to be mentioned.

(Separate sheet can attached for this)

a. 2014-2015

b. 2015-2016

c. 2016-2017

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

6 No of EOT Cranes of capacity 25 ton above and

Span 15m and above manufactured during last 5

years ending 31.03.2017

7 No of EOT Cranes of capacity not less than 25 ton

with SIEMENS/ABB VVVF (VFD) drive & control

systems produced in last 5 years.

8 No of FLP EOT cranes produced (not less than 25

ton capacity) operating for 5 years

9 Shop floor Area Covered

10 No. of Employees (Supplier shall mention contract

personnel separately)

a. Engineers

b. Supervisors

c. Technicians

d. Quality control engineers

Administrative staff

11 Raw Material Sourcing:

a. Steel Plates

b. Rolled sections, Flats

c. Forged Rods, Blanks

d. Round bars (for Axles

e. Seamless pipes

12 Sources of Bought out components:

a. Electric Motors

b. Brakes Imported

c. Gear Boxes

d. Couplings

e. Limit switches

f. Wire ropes

g. Electrical Panels

h. VVF drives

i. Brakes Indigenous

j. Cables

k. IS Circuits

l. FLP items

13 Details regarding out sourcing, if any, of

manufacturing and fabrication works.

14 Handling facility available:

a. Over head/Grantry crane details

(capacity, span, lift)

b. Mobile cranes

15 Load testing Facility Available:

a. Maximum weight available.

b. No.of weights

c. Total test load available

16 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

17 Fixtures available for Welding of Girders of span

more than 15m

18 Welding Professionals:

a. No.of welders (MMAW)

Qualification details

Qualified by

b. No.of Welders (GMAW)


Qualified by

c. No.of welders (TIG)


Qualified by

19 Details of Welding Inspection Equipment &

welding inspector available with supplier (LPT, UT,

MPT, X-rat, etc)

Any out sourcing can be mentioned

20 Forming Facilities available (with brief

specification of each machine)

a. Shearing Machine

b. Cutting Machine

c. Bending Machine

21 Machining Facilities available (with brief

specification of each machine)

a. Turning Lath (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

22 Details of Inspection facilities/ instruments

available

(Brief description & specifications shall be

provided)

23 If third party inspection services are taken for

manufacturing of EOT Cranes give details.

24 Range of Capacity of EOT Cranes manufactured till

now (list with brief specs & customers shall be

provided)

25 Maximum capacity of EOT Crane manufactured

with dimensions, type quantity customer, and

purpose of EOT Crane

26 Maximum dimensions of EOT Crane manufactures

with capacity, Span quantity, customer and

purpose of EOT Crane

27 Special purpose EOT Cranes manufactured, if any,

capacity, dimensions and customer

28 Design facility available:

a. Drafting & Modeling software packages

b. FEM software

c. Other Software

d. Design engineers (with qualification &

experience)

29 Painting facility available

a. Sand/Abrasive blasting facility.

b. Painting equipment

c. Make of paints generally used.

30 General stock level of Raw material/Brought out

items in the factory:

1. Structural steel plates etc.,

2. Alloy steel round bars

3. Bought out items

4. Paints, etc.,

31 Any awards or recognitions obtained through

product excellence

32 Collaboration with other reputed manufactured

and OEMs with product details and Name Principal

supplier, country of origin etc.,

33 Any other relevant information in design,

manufacture and testing of EOT Cranes

34 List of documents enclosed with this questionnaire

35 Any other information would like to add (separate

sheet can be attached)

Signature:

Name:

Date: Designation:

Company:

BID QUALIFICATION CRITERIA FOR SUPPLY OF MEDIUM CAPACITY EOT

CRANES (9No’s)

Bidders who are qualifying /meeting following Technical and Financial

capabilities are eligible to participate in the bid for supply of 9 Nos of EOT Cranes

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 all 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 for last 5 Years in India.

2. The Annual turnover 14 Crores per year on as average shall be done and the

same shall be done for 3 years periods ending with 31.03.2017.

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

Testing and Commissioning of at Least 2 No’s of double girder EOT cranes of

capacity 25 ton or above and Span equal to 15m and above during last 5

years ending 31.03.2017 Bidders have to provide relevant certificates from the

Owners (end users along with the submission of bid for consideration of bid

document).

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

commissioning of EOT cranes with VVVF (VFD) drive control system at least

2 no’s of crane and atleast one crane of capacity not less than 25 ton in the last

5 years.

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

establishment of at least 2 no’s of FLP EOT cranes not less than 25 ton capacity

in the last 5 years.

6. The firm should have facility to full load test and over load testing of 25 ton

EOT crane (hoist and cross travel) at their factory.

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

establishment of capacity EOT cranes 25t and above to the satisfaction of

reputed third party inspection agencies like M/S Loyds register, M/S M.N.Dhastur,

M/S BVQI and Det Norske Veritas (DNV) only.

8. Bidder shall furnish the details of their factory like manpower, machinery,

quality system etc, for department to assess their capability. Bidder shall

submit above information in the format given in “Questionnaire “attached as

Annexure (A) to this BQR

II The following documents shall be submitted along with the application

for prequalification of Bid:

1. Firm establishment certificate and nature of work.

2. Details of work pertaining to EOT cranes completed during the last 5 years

ending 31.03.2017.

3. Satisfactory work Completion certificates of EOT cranes form the clients with

the work order copies.

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 technical

qualification requirements (SI. No I of 3,4 &5).

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

7. IT/TDS certificates for last three years.

8. Current Solvency Certificate.

9. List of EOT crane projects (for capacity 25 ton and above/Span 15mt and above

completed for last 5 years with PO copies).

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

Purchaser name and address.

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

12. Structure and organization 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 & Equipment to be used for the work.

15. Any other relevant information which is related 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 clarification will be sought in this regard.

4. Purchaser is having right to split the purchase of the EOT Cranes during

finalization in views of criticality and delivery schedule, on the basis of lowest

offer. Please note and give acceptance in the compliance form suitably.

IV. Bid Selection Procedure and Process of BID Qualification

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

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

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

to rejection of Bid)

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

status will be evaluated suitable for this project. Feedback from Bidder’s

clients will be verified.

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

Bidder has established above mentioned capacity of manufacturer.

Step-4 If required to visit will be made to their factory/ firm by technical team (ISRO

or third party) for accessing the capacity of manufacturer.

Step-5 Mean while technical Bids will be opened and scrutinized for meeting all

technical specification and supply conditions.

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

If the

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

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

Criteria / requirements will be finally qualifying for opening of the price Bids

evaluation

ANNEXURE - B

Commercial Terms and Conditions of the Contract:

Proposals are invited from the interested Bidders for the enclosed scope of work in two-part bid. Part-1 Technical and Unpriced part of the work and Part-2 Priced Commercial bid.

1. PROPOSAL DOCUMENT

1.1 Overall specifications and functional requirements are detailed in the proposal document. Bidder shall print, sign and stamp each page of proposal as token of acceptance & submit scan copy of the same along with the offer.

1.2 The proposal shall be completely filled in all respects and submitted together with requisite information and Annexure. Any offer incomplete in any particulars is liable to be rejected.

1.3 If the space in the Proposal or any schedule or Annexure thereto is insufficient, pages shall be separately added.

1.4 The Proposal shall be opened on the date and at the time, specified in the Letter Inviting Bid. Proposal not received in time shall not be considered.

1.5 Bidder shall set their quotations in firm figures and without qualifications or variations or additions in the terms of the Proposal documents. Proposal containing qualifying expressions such as "subject to minimum acceptance” or "subject to prior sale" or any other qualifying expressions or incorporating terms and conditions at variance with the terms and conditions incorporated in the Proposal documents are liable to be rejected.

2 PREPARATION OF BIDS

2.1 SITE VISIT: The Bidder may visit SDSC SHAR and acquaint himself fully with the requirements and no claims whatsoever will be entertained on the plea of ignorance of difficulties in the execution of the work. Before submitting the tender, the Bidder shall be deemed to have clearly understood and satisfied himself regarding the work and services, all conditions liable to be encountered during the execution thereof and that prices quoted in the offer are adequate and all-inclusive with respect to all factors, circumstances and conditions likely to be incidental, both direct and indirect, to the work and services. If the bidder wishes to see the site, the bidder may do so within 15 days from the date of issue of tender enquiry.

2.2 VALIDITY OF OFFER: Bid shall remain valid for a period of 4 (four) months from the due date of submission of the Bid. The Bidder shall not be entitled during the said period to revoke or cancel his Bid or to vary the Bid except and to the extent required by Purchaser and communicated in writing. Bid shall be revalidated for extended period as required by Purchaser in writing. In such cases, unless otherwise specified, it is understood that validity is sought and provided without varying either the quoted price or any other terms and conditions of Bid finalized till that time.

2.3 COST OF BIDDING: All direct and indirect costs associated with the preparation and submission of Bid (including clarification meetings and site visit, if any), shall be to

Bidder's account and the Purchaser will in no case be responsible or liable for those costs, regardless of the conduct or outcome of the Bid process.

2.4 APPLICABLE LANGUAGE: The Bid and all correspondence incidentals to and concerning the Bid shall be in the English Language. For supporting document and printing literature submitted in any other language, an accurate English Translation shall also be submitted. Responsibility for correctness in translation shall lie with the Bidder.

2.5 ARRANGEMENT OF BID: The Bid shall be neatly presented and shall not contain any terms and conditions which are not applicable to the Bid. The Bid and all details submitted by the Bidder shall be signed and stamped on each page as token of acceptance by a person, legally authorized to enter into agreement on behalf of the Bidder. Corrections/ alteration, if any, shall also be signed by the same person. Bidder shall submit Power of Attorney in favour of the person who signs the Bid and subsequent submissions on behalf of the Bidder. Purchaser will not be bound by any Power of Attorney granted by the Bidder or changes in the constitution of the firm made subsequent to submission of the Bid or after the award of the contract. Bidder may however, recognize such Power of Attorney and changes after obtaining proper legal advice, the cost of which will be borne by the Bidder. The cancellation of any document such as Power of Attorney, partnership Deed etc should be communicated by the Bidder to the Purchaser in writing well in time, failing which Purchaser shall have no responsibility or liability for any action taken by Bidder on the strength of the said documents. All the relevant papers shall be scanned and uploaded along with bid

2.6 SCHEDULE OF PRICES: The schedule of prices shall be read in conjunction with all the sections of proposal document. The prices quoted by the Bidder shall be firm and fixed till the completion of the work. The price shall be filled in the price format available in e-procurement portal only.

2.7 DOCUMENTS COMPRISING THE BID:

2.7.1 PART – I: TECHNICAL AND UNPRICED COMMERCIAL PART

Technical and un-priced commercial part comprising the following information shall be uploaded in e-procurement portal.

a. Scan copy of bid letter along with one set of proposal document duly signed and stamped on each page as a token of acceptance.

b. Scan Copy of Company’s registration number certificate.

c. Scan copy of Power of attorney in favour of authorized signatory of the bid / proposal documents.

d. All the annexures of the bid shall be duly filled and signed.

e. Scan copy of Un-priced copy of schedule of prices with all other commercial terms and conditions duly filled (Instead of price figures, bidder shall write “QUOTED”) signed.

f. Data sheets for all the equipment & sub-systems

g. Technical details, equipment general arrangement drawings, catalogues etc., as applicable and any other drawing, document as mentioned in the proposal.

h. Audited balance sheet including profit and loss account for the last three financial years showing annual turnover (year ending March 2017).

i. Latest income tax clearance certificate (Current year).

j. Latest solvency certificate for an amount of Rs. 50 lakhs from a scheduled bank (Current year).

k. List of projects in hand & completed indicating the name of the client, contact person, contract value, nature of work, work completed, work balance, name of Consultant, month & year of commencement & completion etc.

l. Organization chart for the proposed work with bio data of key personnel

m. Execution Plan. Any part of the work is planned to outsource, details of the same shall be provided along with bid documents.

n. Any other relevant document, Bidder desires to submit.

2.7.2 PART – II: PRICE BID: Priced commercial bid shall contain schedule of prices, percentage of GST and other taxes, if any, shall be filled in ISRO e-procurement portal only. No deviations to terms and conditions, assumptions, discounts etc. shall be stipulated in price bid. Purchaser will not take cognizance of any such statement and may at their discretion reject such bids.

2.8 BID SUBMISSION

2.8.1 Bid shall be submitted in two parts

Part 1: Techno-commercial part of the bid

Part 2: Priced part of the bid

2.8.2 Offer should be submitted online using standard digital signature of class -3 with encryption/decryption options.

2.8.3 The tenders authorized online on or before the open authorization date and time will only be considered as valid tenders.

2.8.4 Prices shall be mentioned in the space/column provided in the ISRO e-procurement portal only.

2.8.5 Prices shall not be uploaded along with technical specifications in any form. If so, such bids will not be considered.

2.8.6 Un-Priced format (Annexure - C) shall be filled saying “QUOTED” and shall be submitted along with the technical bid. This is only to ensure that the bidder has provided all the details

2.8.7 Prices quoted should be on the basis of FOR Sriharikota or DAP or DDP.

2.8.8 The Purchaser will not pay separately for transit insurance and same shall be included in the cost quoted by the Bidder.

2.8.9 All risks in transit shall be exclusively borne the contractor and the Purchaser shall pay only for such items that are actually received in good condition in accordance with the purchase order.

2.8.10 Bids duly filled in by the Bidder should be submitted as stipulated in the e-procurement portal.

2.8.11 Purchaser will open Part – I of the bid on the due date of opening. Price Bid (Part-II) of the bids which are technically and commercially acceptable shall be opened at a later date with prior intimation to all qualified bidders.

2.8.12 Purchaser reserves the right to reject any or all the Bids without assigning any reasons thereof.

3 DETERMINATION OF RESPONSIVENESS

SDSC SHAR will scrutinize bids to determine whether the bid is substantially responsive to the requirements of the tender documents. For the purpose of this clause, a substantially responsive bid is one which inter-alia conforms to all the terms and conditions of the entire Tender document without any deviations and reservations. The decision of Purchaser shall be final in this regard.

4. SCHEDULE OF PRICE

4.1 CONTRACT price shall include all costs of “ DETAILED ENGINEERING,

FABRICATION, SUPPLY, ERECTION, TESTING AND COMMISSIONING OF EOT

CRANES”, Shop floor testing, packing, forwarding, transport to site, unloading, storage, all

risk coverage, erection, installation, training, testing & evaluation and commissioning of

equipment including associated civil work and any other cost for proper and complete

execution of the CONTRACT.

4.2 CONTRACT prices shall also include all travelling expenses, living expenses, salaries,

overtime, benefit and any other compensation for engineers, supervisors, skilled, semiskilled

workmen, watch and ward staff, laborer and other staff employed by the Bidder, cost of tools

and tackles required for erection and other consumable material required, and all taxes, duties,

and levies as applicable on the date of submission of bid.

4.3 Price quoted shall be firm & fixed. The price shall be filled in the format available in e-

procurement portal. The bidder shall also fill up the format enclosed (Annexure VI in Section

D) without price figures and shall confirm by filling the appropriate fields as “QUOTED”.

4.4 The rate quoted shall be on F.O.R SDSC SHAR, Sriharikota or DAP or DDP basis.

4.5 All rates of taxes/duties/levies applicable with details of percentage and

applicable portion of the price should be spelt out clearly in the offer.

4.6 The taxes applicable for supply, erection & commissioning shall be indicated separately

in terms of percentage in the price bid. If the offers submitted by the bidders are silent on

taxes, it will be presumed that quoted rates are inclusive of taxes & duties and no claim in

this regard will be entertained later.

4.7 The variation in the GST or applicable statutory taxes shall be paid on documentary

evidence submitted by the bidder during this contract.

5. MODE OF PAYMENT

All the payments due to Bidder shall be made through RTGS/ NEFT. Bidder shall submit the banker details and payments can also be made through Electronic Clearance System (ECS).

6. TERMS OF PAYMENTS

6.1 Our standard payment term is 20% of supply value against equivalent bank guarantee submission after PO placement and acceptance, 10% supply value after GA Drawing approval, 60% of supply value plus taxes applicable including transportation charges and packing and forwarding with 30 days after receipt, acceptance of sub-systems and after CLIP inspection at SDSC SHAR, and remaining 10% of supply portion and 100% erection and commissioning charges along with taxes as applicable, TPIA charges etc will be paid within 30 days after successful commissioning and handing over of the EOT Crane and sub systems at SDSC SHAR on submission of Performance Bank Guarantee.

6.2 Wherever advance payment is requested, Bank Guarantee from any Nationalized Bank/Scheduled Bank should be furnished. In case of advance payments, if the bidder is not supplying the material within the delivery schedule, interest will be levied as per the Bank Lending Rate plus 2% penal interest.

6.3 Interest will be loaded for advance payments/stage payments as per the lending rate of Bank and will be added to the landed cost for comparison purpose. In case of different milestone payments submitted by the parties, a standard and transparent methodology of NPV (Net present value) will be adopted for evaluating the offers.

7. DELIVERY SCHEDULE

7.1 Bidder shall follow the following schedule for executing the contract

S. No Mile Stone Expected date of

completion

1 Purchase order date T - (A)

2 Submission GA drawings, sizing and structural

calculations and approval.

T+4 weeks – (B)

3 Supply of EOT ALL Cranes T+ 36 weeks – (C)

4 Erection and Commission and Testing EOT Cranes C + 8 weeks from the site clearance

Note: Readiness of the site shall be obtained from the indenter before commencement

of the erection work.

7.2 The Bidder shall inform the Purchaser within 30 days of any occurrence that is likely to cause delay in delivery. The Purchaser shall determine, in the light of circumstances reported, whether or not any respite or modification of the delivery requirements of the contract can be permitted on this account.

7.3 An extension of the time limit for execution or postponement of delivery shall be granted only in the respect of delay, which is not attributable to the fault or the negligence of the Bidder. An extension of the time limit for execution shall be granted to the bidder to the extent that he establishes force majeure events.

8 LIQUIDATED DAMAGES AND EARNEST MONEY DEPOSIT:

8.1. LIQUIDATED DAMAGES:

In the event of the Bidder failing to complete the work within the delivery period specified in the contract agreement or any extension agreed thereto, the Purchaser shall reserve the right to recover from the Bidder as liquidated damages, a sum of 0.5 percentage per week or part thereof of the undelivered portion of the total contract price of equipment or work. The Total liquidated damages shall not exceed 10.0 percentage of the total Contract price.

8.2. EARNEST MONEY DEPOSIT (EMD)

The Earnest Money Deposit(EMD) of Rs5,00,000/- (Rupees five Lakh Only), refundable (without interest), should be necessarily accompanied with the technical Bid in the form of

Demand Draft drawn in favor of Accounts Officer, SDSC SHAR, Sriharikota failing which the tender shall be rejected summarily.

9 TAXES AND DUTIES:

9.1 GST: The bidder shall clearly indicate the percentage of GST applicable. GSTIN & HSN/SAC for each item to be indicated. GST, TDS if applicable shall be deducted.

9.2 INCOME TAX: Income tax at the prevailing rate as applicable and if applicable from time to time shall be deducted from the bidder’s bills as per Income Tax Act and a certificate issued (TDS Certificate).

10. Taxes and Exemption:

10.1 Excise Duty Exemption: Excise duty exemption will be availed by the

purchaser for this crane. Hence the quotation shall take this into account.

10.2 Custom Duty Exemption: Custom duty exemption will be availed by

the purchaser for this crane. Hence the quotation shall take this into

account.

10.3 Earnest Money Deposit Exemption: Exemption /Benefits to MSME registered

under NSIC. Hence the quotation shall take this into account.

11. RISK COVERAGE:

The Bidder shall arrange comprehensive risk coverage at his own cost covering the value of equipment including transportation to the site from manufacturer’s works, storage at site, fabrication, erection, testing and commissioning at site. The period of such coverage shall be up to contractual completion period or any extension granted by Purchaser thereof.

12. SECURITY DEPOSIT

12.1 The bidder whose tender is accepted will be required to furnish by way of Security Deposit for the due fulfillment of the contract such a sum as will amount to 10 % of the contract price of the work awarded in the form of Bank Guarantee valid till the satisfactory execution of the contract and acceptance.

12.2 The security deposit (bearing no interest) shall be held by the Purchaser as security till satisfactory completion, testing and handing over of all the system and for the due performance of all bidders’ obligations under the contract as per delivery period or extension granted thereof by the Purchaser.

12.3 Within 10 days from the date of receipt of purchase order/ LOI, bidder shall deposit the security deposit to the Accounts officer, Satish Dhawan Space Centre SHAR, Sriharikota as detailed above by any of the following modes.

12.3.1 By a crossed demand draft in favor of Accounts officer, Satish Dhawan Space Centre SHAR drawn on SBI and payable at Sriharikota.

12.3.2 By submission of bank guarantee: The bank guarantee shall be from a reputed international/nationalized/schedule bank.

12.4 In case of breach of contract, the Security deposit shall stand forfeited in addition to other relief available to the Purchaser under this contract.

13 PERFORMANCE BANK GUARANTEE:

The bidder shall guarantee for the performance of the contract by providing bank guarantee in favour of the Purchaser for an amount equivalent to 10 %( ten percent) of the total value of this contract valid till the warranty period of the contract with a claim period of 60days. The performance bank guarantee shall be submitted by the bidder with in fifteen days from the date of accepting the equipment by the Purchaser as per the CONTRACT. The format for the performance bank guarantee shall be obtained from Purchaser.

14 PACKING AND FORWARDING

The Bidder shall arrange to have all the material suitably packed as per the standards & statutes and as specified in the contract. Unless otherwise provided for in the contract, all containers (including packing cases, boxes, tins, drums, and wrappings) used by the Bidder shall be non-returnable.

All packing and transport charges, transit handling costs, transit risk coverage and transport fees of agents employed at the place of delivery or elsewhere, shall be deemed included in the price to be paid to the Bidder.

15 WARRANTY

The bidder shall provide twelve months warranty for the entire system for a defect liability, after final official handing over at his cost. During this period bidder has to provide and adhere to the following:

15.1 This period shall include maintenance, replacement of defective/ failed parts at free of cost.

15.2 Bidder has to attend unlimited breakdown calls.

15.3 Purchaser will not provide any transport/accommodation for this purpose.

15.4 Upon oral or written notification of defects in or malfunctioning of the goods during the warranty period which require corrective action, bidder shall send the necessary personnel to job site to supervise and assume responsibility for repairs and/or replacement, if necessary, of the defective goods or material at his own cost. If Bidder does not respond, within seven (7) days after receipt of notification, the Purchaser has got every right to resolve reported problem and Purchaser may do so at the cost and expense of the Bidder. Bidder shall reimburse to the Purchaser all expenses incurred by Purchaser to repair or replace malfunctioning or non-conforming goods and Forfeit the performance security.

15.5 Purchaser has no obligation to discover defects, patent or otherwise, and this shall be sole responsibility of Bidder. Inspection and clearance for shipment by Purchaser’s inspectors

or Inspection agency appointed by Purchaser shall not relieve Bidder of any of his obligation and duties under the terms and conditions herein.

15.6 Where defects in items are remedied under warranty, the period for which the warranty operates shall be extended by such period, as the items were not available to the Purchaser. Where defects items are replaced by new ones, the full warranty period stipulated in the contract shall apply to such replacement items as from the date of their delivery.

15.7 Bidder shall obtain similar warrantee from each of his sub-bidders. However, the overall responsibility shall lie with the Bidder.

15.8 The Bidder shall guarantee that the equipment furnished by him are in conformance with the requirement of the specifications.

Goods covered by the contract shall be free from defects in design, materials or

workmanship for a period of twelve months from the date of successful

commissioning & acceptance by Purchaser.

16 DISCLOSURE AND USE OF INFORMATION BY THE BIDDER

16.1 If the documents supplied by the Purchaser are marked ‘restricted use’ the Bidder shall take all necessary steps to ensure that the requirements of the contract or any specification, plan, drawing, pattern, sample or information supplied by, or on behalf of, the Purchaser in connection therewith shall not be disclosed to any person other than a person employed or engaged by the Bidder, whether under sub-contract or otherwise, for the performance of the contract.

16.2 Bidder shall guarantee that all information and data received during execution of Contract from Purchaser shall be classified as confidential within the meaning of the Official Secrets Act and will not be divulged to any third bidder without prior written permission of Purchaser. All drawings & documents shall be returned after execution of work.

17 ARBITRATION: In the event of any question, dispute or difference arising under these conditions the purchase order or in connection with this contract, (except as to any matters the decision of which is specially provided for by these conditions) the same shall be referred to the sole arbitration of the Head of the Centre or of some other person appointed by him. The arbitration shall be conducted within India as per Arbitration & Conciliation Act 1996 and the applicable language shall be English. The arbitrator may be a Retired Judge or a Government Servant or any other responsible person appointed by the head of the Purchaser. The award of the Arbitrator shall be final and binding on the parties of this contract.

18 APPLICABLE LAW AND JURISDICTION

The contracts shall be interpreted in accordance with the laws of the Union of India. Any legal issue or dispute arising out of the contract are within the jurisdiction of Courts of Andhra Pradesh, India only.

19 FORCE MAJEURE

a. Force Majeure is an event beyond the control of the bidder and not involving the bidder’s fault or negligence and which is not foreseeable. Such events may include,

but are not restricted to, acts of the purchaser either in its sovereign or contractual capacity, wars or revolutions, hostility, acts of public enemy, civil commotion, sabotage, fires, floods, explosions, epidemics, quarantine restrictions, strikes, lockouts, and freight embargoes.

b. If there is delay in performance or other failures by the bidder to perform its obligation under its contract due to event of a Force Majeure, if a Force Majeure situation arises, the bidder shall promptly notify the purchaser in writing of such conditions and the cause thereof within twenty one (21) days of occurrence of such event.

c. Unless otherwise directed by the purchaser in writing, the bidder shall continue to perform its obligations under the contract as far as reasonably practical, and shall seek all reasonable alternative means for performance not prevented by the Force Majeure event.

d. There may be a Force Majeure situation affecting the purchase organization only. In such a situation the purchase organization is to take up with the bidder on similar lines as above for further necessary action.

20 EXTENSION OF TIME

20.1 If the completion of deliveries of equipment, work is delayed due to reason of Force Majeure the Bidder shall without delay give notice to the Purchaser in writing of their claim for an extension of time. The Purchaser on receipt of such notice may agree to extend the Contract period or delivery date as may be reasonable but without prejudice to other terms and conditions of the Contract.

20.2 Both parties shall keep a record of the circumstances referred to above which are responsible for causing delays in the execution of the services and shall give notice to the other bidder of any such cause as soon as it occurs. An event of Force Majeure, where so ever it occurs, provided it affects either bidder in fulfilling its obligations under this contract, shall justify the affected bidder’s claim of Force Majeure. Should one or both the parties be prevented from fulfilling their contractual obligations by a state of Force Majeure lasting continuously for more than a month, the parties shall consult with each other regarding the future execution of the contract.

21 SAFETY

Bidder shall follow the safety regulations / codes or safety instructions issued by PURCHASER and shall take necessary measures at his own cost.

22 POWER SUPPLY

Electrical power provided by the Purchaser during installation of SPECIAL PURPOSE machine is NOT chargeable. Reasonable quality of normal power will be made available at one point (415V, 3 phase, 50 Hz). However, onward distribution shall be done by the bidder. All electrical installation by the bidder shall be as per safety regulation & standard and will be subjected to Purchaser inspection & approval.

23 WORK RULES

Generally, NO work shall be carried out during night or public holidays unless a written permission is obtained from Purchaser.

24 SITE CLEARANCE

Upon completion of work, Bidder shall remove all his equipment and material from the site within one month or time mutually agreed. Bidder at all times shall keep site in clean condition and remove all unwanted material at regular intervals. In case bidder fails to remove all his equipment and material within the mutually agreed time it is deemed that Purchaser will arrange to remove the same at the bidder’s cost besides imposing penalty for failure.

25 ACCOMMODATION

Very limited accommodation may be provided by Purchaser to senior supervisory staff of the Bidder on chargeable basis subject to availability.

Bidder shall make his own arrangement for accommodation & canteen facility for all its staff, technicians, labour& workers. Transportation shall be arranged by Bidder at his own expenses for his entire staff till the completion of the project.

26 MEDICAL FACILITIES

No medical facilities will be provided by Purchaser at site for Bidder’s site personnel. Bidder shall make his own arrangement at his own expenses for medical facilities for site personnel.

27 PROJECT EXECUTION AND MONITORING

Upon placement of purchase order, bidder shall prepare a detailed programme schedule for review/approval by Purchaser. Bidder shall identify a project team with one senior official as a project leader. Bidder shall submit the project status report every 15 days giving the status of various activities w.r.t. planned schedule for realization of SPECIAL PURPOSE Machine. Bidder shall depute their Project team/ engineers for monthly meeting to review the status and discuss/ resolve minor issues related to project execution at SDSC SHAR/ bidder’s site based on mutual agreement on mutually agreeable dates.

28 ACCEPTANCE AND REJECTION

• On completion of the work or part of the work as specified in the contract by the bidder, bidder shall inform the same to the Purchaser as soon as possible. The Purchaser / its representative shall inspect as per mutually agreeable schedule.

• If the ordered systems, sub-systems etc., do not meet the prescribed specifications or are damaged at the time of delivery or fail during inspection/testing, they shall be rejected and the Bidder / manufacturer shall replace them at their own cost.

• Purchaser has the right to reject the goods on receipt at site during final inspection though the goods have already been inspected and cleared at pre-dispatch stage by the purchaser’s inspector, if they found not meeting the overall performance requirements.

• Goods accepted by the purchaser at initial inspection and in final inspection in terms of the contract shall in no way dilute purchaser’s right to reject the same later, if found deficient in terms of the warranty clause of the contract.

29 SUSPENSION

a. Purchaser may notify the Bidder to suspend performance of any or all of his obligations under the Contract. Such notice will specify the reasons for suspension and the effective date of suspension. Bidder there upon shall suspend the performance of such obligations until ordered in writing to resume performance of Contract by Purchaser.

b. If Bidder’s performance or his obligations remain suspended or the rate of progress is reduced, then, the time of completion will be suitably extended and all costs incurred by Bidder as a result of suspension or reduction in rate of progress will be paid to Bidder provided that the suspension or reduction in the rate of progress is not by reasons of Bidder’s default or breach of Contract.

30 CANCELLATION

a. GENERAL RULE: The Purchaser shall have the right at any time to cancel a contract either wholly or in part by giving written notice by registered mail. From the time of receipt of the written notice the Bidder shall undertake to observe the instructions of the Purchaser as to the winding up of the contract both on his own part and on the part of his sub-bidders.

b. WITHOUT FAULT OF BIDDER: In the case of cancellation of a contract by the Purchaser without any fault of the Bidder, the Bidder shall on receipt of Purchaser’s instructions forthwith take the necessary steps to implement them. The period to be allowed to implement them shall be fixed by the Purchaser after conclusion with the Bidder and, in general, shall not exceed three months.

c. Subject to the Bidder confirming, Purchaser shall take over from the Bidder at a fair and reasonable price all finished parts not yet delivered to the Purchaser, all unused and undamaged material, bought-out components and articles in course of manufacture in the possession of the bidder and property obtained by or supplied to the Bidder for the performance of the contract, except such material, bought-out components and articles in course of manufacture as the bidder shall, with the agreement of the Purchaser, elect to retain.

d. WITH FAULT OF BIDDER: The Purchaser reserves the right, after full consideration of all relevant circumstances, including the observations of the bidder, to cancel a contract in any of the following circumstances.

a. In the event of the Bidder’s failure to meet requirement of the purchase order.

(i) The Technical requirements of the Bidder.

(ii) The Progress and/or delivery requirements.

b. If the Bidder has not observed the provisions of the contract concerning the disclosure and use of information provided by the Purchaser.

c. If the Bidder fails to comply with the provisions of the contract concerning the equipment, supplies and technical documents made available by the Purchaser.

d. If the Bidder transfers his contract without the Purchaser’s authorization or concludes sub-contracts against the Purchaser’s explicit directives.

e. In the event that Bidder unjustifiably repudiates the Contract or fails to ship or dispatch all or part of the goods ordered for reasons other than those attributed to the Purchaser’s actions or as provided in the Force Majeure clause, the Purchaser may, by giving an appropriate notice in writing to the Bidder, fix a Date of Essence by which the Bidder shall complete the dispatch in full. If the Bidder fails to do so, the Purchaser, in addition to his right to recover Liquidated Damages in terms of the Contract, shall also have the right to cancel this Contract and make substitute purchases from other sources. If the goods are in a partial state of fabrication, Purchaser may have the fabrication completed by other means, in which event Bidder shall be liable to the Purchaser for the additional expenses incurred thereby, but shall not have any claim on savings, if any, in such cases.

f. In the event of such cancellation, the Purchaser shall unless otherwise specified in the contract, there is no obligation on the Purchaser to pay losses incurred by the bidder.

ANNEXURE – C1

PRICE BID FORMAT FOR INDIVIDUAL EOT CRANE

Cane Sl No.1 Capacity: 25t S pan: 19m Facility: Casting

Sl. No Particulars Rs.

1 Basic cost of the EOT Crane

2 Cost of Cable Drag Chain System @ /m

3 Cost of Rail @ /m both side

4 GST for supply of EOT Crane, Cable drag chain system and

Rail 5 Erection of the EOT Crane 6 Erection of the Cable drag chain system

7 Erection of the Rail

8 GST for Erection of EOT Crane, Cable drag chain system and

Rail

9 Third party Inspection Charges inclusive of GST - Lumpsum

10 Transportation of the EOT Crane inclusive of GST - Lumpsum

11 packing and forwarding charges inclusive of GST - Lumpsum

Total Cost

ANNEXURE-C2


Cane Sl No.2 Capaci ty: 25t Span: 19m

Facility: Assembly & Decoring facility









Rail




Total Cost

ANNEXURE-C3


Cane Sl No.3 Capaci ty: 30t Span: 10.1m Facility: 4.5t Mixer facility









Rail




Total Cost

ANNEXURE-C4


Cane Sl No.4 Capaci ty: 20t Span: 13.3m Facility: Bowl Cleaning facility









Rail




Total Cost

ANNEXURE-C5


Cane Sl No.5 Capaci ty: 20t Span: 13.3m Facility: Premix Storage facility









Rail




Total Cost

ANNEXURE-C6


Cane Sl No.6 Capaci ty: 20t Span: 11.2m Facility: 2.5t Mixer facility









Rail




Total Cost

ANNEXURE-C7


Cane Sl No.7 Capaci ty: 30t Span: 18.1m Facility: Insulation Machining facility









Rail




Total Cost

ANNEXURE-C8


Cane Sl No.8 Capaci ty: 25t Span: 21.3m Facility: Hardware Preparation facility









Rail




Total Cost

ANNEXURE-C9


Cane Sl No.9 Capaci ty: 25t Span: 15.3m Facility: Hardware Preparation facility









Rail




Total Cost

Annexure - D

PRICE BID FORMAT FOR SPARES

Sl. No Item Description Capacity Qty Amount (Rs.)

1.

Main Hoist EHT Brake Thruster (Imported Thruster)

30t (FLP) 1

2. 30t (Non FLP) 1

3. 25t (FLP) 1

4. 25t(NFLP) 1

5. 20t (FLP) 1

6.

LT EHT Brake Thruster

30t (FLP) 1

7. 30t (Non FLP) 1

8. 25t (FLP) 1

9. 25t(NFLP) 1

10. 20t (FLP) 1

11.

CT EHT Brake Thruster

30t (FLP) 1

12. 30t (Non FLP) 1

13. 25t (FLP) 1

14. 25t(NFLP) 1

15. 20t (FLP) 1

16.

Rotary Limit Switch

30t (FLP) 1

17. 30t (Non FLP) 1

18. 25t (FLP) 1

19. 25t(NFLP) 1

20. 20t (FLP) 1

21.

MPCB for Main Hoist Brake

30t (FLP) 1

22. 30t (Non FLP) 1

23. 25t (FLP) 1

24. 25t(NFLP) 1

25. 20t (FLP) 1

26.

MPCB for LT Brake

30t (FLP) 1

27. 30t (Non FLP) 1

28. 25t (FLP) 1

29. 25t(NFLP) 1

30. 20t (FLP) 1

31.

MPCB for CT Brake

30t (FLP) 1

32. 30t (Non FLP) 1

33. 25t (FLP) 1

34. 25t(NFLP) 1

35. 20t (FLP) 1

36 GST for above spares

37 Total Cost

S a t i sh Dhawan Spac e Cen t e r SHAR S a t i sh Dhawan Spac e Cen t e r SHAR S a t i sh Dhawan Spac e Cen t e r SHAR S a t i sh Dhawan Spac e Cen t e r SHAR

Welcome, Materials Master (isro)31 August 2017,

17:16:08 IST

MAIN VIEW HELP

Preview For STANDARD TERMS AND CONDITIONS

Page Destination: Tender Header Format Type : Normal

. :

GOVERNMENT OF INDIA

DEPARTMENT OF SPACE

SATISH DHAWAN SPACE CENTRE

PURCHASE DIVISION

Tele No.08623-225023/225174/225127 Fax No.08623-225170/22-5028 e-Mail ID : [email protected], [email protected], [email protected]

STANDARD TERMS & CONDITIONS

1.OFFERS SHALL BE SENT ONLINE ONLY USING STANDARD DIGITAL SIGNATURE CERTIFICATE OF CLASS III WITH ENCRYPTION / DECRYPTION. THE TENDERS AUTHORISED ONLINE ON OR BEFORE THE OPEN AUTHORISATION DATE AND TIME ONLY WILL BE CONSIDERED AS VALID TENDERS EVEN THOUGH THE BIDS ARE SUBMITTED ONLINE.

2.THE TENDERER MUST AUTHORISE BID OPENING WITHIN THE TIME STIPULATED IN THE SCHEDULE BY SDSC SHAR. OTHERWISE THE ONLINE BID SUBMITTED WILL NOT BE CONSIDERED FOR EVALUATION. PHYSICAL COPY WILL NOT BE CONSIDERED EVEN THOUGH IT IS RECEIVED BEFORE THE BID SUBMISSION DATE. In case of two-part tenders, parties shall submit their offers as follows:-

1) Part-I – Techno-commercial Bid (No price details shall be mentioned in this bid and shall not upload the details of price along with the techno-commercial bid) 2) Part-II – Price Bid

In view of Two Part Tender, the Offers submitted contrary to above instructions will be summarily rejected. 3.In case, the tenderer is not interested to participate in the tender, the tenderer shall submit regret letter giving reasons, failing which future enquiries will not be sent. 4.Offer Validity: The validity of the offers / tenders should be 90 days (in case of single part tender) and 120 days (in case two part

tender) from the date of opening of the tenders. Tenders with offer validity less than the period mentioned above, will not be considered for evaluation. 5.GST - GST and/or other duties/levies legally leviable and intended to be claimed should be distinctly shown separately in the tender. GST details are given below

GSTIN: 37AAAGS1366J1Z1 LEGAL NAME : SATISH DHAWAN SPACE CENTRE SHAR VALIDITY FROM:29/08/2017

TYPE OF REGISTRATION:REGULAR 6.Customs Duty - SDSC-SHAR is eligible for 100% Customs Duty exemption as per Notification No. 050/2017 539 (b) Dt: 30.06.2017.

This may be taken into account while quoting for import items, if any. In case tenderers offering items considering customs duty exemption, they should also indicate the bill of materials and price, separately, with Customs Duty component and terms and conditions thereto. 8.Advance Payment - Wherever advance payment is requested, Bank Guarantee from any Nationalized Bank/Scheduled Bank should be

furnished. In case of advance payments, if the party is not supplying the material within the delivery schedule, interest will be levied as per the Prime Lending Rate of RBI plus 2% penal interest. Interest will be loaded for advance payments/stage payments as per the prime lending rate of RBI and will be added to the landed cost for comparison purpose. In case of different milestone payments submitted by the parties, a standard and transparent methodology like NPV will be adopted for evaluating the offers.

9.Liquidated Damages - In all cases, delivery schedule indicated in the Purchase Order/Contract is the essence of the contract and if the party fails to deliver the material within the delivery schedule, Liquidated Damages will be levied @ 0.5% per week or part thereof subject to a maximum of 10% of total order value. 10.Performance Bank Guarantee - Performance Bank Guarantee for 10% of the order value should be furnished in the form of Bank

Guarantee from nationalized/scheduled bank or by Demand Draft valid till warranty period plus sixty days as claim period.

Page 1 of 3

11.Security Deposit – Security Deposit for 10% of the order value is mandatory, if the ordered value is Rs.5.00 lakhs and above. Party shall furnish the Security Deposit in the form of Bank Guarantee from nationalized/scheduled bank or by Demand Draft valid till

completion of the contract period plus sixty days towards claim period for faithful execution of the contract. 12.BANK GUARANTEE FOR FIM: Supplier has to submit Bank guarantee for equal value of Free Issue of Materials (FIM) issued by the Department from Nationalised / Scheduled Bank valid till receipt and acceptance of supply and satisfactory accounting of FIM plus sixty days as claim period.

13.The delivery period mentioned in the tender enquiry, IF ANY, is with the stipulation that no credit will be given for earlier deliveries and offers with delivery beyond the period will be treated as unresponsive. 14.The Department will have the option to consider more than one source of supply and final orders will be given accordingly.

15.The bidders should note that conditional discounts would not have edge in the evaluation process of tenders. 16.Non-acceptance of any conditions wherever called for related to Guarantee/ Warranty, Performance Bank Guarantee, Security Deposit, Liquidated damages are liable for disqualification. 17.Wherever installation/ commissioning involved, the guarantee/warrantee period shall reckon only from the date of installation and

commissioning. 18.Purchase/Price Preference will be extended to the MSMEs under the Public Procurement Policy for MSMEs formulated under the Micro, Small and Medium Enterprises Development Act, 2006 and instructions issued by Government of India from time to time. Vendors who would like to avail the benefit of MSME should clearly mention the same and submit all the documentary evidences to substantiate their claim along with tender itself.

19.The drawings, specifications, end use etc., given by the Centre/Unit along with the tender enquiry are confidential and shall not be disclosed to any third party. 20.SPECIAL CONDITIONS FOR SUBMITTING QUOTATIONS IN FOREIGN CURRENCY BY THE INDIAN AGENTS

The Tenderer should submit the following documents/information while quoting:- a)Foreign Principal's proforma invoice/quote indicating the commission payable to the Indian Agent and nature of after sales service to be rendered by the Indian Agent. b)Copy of Agency agreement with the Foreign Principal and the Indian Agent, precise relationship between them and their mutual

interest in the business. c)Registration and item empanelment of the Indian Agent. d)Agency Commission will be paid only Indian Currency.

e)Compliance of the tax laws by the Indian Agent. 21. High Sea Sales- Against High Sea Sale transactions: a.Offers shall be on all inclusive basis including delivery upto Sriharikota at the risk and cost of the supplier. Customs Clearance is the responsibility of the supplier and at his cost and risk.

b.100% payment will be made within 30 days after receipt and acceptance of the items at our site. c. GST as applicable d.Customs Duty Exemption Certificate and other relevant documents required for Customs clearance will be provided.

e.High Sea Sales Agreement furnished by the supplier in accordance with the terms and conditions of our purchase order will be signed and issued by SDSC-SHAR. 22.The following information/ documents are to be submitted wherever applicable.

1.Product Literature 2.Core banking account number of SBI, RTGS Details 3.PAN No. in quotation and invoices

4.GST Registration details. 5.In case of MSME, registration details / documents from Competent Authority. 23.EXCLUSION OF TENDERS

The following tenders shall be summarily rejected from the procurement process a.Tenders received from vendors who have not qualified in terms of their registration. b.Tenders received against publishing of a limited tender in the CPP portal.

c.Tenders of vendors who have been removed from the vendor list or banned/debarred from having business dealings. d.Unsolicited tenders from vendors. e.The tenders which materially depart from the requirements specified in the tender document or which contain false information.

f.The tenders which are not accompanied by the prescribed Earnest Money Deposit. g.The tenders of vendors who have not agreed to furnish Security Deposit, Performance Bank Guarantee and Liquidated Damages. h.The validity of the tenders is shorter than the period specified in the tender enquiry.

i.The tenders received from vendors or their agents or anyone acting on their behalf, who have promised or given to any official of the Centre/Unit/Department, a gratification in any form, or anything of value, so as to unduly influence the procurement process. j.The tenders received from vendors, who, in the opinion of the Centre/Unit, have a conflict of interest materially affecting fair competition.

Page 2 of 3

k.The tenders received from Indian agents on behalf of their foreign Principals/OEMs (in cases where the Principals/OEMs also submit their tenders simultaneously for the same item/product in the same tender).

l.In case two or more tenders are received from an Indian agent on behalf of more than one foreign Principal/OEM, in the same tender for the same item/product. m.If a firm quotes ‘NIL’ charges / consideration, the bid shall be treated as un-responsive and will not be considered.

Page 3 of 3

Documents

भारत सरकार Government of India ... · Fire Protection system for the Vertical Mixer 1 Lot 07 SHAR SP 2018 00 8023 e-procurement ... DBR Location VVVF Drive panels,