ANNEXURE - I - ISRO · Galvanized,6x36,RHO, IWRC, Usha Martin- Make , Tensile strength Min 1960Mpa b) Factor of safety 8.0 . 23 Brakes (EHT) The torque capacity of brakes shall be

ANNEXURE - I

SCOPE OF WORK

� Design, manufacture, supply, erection, testing and commissioning of 04 no’s of EOT Cranes:

Sl No.1: 60t Flame proof DG Top running with VVVF Dual Drive EOT Crane - 01 No

Sl No.2: 60/10t Flame proof DG Top running with VVVF Dual Drive EOT Crane - 01 No

Sl No.3: 60/10t Flame proof DG Top running with VVVF Dual Drive EOT Crane - 01 No

Sl No.4: 60t Flame proof DG Top running with VVVF Dual Drive 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

� Main parameters are enclosed in Annexure – IIA, IIB, IIC & IID.

� Power cable length of each crane shall be considered as per layout mentioned in the annexures-III-A, III-B, III-C & III-D.

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

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

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

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

� 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.

� Key plan of facility enclosed in the Annexure – XI A, XI B, XI C for party reference.

ANNEXURE – II A

Crane Sl No. 01: 60t Flame proof EOT Crane with VVVF Dual Drive:

MAIN PARAMETERS

Sl. No

Description Specification

01 Safe Working Load (t) 60 ton,

02 Type 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. 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 (Propellant/Inhibition Machining 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 17000 mm (Distance between Centre of LT Rails)

09 Height of lift for MH 10000mm

10 Bay length

31000 mm

11

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

4000mm

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

11000 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 0.6m/min through VVVF Drive

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 2000 Left

Not Exceeding 1500 Right

(Left and Right with respective LT Drive)

18 Hook approach clearance (LT)

Not exceeding 3250mm Non Drive End

Not exceeding 3750mm 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.

22 a)Wire rope

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

Min 1960Mpa

b) Factor of safety 8.0

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 motions. The rating of the motor shall be 20% excess of the capacity calculated as per IS: 3177. 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., towards compatibility with VFD to be considered.

29 Limit switches Limit switches Gravity (for up) & Rotary Type (for up& down) for hoist system and two way lever type (1 no) each for LT & CT operations.

30 Power supply 415 Volts, 50 Hz, 3 Phase supply.

31 Control supply Contactor circuit 110 V, AC

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

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

34 Cross Travel cable arrangement

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

35 Power feed arrangement for the hoist

PVC sheathed, flexible cables with multi strand copper conductors cable chain drag system of IGUS make only.

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

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

38 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.

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

Crane Sl No. 02: 60/10t Flame proof EOT Crane with VVVF Dual Drive:

MAIN PARAMETERS

Sl. No


01 Safe Working Load (t) 60/10 ton,

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

03 Duty


04 Location Indoor (Inhibition & Tilting facility)




08 Span 17000 mm (Distance between Centre of LT Rails.)


Height of lift for AH 10000mm

10 Bay length 38000 mm

11


4000mm

12 Distance from floor to top of the rail

11000 mm


500 mm

14 Operating Hoist main

2.5 m/min

speed(m/min) Aux Hoist main

5.0 m/min

LT

main 6.0m/min

CT

main

6.0m/min

15

Operating

speed(m/min)


Hoist micro


Aux Hoist Micro


LT micro


CT












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



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

Min 1960Mpa


23 Brakes (EHT)





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 C

Crane Sl No. 03: 60/10t Flame proof EOT Crane with VVVF Dual Drive:

MAIN PARAMETERS

Sl. No


01 Safe Working Load (t) 60/10 ton,

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

03 Duty


04 Location Indoor (Inhibition facility)




08 Span 14000 mm (Distance between Centre of LT Rails.)


Height of lift for AH 10000mm


11


4000mm

12 Distance from Floor level to top of the rail

11000 mm


500 mm

14 Operating

speed(m/min)

Hoist main

2.5 m/min

Aux Hoist

5.0 m/min

main

LT

main 6.0m/min

CT

main

6.0m/min

15

Operating

speed(m/min)


Hoist micro


Aux Hoist Micro


LT micro


CT















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

Min 1960Mpa


23 Brakes (EHT)





26 Gear box




28 Motor





32 Pendent Control









38 Painting


39 Other points




ANNEXURE – II D

Crane Sl No. 04: 60t Flame proof EOT Crane with VVVF Dual Drive:

MAIN PARAMETERS

Sl. No


01 Safe Working Load (t) 60 ton,

02 Type Flame proof Double girder VVVF Dual Drive EOT crane

03 Duty


04 Location Indoor (NDT facility)




08 Span 20250 mm (Distance between Centre of LT Rails.



11


4000mm

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

10200 mm


500 mm

14 Operating

speed(m/min)

Hoist main

2.5 m/min

LT

main 6.0m/min

CT

main

6.0m/min

15

Operating

speed(m/min)


Hoist micro


LT micro


CT













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)


2Nos of Imported brakes for main hoist and 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 - IV

LIST OF MANUFACTURERS / SPECIFIC BRANDS FOR BOUGHTOUT ITEMS.

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 Glands, Junction Boxes etc., 4. Power & control cables. : IGUS make for cables used in cable drag chain system. Incab/ cable corpn of India, Universal/ Asian/ Finolex/ Polycab/ Lapp/ RPG/ HAVELLS – Pendent/ fixed power & control cables. 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 – 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) Dia

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

CODES AND STANDARDS:

The design, manufacture and testing of the 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: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 : 1980 Specification 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 - VII

General & Technical Specifications

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 in side 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 form 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 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.

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, 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. 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.

01. 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.

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. 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.

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 ii) Intrinsically safe circuit : Pendent and limit switch interfacing.

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 make. The cables used in Drag chain system shall be of IGUS make only suitable to Drag chain applications party shall submit cable schedules & Drag chain selection criteria for approval by SDSC SHAR.

06. MOTORS

All crane motors shall be Flameproof (Ex-d, Temp classification T4) squirrel cage induction motors. Motors shall have S4 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 (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., specific to operation by VFD. Double side shaft to mount encoders.

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 S4 as per IS 325. All motors shall be suitable for Operation with VFD (Inverter Duty)

07. 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.

08. 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).

09.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, etc., in Drive panel and power, 4 auxiliary contactors, MPCB, MCCB etc., shall be provided in adjacent service room where non flame proof equipments are permissible. The panels shall be of Rital make or OEM make or Siemens system home with approved 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 complying requirements suitable for hazardous area classificationzone, GasGroup 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.

10. CIRCUIT PROTECTIVE SWITCHGEAR

One triple pole TPNSFU with HRC fuses/Fuse less feeder like MCCB, rated to carry at least

combined full load currents of the two motions on the crane having largest power (KW). There shall be alarm Indication arrangement and trip arrangement where motor surface temperature 1300 C & 1350 C respectively through dedicated thermistor relay.

11. 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.

12. 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.

13. 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.

14. 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.

15. 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.

16. EARTHING;

The fourth conductor of down shop leads shall be earthen at both ends and serves as the

earthing lead to the crane. The crane structure shall be made continuous by providing jumpers over riveted or bolted joints and the structure is earthed through the fourth set of main collectors and earth lead. All electrical equipment mounted on crane shall be connected to the crane structure by means of earthing links.

Flexible cables shall have a separate earth core serving as earth lead for satisfactory earth

connection of equipments. Additional earthing shall be provided for earthing the crane track rail independently to the ground. Along with cable an additional wire braided flexible copper strip of 12mm wide shall be run as a special earthing from the power source given by purchaser up to the main protective switch gear.

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.

SPECIFICATIONS OF VVVF DRIVE

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 at least equal to the 1. 5 times the motor rated current.

3 Basic Design Particulars

IGBT based Vector controller closed loop encoder feedback for Hoist, CT & LT without encoder feedback.

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

5 Speed Requirement

a) The hoisting and travel drives shall be provided with VVF 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 Micro 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 micro speed. The speed control Logic to be executed with four digital inputs.

6 Ambient Temperature

The ambient temperature shall be considered on minimum 50 C

7 Crane Software

1. Motor and Brake Torque Proving: 1.1 Precise coordination between motor and brake to extend brake life and lower maintenance costs. 1.2 The drive shall completely control motor torque, and 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. 2.2 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 emergency stop. Further movement in hoist direction is prevented. 3. Keypad Security Lockout: To Prevent unauthorized modification of drive controller data.

8 Communication

Drive shall have following minimum features: RS 232 / RS 485 Modbus / Profibus/ Prolinet/ ethernet.

9 System I/O

1.Digital inputs. 2.Digital outputs. 3.Relay O/P (programmable). 4.I/O are required as per logic requirement.

10

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. B) The cabinet shall be 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 Procedure: Powder Coating after seven tank process. I) Control Wiring: 2.5 Sq.mm Flexible Copper Wire, 1.0 Sq.mm Flexible Copper wire for VFD. J) Power Wiring: Min 4Sq.mm Flexible Copper Wire.

K) Main Plate Name Plate & Component label: Acyrilic Engrave with Black Back ground and White Lettering. L) Shrouding: Acyrilic Shrouding 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) Panel Make: RITTAL or OEM make or Siemens system house with approval of SDSC SHAR.

11 Choke or Filter

1. AC input choke of suitable rating shall be provided to limit THD as per IEEE 519 & also THD at the motor terminal should be limited to 5%. 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 at 95 deg C. v)Insulation class H Vi) Insulation resistance between winding to core more than 100 M Ohms.

12 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. (04 No’s) with AOP.

13 Dynamic Braking

1. VFD shall be offered with dynamic braking function, a built in dynamic braking module consisting of power electronic switch (IGBT) and discharge/ braking resistor shall be provided. External DBU not accepted. 2. The braking resistor of a hoisting drive shall be selected considering the possible lowering height of the load being lowered at the maximum speed with full load. 3. The sizing of the braking resistor shall take into consideration the regenerative energy due to overhauling load and the lowering time 4. 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.

14 Dynamic braking Resistors Panel

1. Necessary calculations to be submitted before choosing of DBR rating. 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. 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 resistor is +/- 10%.

15 Compliance

1. VFD shall comply IEC-61800 standards towards VFD functional Safety and Electromagnetic compatibility. 2. VFD shall be provided with safety listing mark from UL.

16 Redundancy features

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

Documents

ANNEXURE - I - ISRO · Galvanized,6x36,RHO, IWRC, Usha Martin- Make , Tensile strength Min 1960Mpa b) Factor of safety 8.0 . 23 Brakes (EHT) The torque capacity of brakes shall be