ANNEXURE T0 INDENT NO. : SHAR/VAST/2014001915 REQUEST … · CIPET road, Thiru-vi-ka Industrial Estate Guindy, Chennai-600032 ... Latest income tax certificate. (r) Latest solvency

SPEC.NO. TATA CONSULTING ENGINEERS LIMITED SECTION: TITLE TCE:7517A-D-EOC-003

450/60 t CAPACITY EOT CRANE FOR SVAB SHEET OF 1

1

ISSUE R0

ANNEXURE T0 INDENT NO. : SHAR/VAST/2014001915

REQUEST FOR PROPOSAL (RFP).

FOR

DESIGN, MANUFACTURE, SUPPLY, ERECTION, TESTING & COMMISIONING OF

450/60 t CAPACITY EOT CRANE FOR SVAB

SPECIFICATIONS & PRICE SCHEDULE OWNER : INDIAN SPACE RESEARCH ORGANISATION PROJECT : SECOND VEHICLE ASSEMBLY BUILDING LOCATION : SDSC-SHAR, SRIHARIKOTA

Specification Prepared by:

6TH Floor, SKCL Central Square-1, No: C28-C35 CIPET road, Thiru-vi-ka Industrial Estate

Guindy, Chennai-600032

SECOND VEHICLE ASSEMBLY BUILDING

SATISH DHAWAN SPACE CENTRE SRIHARIKOTA -524124.

INDIAN SPACE RESEARCH ORGANISATION

SPEC.NO. TATA CONSULTING ENGINEERS LIMITED SECTION: CONTENTS

TCE:7517A-D-EOC-003 450/60 t CAPACITY EOT CRANE FOR SVAB CONTENTS

SHEET : 1 OF 1

REQUEST FOR PROPOSAL FOR 450/60 t CAPACITY EOT CRANE SPECIFICATIONS & ANNEXURES

SEC-TION

SPECIFICATION NO: TCE:7517A-D-EOC-003

ISSUE NO.

TITLE: REQUEST FOR PROPOSAL FOR 450/60 T CAPACITY EOT CRANE

SPECIFICATIONS

A SVAB/CRANE/SPEC R0 GENERAL SPECIFICATION

B SVAB/CRANE/SPEC R0 TECHNICAL SPECIFICATION

C SVAB/CRANE/SPEC R0 450 T HOIST DRIVE CONFIGURATION

D SVAB/CRANE/SPEC R0 QUALITY ASSURANCE PLAN

E SVAB/CRANE/SPEC RO HOOK APPROACHES

ANNEXURES

F1 SVAB/CRANE/SPEC R0 SCHEDULE OF PRICES

F2 SVAB/CRANE/SPEC R0 PREQUALIFICATION CRITERIA

F3 SVAB/CRANE/SPEC

R0 SCHEDULE OF GENERAL PARTICULARS / VENDOR EVALUATION FORMAT

F4 SVAB/CRANE/SPEC R0 DATA TO BE FILLED

F5 SVAB/CRANE/SPEC R0 SCHEDULE OF DEVIATIONS FROM SPECIFICATIONS

F6 SVAB/CRANE/SPEC

R0 SCHEDULE OF TIME FOR MANUFACTURE, DESPATCH AND SHIPMENT TO SITE.

F7 SVAB/CRANE/SPEC

R0 SCHEDULE OF BIDDERS EXPERIENCE & DETAILS OF PRESENT WORKS BEING EXECUTED.

F8 SVAB/CRANE/SPEC R0 CHECK LIST

SPEC.NO. TATA CONSULTING ENGINEERS LIMITED SECTION: A

TCE 7517A-D-EOC-003 REQUEST FOR PROPOSAL

GENERAL SPECIFICATION 450 / 60 t CAPACITY EOT CRANE FOR SVAB

SHEET : 1 OF 31

SECTION -A

GENERAL TERMS AND CONDITIONS OF THE CONTRACT




SHEET : 2 OF 31

PROPOSAL DOCUMENT, CLARIFICATION AND ADDENDUM

Quotations are invited from the interested bidders for the enclosed scope of work in

two part bid. Part-1 technical & unpriced part of the work and Part-2 Priced

commercial part.

Only experienced Bidders who are qualifying in bid -qualification criteria given

in Section F2 only should quote .

The RFP document is organized in six sections as follows.

Section –A General Specification, Terms and Conditions of the Contract

Section –B Scope of Work & Technical Specifications

Section –C 450 t Main hoist drive configuration.

Section –D Quality Assurance Plan

Section- E Hook approaches

Section-F Annexures.

Title of the proposal: “Design, Manufacture, Supply, Erection, Testing and

Commissioning of 450/60 t capacity EOT crane for SVAB”

Date Public Notification issued by ISRO: DD/MM/YYYY

Last Date of downloading tender Document by tendere r: DD/MM/YYYY

Last date of submission of tender documents in onli ne by tenderer:

DD/MM/YYYY

Last date of Bid sealing in online by ISRO: DD/MM/YYYY

Last date for giving open authorisation in online b y tenderer: DD/MM/YYYY

A PROPOSAL DOCUMENT

1.1. Bidder shall sign & stamp each page of the tender document (RFP) as token

of his acceptance and submit the same along with his offer.

1.2. Proposal documents shall remain the property of SDSC SHAR and shall not

be used for any another purpose without the consent of SDSC SHAR.

1.3. The proposal shall be completely filled in all respects and shall be tendered




SHEET : 3 OF 31

together with requisite information & Annexure. Any offer incomplete in any

particulars is liable to be rejected.

1.4. The Proposal (Unpriced Techno-commercial bid) with a complete set of the

required documents shall be up-loaded in ISRO e-procurement website.

1.5. The Proposals shall be submitted on-line before the time limit for bid

submission specified in the Letter Inviting Bid.

1.6. Supplier shall submit the open authorisation on line with in the time limit

specified in the Letter Inviting bid.

1.7. The Proposal will be opened on the date and on the time specified in the

Letter Inviting Bid or as soon thereafter as convenient. Proposal not received

in time will not be considered.

1.8. Bidders shall set their quotations in firm figures and without

variations/additions in the terms of the Proposal documents.

1.9. AMBIGUITY

Should there be any ambiguity or doubt as to the meaning of any of the

tender clause/condition or if any further information is required, the matter

shall be immediately brought to the notice of Head, Purchase & Stores of

SDSC SHAR in writing

B. PREPARATION OF BIDS

1.1 SITE VISIT

Bidder is advised to visit & examine the site and its surrounding to familiarize

himself of the existing facilities & environment and shall collect all other

information which may require for preparing & submitting the Bid and entering

into the contract. Claims and objections due to ignorance of existing conditions

or inadequacy of information will not be considered after submission of the Bid

and during implementation.

1.2 VALIDITY OF OFFER

Bid shall remain valid for acceptance for a minimum period of 4 (four) months

from the due date of submission of the Bid. The Bidder shall not be entitled




SHEET : 4 OF 31

during the said period to revoke or revise his Bid or to vary the Bid except and to

the extent required by SDSC SHAR in writing. Bid shall be revalidated for

extended period as required by SDSC SHAR 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 & conditions of Bid finalized till

that time.

1.3 COST OF BIDDING

All direct and indirect costs associated with the preparation and submission of

bid shall be to Bidder's account and SDSC SHAR will in no case be responsible

or liable for those costs, regardless of the conduct or outcome of the bid

process.

1.4 APPLICABLE LANGUAGE/ MEASUREMENTS

The bid and all correspondence incidental 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.

All the measurements shall be given in metric system.

1.5 ARRANGEMENT OF BID

The Bid shall be neatly presented on white paper with consecutively numbered

pages. It should 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 authorised

to enter into agreement on behalf of the Bidder. (Corrections / alteration, if any,

shall also be signed by the same person).

1.6 SCHEDULE OF PRICES

The schedule of prices shall be read in conjunction with all the sections of

proposal document. The price must be filled online in the same format of

‘Schedule of Prices’ in Section F1. No copy of price bid shall be enclosed along

with other document and upload the same any where in the e-procurement

portal.




SHEET : 5 OF 31

1.7 DOCUMENTS COMPRISING THE BID

Bids shall be arranged in the following order.

1.7.1 Part – I : Technical and Unpriced Commercial Part

Technical and unpriced commercial part shall comprise the attachments,

specifying attachment number arranged in the order as follows:

(a) Submission of bid letter.

(b) Demand draft of Rs: 1 lakh as Earnest money Deposit (EMD).

(c) Demand draft for tender fee

(d) Power of attorney in favour of authorised signatory of the bid /

proposal documents.

(e) All the annexure in Section-F1 to F8 enclosed in proposal duly filled,

signed and sealed

(f) Bid qualification criteria for supply of 450t / 60 t capacity EOT crane

and all supporting documents.

(g) General arrangement drawings of 450t / 60 t capacity EOT crane

along with main hook approach.

(h) Write-up on the procedure proposed to be followed for erection of 450

/60 EOT crane.

(i) Drawing for interfaces required for connecting pulleys system to roof

top / roof truss for erection of Crane girder / rope drum etc.

(j) Assembly shop layout drawings where control assembly of crane is

planned.

(k) Fabrication shop layout where fabrication of Girder is planned.

(l) Furnace details for stress relieving for main girder.

(m) Details of turning machines for machining rope drum of Ø3m or

greater.

(n) Details of health monitoring system proposed for gear boxes in

hoisting drives.




SHEET : 6 OF 31

(o) Unpriced copy of schedule of prices with all other commercial terms,

taxes, duties, exemption certificates and conditions duly filled (Prices

to be kept blank), signed and stamped.

(p) Audited balance sheet including profit and loss account for last three

financial years showing annual turn over

(q) Latest income tax certificate.

(r) Latest solvency certificate from a scheduled bank.

(s) Description of the procedures adapted for material procurement,

fabrication & control assembly with deviations from technical

specification and proposed design modifications.

(t) Data sheets for all the equipment & checklists enclosed in proposal

duly filled, signed & stamped.

(u) Technical literature & data sheets of equipment / machinery used by

him and any other document as mentioned in the proposal.

(v) Project execution plan

(w) Bar chart for supply & erection schedule indicating the date of

completion of various activities so as to complete the execution of the

contract within the time frame stipulated in the tender specification.

(x) List of items which require Customs duty exemption certificate from

SDSC-SHAR.

(y) List of items which require Excise duty exemption certificate form

SDSC-SHAR.

(z) List of recommended spares including unit prices.

(aa) Any other relevant document, bidder desires to submit.

1.7.2 Part – II : Priced Commercial Bid

Priced commercial bid shall be filled on line in the price bid format. Schedule of

prices also to be filled in the online format and no separate document shall be

attached. Deviations in terms and conditions, assumptions, conditions, discounts

etc. shall be stipulated in format specified in the portal. SDSC SHAR will not take




SHEET : 7 OF 31

cognizance of any such statement and may at their discretion reject such bids.

C. BID SUBMISSION

Bids duly filled in by the Bidder should invariably be submitted as stipulated in

the Letter inviting bid. Bids shall be submitted in the following manner.

1.1 PART – I : UN PRICED TECHNO-COMMERCIAL PART OF THE BID FOR THE WORK

2 Complete Techno–commercial part of the bid shall be filled online in the

“vendor Specified Terms’ form of the e-tender. Any documents related

(demand draft for tender fee & EMD ), technical literature, guarantee /

warrantee certificates and any other relevant documents as per the tender

shall be scanned in lower resolution format and uploaded to the e-tender

under ‘Documents solicited from Vendor’ form only in ISRO e-procurement

portal ( https://eprocure.isro.gov.in ). In case if the space for uploading is

not sufficient, hard copy of the balance documents shall be submitted before

due date.

Envelope of technical bid shall be marked with following:

PART-I TECHNO-COMMERCIAL BID

Name of client : Satish Dhawan Space Centre SHAR

Indian Space Research Organisation

Title of the proposal : “Design, Supply, Erection, Testing and

Commissioning of 450/60 t capacity

EOT crane for SVAB”

Due date and time of the opening : DD/MM/YYY

From (Name of the bidder with

address)

:




SHEET : 8 OF 31

To: Head, Purchase & Stores Satish Dhawan Space Centre SHAR ISRO, Dept. of Space Govt. of India Sriharikota – 524124, SPSR Nellore Dist, Andhra Pradesh, India

The deviation statement and checklist shall be filled online, without which the

bid will not be considered.

2.1 PART – II : PRICE PART OF THE BID FOR THE WORK

Price bid shall be filled in the on-line ‘price bid’ form of the e-tender only in ISRO e-

procurement website https://eprocure.isro.gov.in . The cost of spares and

other prices shall be filled in the respective forms available on-line in the e-

portal. Any other terms and conditions given in this part shall not be considered and

if insisted upon by the Bidder, bids are liable for rejection.

a) SDSC SHAR may open Part – I of the bid on the due date of opening subject to

meeting the minimum evaluation criteria. Price Bids (Part-II) of technically and

commercially acceptable offers shall be opened at a later date.

b) SDSC SHAR reserves the right to reject any or all the Bids without assigning any

reasons thereof.

c) Any bids/offers with price details in Techno-Commer cial Offer (Part –I)

shall be rejected.

d) SDSC SHAR reserve rights to place order for either full quantities of all items or

partial quantities and partial items based on the unit rates available.

D. Vendor Evaluation Format

SDSC SHAR seeks response to the given questionnaire for assimilating data

which would be used for evaluating the capability of the supplier for executing the

referred work. Hence, the supplier is requested to provide only genuine data and

any discrepancy found at a later point of time may result in rejection of the

supplier from purchase process. Furnishing of data cannot be construed as

automatic qualification for participation in the tender. Questionnaire should be

signed by a responsible and authorized person of the Company / Agency.




SHEET : 9 OF 31

Schedule of general particulars / vendor evaluation format shall be filled as per

Section: F3. Schedule of Bidders experience and details of present works being

executed are to be filled as per Section :F7.

Note: In order to consider as valid experience, all the experience has to be supported with the technical details, completion certificate and purchase order.

E. DETERMINATION OF RESPONSIVENESS

SDSC SHAR will scrutinize tenders to determine whether the tender is

substantially responsive to the requirements of the tender documents. For the

purpose of this clause, a substantially responsive tender 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 SDSC SHAR shall be final in this

regard.

F. EARNEST MONEY DEPOSIT

2.2 The tenderer shall remit Rs. 1 Lakh as Earnest Money Deposit (EMD) in the

form of demand draft (DD) with the tender, failing which the tender will not be

considered.

2.3 The EMD shall be remitted by a DD from any Nationalized Bank in favour of

ACOOUNTS OFFICER Satish Dhawan Space Centre SHAR, Payable at SBI,

Sriharikota.

2.4 Cheque will not be accepted towards EMD.

2.5 EMD by the unsuccessful tenderer will be refunded after the finalization of

tender. EMD shall not bear any interest.

2.6 EMD of the successful tenderer will be refunded after receipt of Performance

Security.

2.7 DD Number and other reference details shall be filled on-line, and the original

DD shall be sent to Head, Purchase & Stores, Satish Dhawan Space Centre

SHAR, ISRO, Dept. of Space, Govt. of India,Sriharikota – 524124, before the

tender due date.




SHEET : 10 OF 31

G BID EVALUATION 2.1 During evaluation, SDSC SHAR may request Bidder for any clarification on the

bid OR additional documents.

2.2 Techno-commercial discussion shall be arranged with Bidder, if needed. Bidder

shall depute his authorised representatives for attending discussions. The

representatives attending the discussions shall produce authorisation from his

organisation to attend the discussion and sign minutes of meeting on behalf of

his organisation if required. The authorised representative must be competent

and empowered to settle/decide on all technical and commercial issues.

2.3 Bidder must provide the point by point compliance to the technical

specifications along with deviations as per “ Schedule of deviations” attached

in section F5. The tender will be rejected, if the deviations are not acceptable to

the Department.

2.4 Performance of Bidder on similar nature of works executed/ under execution

shall be taken into consideration before selecting the Bidder for opening his

price bid.

2.5 The time schedule for completion is given in the Proposal document. Bidder is

required to confirm the completion period unconditionally.

2.6 If necessary, to arrive at evaluated prices, wherever applicable, loading on total

quoted prices shall be done.

2.7 SDSC SHAR reserves the right to accept a bid other than a lowest and to

accept or reject any bid in full or part without assigning any reasons. Such

decisions by SDSC SHAR shall bear no liability whatsoever consequent upon

such decision.

2.8 SDSC SHAR reserves the right to split the order or alter the quantities

specified based on prices quoted for part work or unit rate quoted by BIDDER.

2.9 The Bidder, whose bid is accepted by SDSC SHAR, shall be issued a Letter of

Intent (LOI) /Purchase Order (PO) to proceed with the work. Bidder shall

confirm acceptance by returning a signed copy of the LOI/PO.




SHEET : 11 OF 31

SECTION-A.1

GENERAL SPECIFICATION




SHEET : 12 OF 31

1.0 INTRODUCTION

SDSC SHAR invites tenders in sealed covers from reputed firms with proven ability

to “ Design, Manufacture, Supply, Erection, Testing and Commissioning of

450/60 t capacity EOT crane for SVAB” as per the specifications

2.0 SCOPE OF WORK AND TECHNICAL SPECIFICATIONS

The detailed scope of work and technical specifications are given in Sections B, C,

D, & E of RFP document. The general terms and conditions are given below.

3.0 SUPPLIER's OBLIGATIONS & FUNCTIONS

3.1. SPECIFICATIONS AND DRAWINGS

The Supplier shall execute the works in compliance with the provisions of

CONTRACT, good engineering practices and codes requirements.

3.2. SUBMISSION OF TECHNICAL DOCUMENTS

Supplier shall prepare and submit to SDSC SHAR for approval of following

documents and drawings:

3.2.1. Technical literatures & data sheets of equipment used by him.

3.2.2. Design calculations for the complete crane.

3.2.3. General arrangement drawings of the crane.

3.2.4. Fabrication shop layout for fabricating 37.5 m long girder.

3.2.5. Details of heat treatment / stress relieving equipment

3.2.6. Assembly Shop layout drawings suitable for control assembly of Crane.

3.2.7. Erection sequence schedule along with erection drawings.

3.2.8. No activity shall be executed unless SDSC SHAR’s approval is obtained. The

above documents shall be submitted in a format approved by SDSC SHAR.

3.3. DESIGN, FABRICATION & SUPPLY

Supplier shall carry out detailed engineering, fabrication and supply the Crane in

accordance with the scope, technical specifications and terms & conditions of

contract.




SHEET : 13 OF 31

3.4. DELIVERY AND STORAGE

3.4.1. Dispatch Instructions given in the Contract shall be strictly followed. Failure to

comply with the instructions may result in delay in payment apart from

imposing any other charges as may be deemed to fit.

3.4.2. The Supplier shall be responsible for transporting all the equipment to site,

unloading and storage.

3.4.3. No equipment shall be delivered without obtaining dispatch clearance from

SDSC SHAR.

3.4.4. All the equipment shall be properly packed to avoid any damage during

transportation / handling / storage.

3.4.5. The equipment received at site shall be stored at a place assigned for this

purpose.

3.4.6. Supplier shall take proper care while storing the equipment and shall provide

watch & ward at his own cost.

4.0 INSTALLATION

4.1. GENERAL

4.1.1. Supplier’s staff shall include adequate number of competent erection

engineers with proven experience on similar works to supervise the erection

works and sufficient skilled, unskilled and semiskilled labour to ensure

completion of work in time.

4.1.2. Supplier's erection staff shall arrive at site on date agreed by SDSC SHAR.

Prior to proceeding to work, Supplier shall however, first ensure that

required/sufficient part of his supply has arrived at site.

4.1.3. Erection of equipment may be phased in such a manner so as not to obstruct

the work being done by other Suppliers and / or operating staff who may be

present at that time.

4.1.4. During erection, Department's quality team / their engineer will visit site from

time to time with or without Supplier’s engineer to establish conformity of the

work with specification. Any deviations, deficiencies or evidence of

unsatisfactory workmanship shall be corrected as instructed by Department.




SHEET : 14 OF 31

4.1.5. Supplier shall carry out work in a true professional manner and strictly adhere

to the approved drawings. Any damage caused by Supplier during erection to

new or existing building / environment shall be made good at no extra cost to

Department.

4.2. RECORDS

Supplier shall maintain records pertaining to the quality of erection work in a

format approved by Department. Whenever erection work is complete, Supplier

shall offer erected equipment for inspection to Department's engineer who along

with Supplier's engineer will sign such records on acceptance.

4.3. CRANE ERECTION

4.3.1. Supplier shall carry out the works in accordance with the specific instructions

given on the approved drawings, method statements, manufacturer’s

drawings / documents or as directed by Department. Equipment shall be

erected in neat manner so that they are level, plumb, and square and properly

aligned and oriented. Tolerances shall be as established in manufactures

drawings or as stipulated by Department. No equipment shall be welded or

bolted, until its alignment is checked and found acceptable by Department.

4.3.2. Supplier shall provide all supervision, labour, tools, machines, cranes,

equipments, scaffolding, rigging material and incidental material such as

bolts, wedges, anchors, etc. required to complete the works. Supplier shall

also provide at his own cost all such consumables like oxygen - acetylene

gas, welding rods, grinding wheels, temporary supports, shims etc. required

to complete work.

4.3.3. Supplier shall take utmost care while handling instruments, delicate

equipment, panels etc. and protect all such equipment on erection.

4.4. SAFETY

Supplier shall follow the safety regulations / codes and shall take necessary

measures at his own cost.

4.5. ERECTION & CONSTRUCTION POWER

4.5.1. Electrical power and available material handling equipment may be extended

by SDSC SHAR on chargeable basis, as per the tariff rules of State Electricity




SHEET : 15 OF 31

Board and SDSC SHAR. Reasonable quality of normal Construction power

will be made available at one point (415V, 3 phase, 50 Hz). However onward

distribution shall be by the supplier. Installation of necessary energy meters,

switchgear & distribution system, etc for Construction power in a safe manner

in strict conformity with local rules & regulations will be responsibility of

supplier.

4.5.2. During non-availability of power, supplier shall make his own arrangement of

alternate power source at their cost.

4.6. WORK RULES AT SDSC-SHAR

The work shall be carried out on SDSC-SHAR working days only or permission

to be obtained from the contract manager for late hours / holidays. .

4.7. SITE CLEARANCE

Upon completion of work, supplier shall remove all his equipment and material

from the site within one month or time mutually agreed. Supplier at all times

shall keep site in clean condition and remove all unwanted material at regular

intervals. In case supplier fails to remove all their equipment and material within

the mutually agreed time, it is deemed that SDSC SHAR will arrange to remove

the same at Supplier’s cost.

4.8. ACCOMMODATION

4.8.1. Accommodation will not be provided by SDSC SHAR to Contractors.

4.8.2. Supplier shall make their own arrangement for accommodation,

transportation & canteen facility for all his staff, technicians, labour & workers.

4.9. MEDICAL FACILITIES

No medical facilities will be provided by SDSC SHAR. Supplier shall make their

own arrangement at their own expenses for medical facilities for site personnel.

4.10. WORK PROGRAMME

Supplier shall prepare a detailed programme schedule for review / approval by

SDSC SHAR. Supplier as per exigencies of work shall revise and update

programme periodically.




SHEET : 16 OF 31

4.11. SUB-CONTRACTS

4.11.1. No work shall be sub-contracted with out prior approval of SDSC SHAR.

4.11.2. Supplier shall be responsible for the proper execution of any sub-contract

placed by him in connection with this purchase order.

4.11.3. Supplier shall furnish to SDSC SHAR the copies of all un-priced sub-orders

showing promised delivery dates and places.

4.12. CHANGES AND MODIFICATION TO SPECIFICATIONS, D RAWINGS AND QUALITATIVE / QUANTITATIVE REQUIREMENTS

4.12.1. Supplier shall obtain approval from SDSC SHAR before initiating the action

for procurement of bought out items.

4.12.2. During the fabrication review, supplier has to carryout the mutually agreed

modifications to meet the overall requirement.

5.0 RECORD OF DRAWINGS AND O&M MANUALS

5.1. Supplier shall submit 3 hard copies & one soft copy of all the approved drawings

incorporating any modification / changes made during the execution of

CONTRACT. All these drawings shall be marked as 'As Built'.

5.2. Supplier shall submit 3 hard & one soft copy of O&M manual. These manuals

should indicate weekly, monthly and yearly maintenance schedule and other

instructions necessary for safe maintenance of equipment.

5.3. Submission of the drawings and manuals shall be a precondition for releasing of

any final payment due to Supplier.

6.0 EXCISE DUTY

SDSC-SHAR is eligible for Excise Duty Exemption under Notification No. 64/95

dated 16.03.1995 as amended by Notification No. 15/2007 dated 01.03.2007 and

10/97 with amendments SDSC-SHAR will provide necessary Exemption

Certificate. No claim for payment of Excise Duty or Cenvat reversal will be

allowed later. The supplier has to consider this into account while submitting

quotations.




SHEET : 17 OF 31

7.0 CUSTOMS DUTY

7.1. SDSC-SHAR is eligible for 100% Customs Duty exemption as per Notification

No.12/2012 dated 17.03.2012. This may be taken into account while

considering the import of items.

7.2. The customs duty that becomes payable even against production of customs

duty exemption certificate (limiting to the items as per the foreign exchange

component indicated in the price schedule) will be reimbursed on production of

documentary evidence (copy of assed Bill of entry & TR-6 Challan). Hence this

component need not be included in the quoted price.

7.3. Customs clearance and other formalities at the destined port within the country

shall be handled by the Supplier at his own cost. Further the transportation

from the port to the work of Supplier or site shall be arranged by Supplier at

his own cost.

8.0 SALES TAX / VAT

With effect from 01.04.2007, the facility of Inter-State purchases by

Government Departments against Form-D has been withdrawn. Now the rate

of CST on the Inter-State sale to Government Departments shall be the rate

of VAT/State Sales Tax applicable in the State of the selling dealer.

Accordingly, the suppliers have to clearly indicate the %age of CST/ VAT

applicable against each case in their tenders.

9.0 SERVICE TAX

Service tax, if applicable shall not be included but indicated separately in

schedule of prices (percentage of service tax applicable & amount on which it

is applicable)

10.0 RISK COVERAGE

The Supplier 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, erection, testing and commissioning at

site. The period of such coverage shall be up to contractual completion period

or any extension granted by Department thereof.




SHEET : 18 OF 31

11.0 INCOME TAX

Income tax at the prevailing rate as applicable and if applicable from time to

time shall be deducted from the supplier's bills as per Income Tax Act and a

certificate issued (TDS Certificate).

12.0 PERFORMANCE SECURITY

12.1. The supplier, whose tender is accepted, will be required to furnish by way of

Performance security for the due fulfilment of the contract such a sum as will

amount to 10 % of the contract price of the work awarded.

12.2. The Performance security (bearing no interest) shall be held by the

Department as security till satisfactory completion, testing and handing over of

all the system and for the due performance of all suppliers’ obligations under

the contract as per delivery period or extension granted thereof by the

Department.

12.3. The supplier within 10 days of Purchase Order or signing of Contract , deposit

with the Accounts officer, Satish Dhawan Space Centre SHAR, Sriharikota as

detailed above by any one or more of the following modes namely

i. By a crossed demand draft in favour of Accounts officer, Satish

Dhawan Space Centre SHAR drawn on SBI and payable at

Sriharikota.

ii. By a bank guarantee in the prescribed format (required format will be

provided after award of contract). The bank guarantee shall be from a

nationalized bank for & shall be valid for 30 days beyond completion

period.

12.4. In case of breach of contract, the Performance Security shall stand forfeited in

addition to other relief available to the Department under this contract.

13.0 PACKING AND FORWARDING

13.1. The Supplier shall arrange to have all the material suitably packed as per the

standards 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 Supplier shall be non-returnable.




SHEET : 19 OF 31

13.2. 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 Supplier.

14.0 ARBITRATION

In the event of any question, dispute of difference arising under these conditions

or any conditions contained in 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 Purchase Office or some other person appointed by him, it will be no

objection that the arbitrator is a Government Servant that he had to deal with

matter to which the contract relates or that in the course of his duties as

Government Servant he had expressed views on all or any of the matters in

disputes or difference. The award of the arbitrator shall be final and binding on

the parties of this contract.

It is Term of this contract:

a. If the arbitrator be the head of the purchase office.

i. In the event of his being transferred or vacating his office by

resignation or otherwise, it shall be lawful for his successor-in

office either to proceed with the reference himself, or to appoint

another person as arbitrator, or.

ii. In the event of his being unwilling or unable to act for any reason,

it shall be lawful for the Head of the Purchase Office to appoint

another person as arbitrator: or

b. If the arbitrator be a person appointed by the Head of the Purchase

Office in the event of his dying, neglecting or refusing to act, or resigning

or being unable to act, for any reason, it shall be lawful for the Head of

the Purchase Office either to proceed with the reference himself or to

appoint another person as arbitrator in place of the outgoing arbitrator.

Subject as aforesaid, the Indian Arbitration and Conciliation Act, 1996

and the rules there under and any statutory modifications thereof for the




SHEET : 20 OF 31

time being in force shall be deemed to apply to the arbitration

proceedings under this Clause. The arbitrator shall have the power to the

extent with the consent of the Purchaser and the Contractor the time

making and publishing the award. The venue of arbitration shall be place

as the purchaser in his absolute discretion may determine. Work under

the Contract shall, if reasonably possible, continue during arbitration

Proceedings.

c. In case order is concluded on the public Sector Undertakings, the

following Arbitration Clause will be applicable.

In the event of any dispute or differences relating to the interpretation and

application of the provisions of contracts, such dispute or difference shall

be referred by either party to the Arbitration of one of the Arbitrator in the

Department of Public Enterprises to be nominated by the Secretary to the

Government of India in-charge of the Bureau of Public Enterprises. The

Indian Arbitration and Conciliation Act, 1996 shall not be applicable to the

Arbitration under this clause. The award of the arbitrator shall be binding

upon the parties to the dispute provided, however, any party aggrieved by

such award may make a further reference for setting aside or revision of

the award to the Law Secretary, Department of Legal Affairs, Ministry of

Law & Justice, Government of India. Upon such Additional Secretary

when so authorised by the Law Secretary whose decision shall bind the

parties finally and conclusively. The parties to the dispute will share

equally the cost of arbitration as intimated by the arbitrator.

15.0 APPLICABLE LAW AND JURISDICTION

The laws of India shall govern this purchase order for the time being in force.

The Courts of Andhra Pradesh, India only shall have jurisdiction to be with

and decide any legal matters or disputes what so ever arising out of the

purchase order.

16.0 FORCE MAJEURE

Should a part or whole work covered under this purchase order be delayed

due to reasons of Force Majeure which shall include legal lockouts, strikes,




SHEET : 21 OF 31

riots, civil commotion, fire accident, quarantines, epidemic, natural calamities

and embargoes the completion period for work, equipment referred to in this

agreement shall be extended by a period not in excess of the duration of such

Force Majeure. The occurrence shall be notified within reasonable time.

17.0 GUARANTIES

The Supplier shall guarantee that the equipment furnished by him is in

conformance with the requirement of the specifications. Goods covered by

the contract shall be free from defects in materials or workmanship for a

period of Twelve months from the date of successful commissioning &

acceptance by Department.

18.0 WARRANTY

The bidder shall provide 12 months warranty for the entire system for a defect

liability, after final official handing over at his cost. During this period, supplier

has to provide and adhere to the following:

18.1. He has to attend quarterly based preventive maintenance visits and

breakdown maintenance calls. All the defective components have to be

replaced or rectified on one to one basis.

18.2. Break down maintenance should be responded within 48 Hours time and shall

be completed within 48 Hours after respond.

18.3. Department will not provide any transport/accommodation.

18.4. In case vendor failed to attend and repair the system within 7 days from the

date of reporting the problem, Department will reserve right to forfeiting the BG

apart from withheld of any payment payable to the vendor.

18.5. 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 SDSC SHAR. Where defect items are replaced by new ones, the

full warranty period stipulated in the purchase order shall apply to such

replacement items as from the date of their delivery.

19.0 SCHEDULE OF PRICE

19.1. CONTRACT price shall include all costs of “ Design, Manufacture, Supply,

Erection, Testing and Commissioning of 450/60 t cap acity EOT crane for




SHEET : 22 OF 31

SVAB”, shop testing, packing, forwarding, transport to site, unloading,

storage, all risk coverage, erection, installation, testing & evaluation and

commissioning of equipment including any other cost for proper and complete

execution of the CONTRACT.

19.2. 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, labours and

other staff employed by the Supplier, 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.

19.3. Price shall be firm & fixed.

19.4. Supplier shall quote the prices similar to price bid format enclosed as Section

–F1

19.5. The rate quoted shall be on FOR SDSC SHAR, Sriharikota basis.

19.6. The taxes applicable for supply, transportation and erection & commissioning

shall be indicated separately in the price bid. If the offers submitted by the

tenderers 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.

19.7. Department is exempted from Customs Duty and Excise Duty necessary

Exemption Certificate will be provided by the Department. This may be taken

into account while quoting.

20.0 DISCOUNTS

Tenderer shall not indicate any discount separately and quoted price should

be after deducting the discount.

21.0 MODE OF PAYMENT

All the payments due to Supplier will be made in Indian currency by crossed

“Account Payee” cheque sent to the registered office of the Supplier. Bidders

can submit the banker details and payments can also be made through ECS.




SHEET : 23 OF 31

22.0 TERMS OF PAYMENTS

General guideline TERMS OF PAYMENTS are as indicted below. Any

deviation to these payment terms to be brought out.

22.1. FOR SUPPLY OF CRANE

22.1.1. 20% of supply cost as advance against submission of bank guarantee for an

equal amount from a reputed nationalized/scheduled bank and shall be valid

till Contract completion period. Format of Bank guarantee shall be obtained

from Department after award of contract.

22.1.2. 10% of supply cost as against completion of design, submission of design

calculation, General arrangement drawings with hook approaches and

acceptance by SDSC engineers.

22.1.3. 10% of supply cost as milestone payment after releasing purchase orders for

major bought out items and identification of major raw-materials for

fabrication.

22.1.4. 50% of supply cost payment against receipt of complete material at

Purchasers / Department site, along with 100% VAT/CST.

22.1.5. 10% of supply cost after successful commissioning & acceptance by

Department of equipment and system covered under contract and against

submission of Performance bank guarantee of equal amount valid till

warranty period plus 3 months claim period.

22.2. FOR LOAD TESTING OF CRANE AT MANUFACTURING SH OP

22.2.1. 90% of load testing charges along with any applicable tax after receipt of

complete material at purchasers / Department site.

22.2.2. 10% of load testing charges after Commissioning and acceptance of the

system.

22.3. FOR TRANSPORTATION CHARGES

22.3.1. 90% of transportation charges along with any applicable tax after receipt of


22.3.2. 10% of transportation charges, Commissioning and acceptance of the

system.




SHEET : 24 OF 31

22.4. FOR ERECTION, TESTING AND COMMISSIONING OF CRANE AT SITE

22.4.1. 20% of erection cost as mobilisation advance after mobilisation at site &

against submission of bank guarantee valid till erection, commissioning and

acceptance.

22.4.2. 70% of erection cost against pro-rata progress at site (duly accepted by

Department).

22.4.3. 10% of erection cost along with Service tax after successful commissioning

and acceptance by Department of equipment and system covered under

contract and against submission of performance bank guarantee of equal

amount valid for guarantee/warranty period.

22.5. FOR THIRD PARTY INSPECTION CHARGES

22.5.1. 50% of third party inspection charges along with service tax after receipt of


22.5.2. 50% of third party inspection charges along with service tax after Erection,

Commissioning and acceptance of the system.

22.6. FOR ALL OTHER CHARGES LIKE SPARES & HEALTH MO NITORING SYSTEM

22.6.1. 100% of all other charges will be paid after commissioning and acceptance of

the system.

23.0 PERFORMANCE BANK GUARANTEE

23.1. The supplier shall guarantee for the performance of the equipment by

providing bank guarantee in favour of the Department for an amount

equivalent to 10 % (ten percent) of the total value of this contract valid till

the warranty period of the contract plus 3 months claim period.

23.2. The performance bank guarantee shall be submitted by the supplier with in

fifteen days from the date of accepting the equipme nt as per the

CONTRACT. Format for the performance bank guarantee shall be obtained

from the Department.

24.0 DELIVERY SCHEDULE




SHEET : 25 OF 31

The realization of Crane within the schedule is very essential. Hence, bidders

are requested to adhere to the schedules given below. Crane as per the

specifications of the contract shall be delivered within twenty months from the

date of release of LOI/Purchase Order, including the site erection &

commissioning and acceptance by the Department.

Contractor shall follow the following schedule for executing the contract:

S.No Description of Target Responsibility

Target Completion Date

1 Purchase Order release Dept. T

2 Kick off meeting Vendor & Dept.

T + 10 days

3 Completion of design and acceptance by department.

Vendor & Dept.

T + 1 month

4 Preparation of fabrication / part drawings and bill of materials & review.

Vendor & Dept.

T + 2 month

5 Release of orders for raw material, bought out items and fabrication works

Vendor T + 3 months

7 Completion of fabrication / manufacturing of items.

Vendor T + 12 months

8 Completion of Control assembly of the Crane.

Vendor T+ 14 months

9 Receipt of all items at Department site. Vendor 2 months from the date of dispatch clearance

11 Erection, Commissioning of the equipment. Vendor 4 months from the date of site clearance for erection

25.0 LIQUIDATED DAMAGES

In the event of the Supplier failing to complete the work within the delivery period

specified in the contract agreement or in extension agreed thereto, Department

shall reserve the right to recover from the Supplier 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. However, the total liquidated damages shall




SHEET : 26 OF 31

not exceed 10.0 percentage of the total Contract price. The LD reckoning date

shall be T+14 months for supply portion and 4 months from the date of clearance

for erection & commissioning portion of the contract price.

26.0 DISCLOSURE AND USE OF INFORMATION

26.1. If the documents supplied by SDSC SHAR are marked “Strictly

Confidential” , supplier shall take all necessary steps to ensure the same.

26.2. Supplier shall guarantee that all information and data received during

execution of Purchase Order from SDSC SHAR shall be classified as

“confidential” within the meaning of the Official Secrets Act and will not be

divulged to any third party without prior written permission of SDSC SHAR. All

drawings & documents shall be returned after execution of work.

26.3. No publicity of any kind whatsoever regarding this work shall be given without

prior clearance from SDSC-SHAR.

27.0 ACCEPTANCE AND REJECTION:

ACCEPTANCE AND REJECTION:

On completion of the work or part of the work as specified in the contract, the

representative of the Department referred to, shall check as soon as possible,

but in any event within one month of notification of readiness for acceptance

that the work performed complies with the contract requirements as regards

quantity and quality.

In the event of rejection of any of the articles, whereby the Supplier feels

himself aggrieved, he may within eight days of the receipt of notification of

rejection and before such articles have been removed from the place of

inspection, give the Department notice of objection. Such objection shall be

considered by a Board of Appeals of the Department. The Department shall,

without prejudice to the arbitration clause in the contract, take a decision upon

presentation of the Board's findings.

On completion of tests, the members of the Inspection Organisation of the

Department or Inspection agency appointed by Department shall prepare a

report, which must be countersigned by the Supplier.




SHEET : 27 OF 31

28.0 SUSPENSION:

28.1. Department may notify the Supplier 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. Supplier there upon shall

suspend the performance of such obligations until ordered in writing to resume

performance of Contract by Department.

28.2. If Supplier’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 Supplier as a result of suspension or reduction in rate of

progress will be paid to Supplier provided that the suspension or reduction in

the rate of progress is not by reasons of Supplier's default or breach of

Contract.

29.0 CANCELLATION

29.1. GENERAL RULE

The Department 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 Supplier shall undertake to observe the

instructions of the Department as to the winding up of the contract both on his

own part and on the part of his sub-suppliers.

29.2. WITHOUT FAULT OF SUPPLIER

In the case of cancellation of a contract by the Department without any fault

of the Supplier, the Supplier shall on receipt of Department's instructions

forthwith take the necessary steps to implement them. The period to be

allowed to implement them shall be fixed by the Department after conclusion

with the Supplier and, in general, shall not exceed three months.

Subject to the Supplier confirming, Department shall take over from the

Supplier at a fair and reasonable price all finished parts not yet delivered to

the Department, all unused and undamaged material, bought-out components

and articles in course of manufacture in the possession of the supplier and

property obtained by or supplied to the Supplier for the performance of the

contract, except such material, bought-out components and articles in course




SHEET : 28 OF 31

of manufacture as the supplier shall, with the agreement of the Department,

elect to retain.

29.3. WITH FAULT OF SUPPLIER:

The Department reserves the right, after full consideration of all relevant

circumstances, including the observations of the supplier, to cancel a contract

in any of the following circumstances.

29.3.1. In the event of the Supplier's failure to meet

(i) The Technical requirements of the Supplier.

(ii) The Progress and/or delivery requirements.

29.3.2. If the Supplier has not observed the provisions of the contract concerning the

disclosure and use of information provided by the Department.

29.3.3. If the Supplier fails to comply with the provisions of the contract concerning

the equipment, supplies and technical documents made available by the

Department.

29.3.4. If the Supplier transfers his contract without the Department's authorization or

concludes sub-contracts against the Department's explicit directives.

29.3.5. In the event that Supplier 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 Department’s actions or as provided in the Force Majeure

clause, the Department may, by giving an appropriate notice in writing to the

Supplier, fix a Date of Essence by which the Supplier must complete the

dispatch in full. If the Supplier fails to do so, the Department, 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, Department may

have the fabrication completed by other means, in which event Supplier shall

be liable to Department for the additional expenses incurred thereby, but shall

not have any claim on savings, if any, in such cases.

In the event of such cancellation, the Department shall unless otherwise

specified in the contract, only pays.




SHEET : 29 OF 31

- In the case of a fixed-cost contract for the supply of equipment or

material. The contractual value of items delivered and accepted under

the contract before receipt of notification of cancellation, or to be

accepted under the special conditions of cancellation.

- In the other cases.

A fair and reasonable price in respect of such work as has been carried

out prior to the receipt by the Supplier of notification of cancellation.

30.0 FRAUDULENT PRACTICES, BRIBERY AND CORRUPTION OF GOVERNMENT SERVANTS

The contractor represents and undertakes that he has not given, offered or

promised to give, directly or indirectly any amount, gift, consideration, reward,

commission, fees, brokerage or inducement to any person in service of the

department or otherwise in procuring the contracts or forbearing to do or for

having done or forborne to do any act in relation to the obtaining or execution

of the contract or any other contract with the Government for obtaining a

contract or showing or forbearing to shoe favour or disfavour to any person in

relation to the contract or any other contract with the government. Any breach

of the aforesaid undertaking by the contract or any one employed by him or

acting on his behalf or for his benefit (whether with or without the knowledge

of the contractor) or the commissioning of any offence by contractor or any

one employed by him or acting on his behalf, as defined in chapter IX of the

Indian Penal code, 1860 or the prevention of corruption Act. 1947 or any

other Act enacted for the prevention of corruption shall, without prejudice to

any other legal action, entitle the Department to cancel the contract either

wholly or in part, and all or any other contracts with Contractor and recover

from the Contractor such amount or the monetary value thereof and the

amount of any loss arising from such cancellation without any entitlement or

compensation to the Contractor. The Department will also have the right to

recover any such amount from any contracts concluded earlier between the

contractor and the Government of India. The contractor will also be liable to

be debarred from entering into any contract with the Government of India for

a minimum period of five years. A decision of the Department to the effect

that a breach of the undertaking had been committed shall be final and

binding on the Contractor.




SHEET : 30 OF 31

31.0 GENERAL PROJECT INFORMATION:

1.0 Project Title : Second Vehicle Assembly Building (SVAB) 2.0 Location of Plant : Shriharikota, AP

3.0 Elevation : 4.2 m 4.0 Access to Site : Road

From North of Chennai is apprx. 100 km. From East of Sullurpetta in Nellore dist is approx 28km. Rail Chennai – Vijayawada rail track line.

5.0 Terrain : Uneven with level varying significantly. 6.0 Climatic Conditions

a) Temperature

Mean of daily max : 42.2 0C Mean of daily min. : 11.8 0C Maximum Temperature : 44.6 0C

i. Design ambient temperature : 45.0 0C

for performance guarantee

ii. For electrical system design : 50 0C

b) Relative humidity

i. Range : 15% to 100%

ii. Design relative humidity : 70% for performance guarantee

c) Rainfall

i. Annual average maximum : 1331.3 mm

7.0 Wind Load

a) Basic wind speed : 65m/s

(Enhanced by a factor 1.3)




SHEET : 31 OF 31

8.0 Seismic Data : As per IS : 1893 latest issue

Zone : Zone III 9.0 Auxiliary Power Supply : Electrical equipment to be

supplied against this specification shall be suitable for operation on the following supply system :

a. For motors rated 200kW : 415V, 3-phase, 3-wire, effectively and below and motors rated upto 250kW with VFD earthed AC

b. Uninterrupted power : 230 V, 1 phase, 50 Hz, 2 wire supply AC supply

c. Space heaters : 240V, 1-phase, 2 wire, 50Hz

(for motors rated 30kW AC system with effectively and above) earthed neutral.

d. Instrumentation controls : 24V, (including solenoid valves)

and annunciation for instrumentation system only. This power supply has to be

derived by the vendor from AC UPS supply.

e. Lighting fixtures : 240V, 1 phase, 2 wire, 50 Hz,

earthed system.

f. Space heaters in panels : 240V, 1 phase, 2 wire, 50 Hz, earthed system

g. Construction power : 415 V + 10%, 3 phase, 4 wire,

50 Hz + 5%, AC supply at one place. Further distribution by Bidder on Chargeable basis.

h. All devices shall be suitable for continuous operation over the entire range of voltage and frequency indicated below without change in their performance :

AC supply : Voltage variation + 10%

Frequency variation + 5%

Combined voltage & Frequency variation: 10%

SPEC.NO. TATA CONSULTING ENGINEERS LIMITED SECTION: B

TCE 7517A-D-EOC-003 TECHNICAL SPECIFICATION FOR

450 / 60 T EOT CRANE

SHEET : 1 OF 56

SECTION -B

TECHNICAL SPECIFICATION




SHEET : 2 OF 56

1.0 SCOPE

This specification covers the description of scope of work, technical parameters, Design features, constructional features of major sub systems and interfaces pertaining to 450 / 60 t capacity EOT crane. The scope of the tenderer shall include Design, manufacture, control assembly at contractor’s works, testing & inspection at contractor’s works, packing, forwarding, transportation, transit insurance, delivery at site (SDSC-SHAR), erection, testing and commissioning which involves load testing of the integrated system at site and carrying out performance / acceptance tests of the system as per enclosed specification under the supervision of ISRO & Third party inspection agency (TPIA).

1.1 QUANTITY

a) 450 / 60 t capacity EOT crane - One (1 set)

1.2 DETAILED SCOPE OF WORK 1.2.1 Design, preparation of drawings, procurement, manufacturing, assembling,

painting and shop testing of 450 / 60 t capacity EOT crane. 1.2.2 Dismantling of all items, supply of the same to SDSC-SHAR in appropriate

packages for complete protection of equipment during transportation and storing at site to protect from rain. Covered area storage shall be considered for all critical electrical items.

1.2.3 Submission of design calculations and general assembly drawings for review and acceptance.

1.2.4 Selection, procurement and supply of LT rails, rail clips, fish plates and other accessories.

1.2.5 Erection of LT rails and its accessories, erection of all subsystems of the crane, testing and commissioning of crane.

1.2.6 Supply of all cables required for crane operation, from incoming power panel at 4 m level to the crane and pendant socket cable to all levels on both sides from the panel room at 82 m level in SVAB.

1.2.7 Providing double earthing cables for the crane up to earth pits outside the building.

1.2.8 Cable laying in trays and clamping of all the above cables including both end terminations.




SHEET : 3 OF 56

1.2.9 Hoist drive of 450 t capacity shall be Dual drive with planetary gear box and Dual

load path (preliminary configuration of main hoist is shown in section: C). Both ends of the rope drum are to be connected with planetary gear box. Two motors are to be connected to each planetary gear box, so that even if one motor fails, it should be possible to lift the load with other motor at half the speed. Each drive ( i.e. 1no. of planetary gear box connected to one end of rope drum with two motors) shall be capable of lifting 450 t at 3m/min. Each motor shall be provided with two number of brakes. Encoder type speed sensors are to be provided on both the sides of rope drum.

1.2.10 Hoisting drive of 60 t capacity shall be conventional hoist system with single motor connected to parallel shaft helical gear box of standard make. Two number of brakes shall be provided for motor.

1.2.11 Scope includes 1 year comprehensive maintenance warrantee from the date of commissioning and handing over. Spares required during warrantee period also to be listed along with offer and supplied along with crane.

1.2.12 The realisation of the crane shall be carried out under the inspection of a reputed third party inspection agency. The scope shall include arranging the third party inspection agency for the entire scope of the work. The agency shall report to the purchasers technically for all inspection works and shall meet the requirements of the purchaser.

1.2.13 Third party inspection of all items including raw material inspection, fabrication,

Machining, sub-assembly, control assembly, testing at shop, erection, commissioning and load testing.

1.2.14 Erection of all subsystems, testing and commissioning of Crane at site.

1.2.15 Tackles, Winches, pulleys, ropes etc.. for erection of crane. 1.2.16 Stress relieving for all the welded items, during fabrication as well as erection

using an approved thermal cycling procedure in a calibrated furnace. Thermocouples shall be mounted at critical locations on the job wherever required. The TTR charts are to be submitted with the approval of TPIA.

1.2.17 Grid blasting and primer painting as per detailed specification. All machined

surfaces are to be protected with anti-corrosive coats. All box sections to be painted before closing. Final painting to be done after testing & commissioning.

1.2.18 Initial lubricants / oil / grease filling of all gear boxes, thruster brakes etc.

1.2.19 Load testing of Crane.

1.2.20 Welding qualification plan, control assembly, number of sub-assemblies

proposed, mode of transportation, internal inspection scheme, machining details, painting scheme, etc along with QAP shall be submitted by the tenderer.




SHEET : 4 OF 56

1.2.21 Tool box containing all necessary tools like torque wrench, portable hydraulic

jacks, hand grease gun, set of spanners, screw driver etc required for the maintenance of the crane shall be given

1.2.22 The entire design, fabrication, supply, erection and commissioning work shall be

completed within 20 months from the date of purchase order.

1.2.23 Training of SDSC-SHAR engineering personnel about operation, maintenance and trouble shooting of cranes during commissioning of crane.

1.2.24 Performance Testing of Crane at site

� After control assembly at CONTRACTOR’S SHOP.

� No load idle run test with all measurements suggested in IS. � Verification of Hook approaches for CT & LT. � Full capacity Load test along with all measurements suggested in IS

(optional)

� After final erection at PURCHASER’s site.

� No load test � Full capacity Load test along with all measurements suggested in IS. � Over load test up to 125% of the rated load.

1.3 EQUIPMENT AND SERVICES TO BE PROVIDED BY SDSC S HAR AT SDSC SHAR:

1.3.1 Loads for load testing of crane.

1.3.2 Gantry Girder for LT travel ( LT rails, rail clips, fish plates associated fasteners are in the scope of contractor/tenderer scope) .

1.3.3 Power supply on chargeable basis for erection.

1.3.4 Interface provision ( 2 nos. of 75t capacity hooks) on roof / roof truss of SVAB for tackle for erection of the girder, trolley, rope drum etc. (tackle for erection of girder, trolley, rope drum etc... is under contractor/tenderer scope)

1.4 TECHNICAL PARAMETERS OF 450T / 60T EOT CRANE:

1.4.1 Designation : Electrically Operated Travelling crane for SVAB.

1.4.2 Quantity required : 1 (One).

1.4.3 Crane classification : As per IS:13834

1.4.4 Mechanical class : M5

1.4.5 Location : Indoor

1.4.6 Type : Over head / Double girder.




SHEET : 5 OF 56

1.4.7 Type of girder : Box.

1.4.8 Main hoist Capacity : 450 t

1.4.9 Auxiliary hoist capacity : 60 t

1.4.10 Span ( LT rail’s centre to centre distance): 37.5 m

1.4.11 LT travel length : 68 m

1.4.12 Range of lift for main hoist : 82.0 m

1.4.13 Range of lift for Auxiliary hoist: 82.0 m

1.4.14 Operating floor elevation : All floors

1.4.15 Type of main Hook : Crossby make Ramshorn type of Mckissick Duplex model

1.4.16 Type of Auxiliary hook : C-hook with plain shank, standard depress type.

1.4.17 Distance between main & Aux. hook: ≤ 2900mm.

1.4.18 Trolley gauge (CT rail centre to centre distance): ≤11000mm.

1.4.19 Overall buffer to buffer distance of crane bridge (buffers for LT): ≤17000mm.

1.4.20 Main hoist rope drum diameter : ≥3000mm.

1.4.21 Speed of main hoist with load : Main 3 m/min Creep 0.3 m/min

1.4.22 Speed of main hoist without load : Main 6 m/min

1.4.23 Speed of Auxiliary hoist with load : Main 4 m/min Creep 0.3 m/min

1.4.24 Speed of auxiliary hoist without load : Main 8 m/min

1.4.25 Speed of Long travel : Main 4 m/min Creep 0.3 m/min

1.4.26 Speed of Cross travel : Main 4 m/min Creep 0.3 m/min

1.4.27 Method of operation : Detachable pendant push button ( intrinsically Safe pendants at east side of the floors at each of 22 levels, 2 nos at SAT at 15m and 23m level & 1 nos at NAT at ground floor.

1.4.28 Long travel walkway required : Yes

1.4.29 Design of seismic coefficient for the crane: As per IS: 1893 latest issue, Zone-III

1.4.30 Design of Crane : As per IS: 807 & IS: 3177.

1.4.31 Design of rope drum & Sheaves : As per IS: 3177 & IS:4137.

1.4.32 Design of Wire rope : As per IS: 2266.

1.4.33 Design of lifting hooks : Forged and Heat treated alloy steel / Carbon steel As per IS:15560 / IS:5749 for 60 t hook.

1.4.34 Design of Crane rails : IS:3443

1.4.35 Lubrication : SemiCentralised / Group lubrication with Motorised pump and hand operated as standy.

1.4.36 Brakes for Main Hoist : Electro hydraulic thruster brakes- 2 nos. per




SHEET : 6 OF 56

motor (1 working + 1 redundant)

1.4.37 Brakes for Auxiliary Hoist : Electro hydraulic thruster brakes- 2 nos. per motor (1 working + 1 redundant)

1.4.38 Brakes for LT & CT : Electro hydraulic thruster brake- 1 no each.

1.4.39 Deflection of main Girder : Maximum of 1/1000 of Span With load at the centre

1.4.40 Over load test : 125% for hoisting & Crane motions

1.4.41 Limit Switches for hoist : Two nos. of limit switches (1 no. rotary limit switch with self-reset & 1 no. gravity operated hand reset type limit switch) for main hoist & Aux. hoist.

1.4.42 Limit switches for LT & CT : 2 nos of Lever type limit switches.

1.4.43 Wire rope : 35 x7 construction, Power form Steel core, galvanised Condition, tensile designation of 2160 N/mm2 with F.O.S of 8.

1.4.44 Control : VVVF drives for all drives control with redundant drive unit

1.4.45 Control cables : minimum 1.5sq.mm stranded copper FRLS cables

1.4.46 Lighting cables : minimum 2.5sq.mm single core stranded copper FRLS cable

1.4.47 Hook approaches : As per the crane hook approach diagram.

1.4.48 Electrical contactors’ : 300 starts/ hr (AC4 duty)

1.4.49 Rope drum fleet angle :≤ 3.5˚ to avoid mis-spooling of rope.

1.4.50 Rope reeving system : Single reeving system to maintain hook at centre of the rope drum

2.0 DESIGN REQUIREMENTS

2.1 The equipment shall be designed for maximum reliability and availability particularly in respect of the following.

2.1.1 The equipment shall be of proven design, using materials established as appropriate to the intended service. Fabrication / manufacturing processes shall be subject to quality surveillance and tests as specified.

2.1.2 The BIDDER shall indicate the specific design features that contribute towards better availability and shall support this data by actual figures on similar capacity cranes in operation.

2.2 The Crane shall be a complete unit with bridge girder, end carriages, for long travel, travelling trolley for cross travel, rope drums, wire ropes, etc.,

a) The steel used shall be of recent manufacture, free from corrosion /rust and free from defects and should be in conformance to the standards mentioned in the specification.




SHEET : 7 OF 56

b) All electrical accessories shall be designed to make the equipment complete in all respects.

2.3 The hoisting and travel drives shall be provided with VVVFD for varying the speed to achieve creep speed.

2.4 Crane has to safely handle the Sub-systems of the launch vehicle received at ground in vertical or horizontal condition.

2.5 Crane shall also be used to tilt the sub-systems received in horizontal condition to vertical. During tilting, LT motion of the crane shall be used along with the tilting fixtures. This is to be taken to account while configuring the orientation of rope drums.

2.6 Crane hook shall have a reach to the closest point possible from all side walls / doors to handle various hardware items.

2.7 Each hook block shall be operated on ball or roller thrust bearings and shall rotate freely. The Ramshorn hook for 450 t and C hook for 60 t capacity shall also have safety latches.

2.8 Interface shall be provided on Ramshorn hook to connect single eyed handling systems.

2.9 Brakes shall be effective and accurate to stop the crane within a very short distance and in a safe and smooth manner.

2.10 Brakes shall be operated using electro-hydraulic non flameproof thrusters. All motions shall be provided with redundant brake. One brake shall be able to hold the SWL safely. All thruster brakes shall be reliable. The brakes shall apply automatically when power to drive motor is cut-off or fails.

2.11 Thrusters brake shall have reserve of at least 30% stroke length available for necessary adjustment as well as provision for adjustment of time for upward and downward travels of the piston.

2.12 All brakes shall have smooth braking capacity to decelerate in a safe manner to avoid any derailment even when applied at maximum speed. The braking action of hoist motion shall be such that there shall not be any jerks for the objects being lifted at main speed

2.13 Dual drive control system (VVVF Drive control) shall be provided for all motions of crane. In case of failure of one drive system, the crane should be operable without any problem.

2.14 The crane shall have precise control/movement to align the parts for integration with variable speeds (VVVF Drive control).

2.15 Crane shall be operable from any floor using plug-in type light weight pendent (two spare pendants should be supplied).

2.16 SVAB crane shall be operated from pendant control at 22 platform levels at different elevations. The pendants are to be located at elevations of 0.0 m, 4.0 m, 7.0 m, 11.0 m, 15.0 m, 19.0 m, 23.0 m, 27.0 m, 31.0 m, 35.0 m, 38.0 m, 42.0 m, 47.0 m, 51.0 m, 55.0 m, 59.0 m, 63.0 m, 67.0 m, 70.0 m, 74.0 m, 78.0 m and




SHEET : 8 OF 56

82.0 m. Also 2 nos in SAT at 15m and 23m level & 1 nos. at NAT location at ground floor.

2.17 Intrinsically safe junction boxes and plug sockets shall be provided on either sides of the platform level. Three numbers of portable trolley type, intrinsically safe, multi-pin plug-in type light weight pendants shall be provided along with a lead cable of 30 m length to plug the same at any of the plug sockets at various platform levels. Light weight pendants with interlock arrangement shall be provided.

2.18 An emergency stop pushbutton shall be provided in the intrinsically safe pendant. On operation of this emergency push-button, all electro-hydraulic brakes shall be applied immediately to all motions and drives shall be stopped.

2.19 Electrical contractors shall be suitable for 300 starts/hr (AC4 duty).

2.20 All electrical equipment and fittings shall be suitable for ZONE- I operation as per IS:5572. Enclosures wherever specified shall be of IP55. Intrinsically safe apparatus and circuits, wherever specified shall belong to category II B and shall be as per IS:5780. The temperature classification shall be T4 of IS: 8239.

2.21 Each hoist motion shall be provided with self-contained, sturdy and automatic braking system to prevent over speeding of the hoist. These over speed brakes may be mechanical load brake type, AC regenerative or DC dynamic type.

3.0 DESIGN AND STRUCTURAL CONSTRUCTION

3.1 GENERAL

3.1.1 The crane shall be a complete unit with bridge girder, end carriages for long travel, travelling trolley for cross travel, rope drums, wire ropes, sheaves, drive units, brakes, rails and fixtures, rail clamps, end stops, buffers, conductors, all electrical etc. to make the equipment complete in all respects.

3.1.2 The steel used for the crane construction shall be of standard quality. All materials used shall be of recent manufacture and free from defects, mill scales, laminations, pittings, flakes, rust etc. All welds shall be free from defects like blowholes, lack of penetration, slag intrusions, etc.

3.1.3 In the design of components on the basis of strength, factor of safety shall not be less than five (5) on ultimate strength. Impact, fatigue, wear and stress concentration factors shall be taken into account, wherever applicable

3.1.4 The stresses in all components of hoist mechanism and gear boxes should not exceed 60% of the yield point of the material for the component under break down conditions of motor i.e. pull out torque of motor.

3.1.5 All mechanical components in Hoist (vertical load path), shall be designed for infinite fatigue life. Fatigue analysis shall be based on the crane maximum rated load.

3.1.6 Materials with less than 15% elongation shall not be used for any of mechanical load bearing component except for electrical motors, panels and hydraulic components.




SHEET : 9 OF 56

3.1.7 Stress concentration factors shall be considered in mechanical design for calculating working stresses and also combination of stress concentration factors shall be considered at required conditions.

3.1.8 No cast iron part should be used as load bearing member on the crane except for electrical equipment. Similarly wood or combustible material and Bush bearing should not be used in any part of the crane.

3.1.9 Number of falls for Main hoist shall be 24 and for auxiliary hoist shall be 8. However bidder is free to change the number of falls based on achieving maximum hook approaches.

3.1.10 Crane shall be rigid in construction and all movements shall be smooth and non-jerky.

3.1.11 Design shall provide for easy maintenance of all parts particularly the wheel bearings on end-trucks. Necessary safe and sufficient working space shall be provided all around the sub systems for easy maintenance.

3.1.12 Where any portion of the structure is not free to expand or contract under variation of temperature, allowance shall be made for stress resulting from these conditions and the co-efficient of expansion for each degree centigrade variation of temperature above and below normal being taken as 0.000012 for mild steel. Maximum range of variation of temperature shall be given. Clause 8 of Section II of IS: 800 – code of practice for use of structural steel in General Building construction shall also apply.

3.1.13 For load carrying members like the component plates, bars, angles and other rolled sections the minimum thickness shall be 4.9mm (6 SWG). For unsealed tubes the minimum thickness shall be 8 mm. Chequered plates for platforms shall be of minimum 6 mm thick.

3.1.14 Unless otherwise specified, only welded joints shall be used. Where welding is not practicable, turned and fitted bolts shall be used. Connection between carriages and main girders shall be by means of machined bolts fitted in reamed holes. Minimum number of turned and fitted bolts in connection shall not be less than two.

3.1.15 Transverse fillet welds on load carrying members shall be avoided. If side fillets are used in end connections, the length of each side fillet should not be less than the edge distance between the fillets.

3.1.16 Splices shall be designed to resist one and half times the forces and moments to which they are subjected to, but in no case it shall be less than 2/3rd of the effective strength of the material spliced except that splices in the webs of the plate girders shall be designed for full strength of the web in shear as well as bending. For splicing tension members, the net section of the splice plate shall be ten percent more than that of the material spliced. Splices shall be proportioned and arranged, so that the gravity axes of the splices are in line with the gravity axis of the member to avoid eccentricity.

3.1.17 Overall buffer to buffer distance shall be preferable limited to ≤ 17m.

3.1.18 Wheel base of the trolley shall be preferably limited to ≤ 10m.




SHEET : 10 OF 56

3.1.19 Trolley gauge shall be preferably limited to ≤ 11m.

3.1.20 Crane height from LT rail shall be preferably limited to ≤ 9.5m.

3.1.21 Diameter of rope drum shall be ≥ 3 mtr.

3.2 DRIVE MECHANISM

3.2.1 The design of components shall be 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 IS :3177 for group classification M5.

3.2.2 Drive shall be designed with adequate margin to give best performance and efficiency. Safety arrangements shall be incorporated to prevent damage to motors on account of mechanical overload and electrical faults, etc due to over stressing and other detrimental conditions.

3.2.3 All machinery for the drive unit shall be properly aligned.

3.2.4 Castings and forgings shall be of tested quality confirming to their respective material specifications and shall be free from flaws and objectionable imperfections.

3.3 MAIN HOISTING DRIVE

3.3.1 Hoist drive of 450 t capacity shall be Dual drive with planetary gear box and Dual load path (preliminary configuration of main hoist is shown in section: C).

3.3.2 Both ends of the rope drum are to be connected with planetary gear box. Two motors are to be connected to each planetary gear box, so that even if one motor fails, it should be possible to lift the load with other motor at half the speed.

3.3.3 Each drive (i.e. 1no. of planetary gear box connected to one end of rope drum with two motors) shall be capable of lifting 450 t at 3m/min continuously.

3.3.4 Selection of drive mechanism 1 or 2 to be provided in the pendant.

3.3.5 Failure of any drive element in one mechanism shall lead to failure of power to all brakes and all brakes to be applied to all the motors to hold load in safe position.

3.3.6 After holding the load in safe position, the selection of drive mechanism to be changed in the pendant. Other operations of the crane are to be carried out for completing the intended operation.

3.3.7 Each motor shall be provided with two number of brakes.

3.3.8 Encoder type speed sensors are to be provided on both the sides of rope drum.

3.4 AUXILLARY HOISTING DRIVE




SHEET : 11 OF 56

3.4.1 Hoisting drive of 60 t capacity shall be conventional hoist system with single motor connected to parallel shaft helical gear box of standard make.

3.4.2 Two number of brakes shall be provided for motor.

3.5 BRIDGE GIRDER

3.5.1 The crane shall be of double girder type and design shall be in accordance with latest edition of IS:807.

3.5.2 Girders shall be cambered to an amount equal to the deflection caused by the dead load plus one half of the live load and the trolley.

3.5.3 The bridges shall not deflect more than 1/1000 of span with safe working load on the trolley, with trolley stationed at mid span and excluding deflection due to dead load.

3.5.4 The bridge girder shall be of box section. The exterior surface shall be smooth and free from projections, so as to minimize dust collection on it.

3.5.5 For box plate girders in addition to the required full-length diaphragms, short diaphragms shall be inserted where required to transmit the trolley wheel load to the web plates and to limit the maximum stress in the trolley rail within safe permissible stress.

3.5.6 Breathing holes shall be provided in completely enclosed welded box type girders. Drain holes shall be provided at all places where water or oil is likely to collect.

3.5.7 Wherever practicable, means of access shall be provided for inside inspection of completely enclosed box girders.

3.5.8 In bridge girder strength calculations, the trolley rails and chequered plates shall not be considered as load carrying members.

3.5.9 Each girder shall carry a rail on which a wheeled trolley shall run.

3.5.10 The bridge girder shall have enough strength to carry the rated load without causing undue stress or deflection.

3.5.11 Bridge girders shall be connected to the end carriages by large gusset plates. The bridge girders shall be attached to the end carriages by welded connection if the end carriages are in two pieces or by turned barrel bolts in case of one piece.

3.5.12 The main girders shall extend over the whole width of the end carriage and the extension shall have sufficient section to take maximum reaction and moment.

3.5.13 The girders shall preferably be notched at the ends to receive the end carriage and shall be secured along the vertical edge of the notch in addition to being secured along the top edge. If this arrangement is not possible, bridge girders connected to the end carriages shall be designed to take up full effect of torsion in addition. Adequate top and bottom gussets shall also be provided between the end carriages and bridge girders.

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




SHEET : 12 OF 56

3.6 RULING DIMENSIONS & RATIO

3.6.1 For compression members, the slenderness ratio shall not exceed 120. In case of other load carrying members and subsidiary members, the slenderness ratio shall not exceed 180.

3.6.2 For girders, the following values of maximum span to depth ratio shall be governing: Plate girders : Span/Depth= 18 Lattice girders : Span/Depth=12

3.7 DEFLECTIONS AND CAMBER

3.7.1 Total maximum vertical deflection of the girders for the live load plus trolley and not including impact or dead load of the girder shall not exceed limit of span /1000.

3.7.2 The girders shall be cambered by an amount equal to the maximum deflection due to dead load plus one half the live load and trolley

3.8 BRIDGE DRIVE (LT)

3.8.1 If central drive is not feasible for LT, independent corner drives are to be selected. Suitable control system shall be provided to apply equal driving effort at each drive wheel of bridge to prevent one end travelling faster than the other. However, the shaft at each corner shall be designed with sufficient margin, so that individual drive shaft can take full load.

3.8.2 For bridge drive torsional deflection in the cross travel drive shaft shall be limited to safe value as per applicable code.

3.9 END CARRIAGES

3.9.1 End carriages connected with bridge girder at the two (2) ends shall be made from structural steel

3.9.2 End carriage design shall be such that it facilitates easy removal of the wheels for maintenance. Suitable jacking pads shall be provided for maintenance and easy removal of crane wheels.

3.9.3 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 Bogies, articulated end carriages shall be used. Wherever possible, the end carriages shall be in two halves. Each halves shall be rigidly connected to the respective bridge girder in the fabricated shop.

3.9.4 The wheels shall be double flanged for overhead crane. The wheels shall be machined on their treads to match the runway rail section for overhead crane.

3.9.5 Wheel base and structural frame of the end carriages shall be designed and connected with bridge girder in such a way that the crane remains square and skewness is prevented. The ratio between wheelbase and crane span shall be as stipulated in IS 807.




SHEET : 13 OF 56

3.9.6 End ties for cranes with more than four bridge wheels shall be of rigid type. End ties shall be constructed of box sections in structural steel.

3.9.7 Equalizer bridge trucks shall be incorporated into the end carriage design to promote equal sharing of bridge wheel loads, and equalizer pins shall be provided between the equalizer trucks and equalizer beam and/or the rigid bridge frame structure.

3.9.8 End ties shall be designed to resist the loads due to crane movement and the load combinations as per IS807 & IS4137.

3.9.9 End carriage length (i.e buffer to buffer length) shall be less than 17m.

3.10 BUFFER, STOPS & SWEEPS

3.10.1 Spring Loaded buffers or any other better type buffers shall be fitted on the four corners of the crane, also on the four ends of the bride girder and trolley for soft stopping of crane and trolley respectively.

3.10.2 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 bolts are not in direct shear.

3.10.3 Buffers shall be designed to absorb the kinetic energy released at 50% of the full load rated travelling speed, the average rate of deceleration not exceeding 5 m/s2 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.

3.10.4 Suitable end stops welded to the bridge girder shall be provided to contact the buffers mounted on the trolley. Spring or rubber buffers shall also be provided on the end carriages. Suitable end stops welded to the long runway girder shall be provided to contact the buffers mounted on the end carriages.

3.10.5 Bridge and trolley wheel stops shall be provided before the end stops. These shall match to wheel radius. Wheel stops to prevent rails from creeping and trolley from running off the bridge shall be abutted against ends of rails. Wheel stops shall be welded to the girder

3.10.6 Sweeps shall be attached to the end carriages and to the trolley, to remove foreign material from the rails.

3.11 TRAVELLING TROLLEY

3.11.1 Trolley drive (CT) shall be achieved by single increased safety motor in which motor shall drive a common output shaft through proper gearbox and tractive power shall be transmitted to the geared wheels by means of pinions mounted on both ends of the output shaft. No open reduction gear is to be used. The torsional rigidity of CT drive shaft shall be such that jerks are avoided where trolley is moving or stopping.

3.11.2 Equaliser sheaves shall be mounted on the trolley frame in such a manner that deflection resulting from the force on the sheaves are not directly transmitted to the hoisting mechanism.

3.11.3 Sheaves shall be so arranged on the trolley that rope reeving arrangement




SHEET : 14 OF 56

resulting there will ensure lifting of the load almost in a vertical line with minimum of swing or side movement.

3.11.4 Trolley frames shall be fabricated from rolled structural steel sections and plates to form a rigid & robust structure and shall be arranged to afford maximum accessibility to mechanical and electrical parts placed on it.

3.11.5 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. Connections between the two parts of the trolley shall be done by machined bolts.

3.11.6 For double girder crane, the trolley shall be provided with chequered plate platforms with openings for ropes, sheaves etc. Hand railings shall be provided all around the platform.

3.11.7 Suitable jacking pads shall be provided for maintenance and easy removal of wheels.

3.11.8 No parts shall be mounted under the trolley except for the gravity limit switch weight. Top pulley block and all other pulleys, equalizer bars, fitments shall be mounted on the top of trolley platform only.

3.11.9 Trolley shall be designed such that at the highest position of hook there shall be a clear distance of 700 mm between the lowest point of trolley obstruction and the highest point of bottom block.

3.11.10 Safe access for maintenance and removal of all mechanical and electrical parts must be ensured without any additional scaffolding.

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

3.11.12 All electrical cables on trolley shall be so laid that they are not liable to be damaged and can be easily inspected and maintained.

3.12 TROLLEY RAIL:

3.12.1 Trolley track rails made of rail steel shall be clamped to the girder with double bolt clamping plates spaced not more than 900mm apart with welded alignment blocks between every two clamps such that distance of a clamp from any adjacent block shall not be more than 450mm. Rails shall be prevented from creeping in the longitudinal direction by rail stops, welded. Rails shall be fastened by clamps held by studs welded to cover plates, spacing of clamps and alignment blocks being as stated earlier.

3.13 ROPE DRUMS

3.13.1 Design of rope drums in all aspects shall be as per section 8.4 of IS 3177, IS: 4137 and IS:6938

3.13.2 Rope drums shall be provided with flanges at both ends.

3.13.3 Rope drum structure shall be designed such that the bearings are mounted




SHEET : 15 OF 56

under compression to minimize potential for failures of bearings and to increase the probability of maintaining the mesh between the drum gear and drive gear in case of bearing failure.

3.13.4 Rope drums shall be welded / fabricated type of IS: 2062 grade B. All fabricated rope drums shall be stress relieved.

3.13.5 Length of the rope 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 when hook is at highest position. Each rope end shall be clamped with minimum two clamping wedges with at least two numbers of bolts on each clamping.

3.13.6 Drums shall be machine grooved right and left with grooves of a suitable shape for the rope used.

3.13.7 Fleet angle of Wire rope from drum to sheave shall not be more than 3.5˚ and drawings and calculations shall be provide in this regard.

3.13.8 In event of failure of a drum shaft or bearing, the drum must be retained on the trolley without falling.

3.13.9 Diameter of rope drum shall be ≥ 3 mtr .

3.13.10 Speed sensor of rope drum to be provided. Any over speed of the rope drum shall result into application of all brakes to the motors.

3.14 WIRE ROPES

3.14.1 Wire ropes shall be of thirty five (35) strands of seven (7) wires per strand construction with independent wire rope core (IWRC). The ropes shall be regular lay, right hand, non-rotating type as specified in IS: 6938 and IS: 2266.

3.14.2 Hot dip galvanized wire ropes shall be used in all applications. All particulars related to these galvanized wires shall confirm to the requirements for the type B galvanized as per IS: 1835.

3.14.3 The wires shall be made of steel with tensile designation 2160 (minimum tensile strength 2160 N/mm2). Selection of size of wire rope in general shall be as per section 8.3 of IS:3177.

3.14.4 The factor of safety shall be minimum 8 based on nominal breaking strength and the safe working load shall be as per IS:3177. The load shall include rated load on hooks, weight of the bottom block and the weight of rope

3.14.5 The rope shall be fastened to the drum with an attachment having strength equal to that of the rope. The rope fastening at the swinging end shall be aligned so as to prevent rope coming off its reeving. Rope shall be of sufficient length so that two (2) full laps shall remain on the drum at extreme low position of the hook. Reverse bends or cross bends and bird caging shall be avoided.

3.14.6 In event of hook over travel, where the lower block contacts the crane trolley structure, the ropes shall not be cut or crushed.




SHEET : 16 OF 56

3.14.7 No joints shall be used for wire ropes.

3.15 ROPE SHEAVES

3.15.1 The sheaves shall be of forged steel and design shall confirm to IS: 3177 and IS:4137.

3.15.2 Sheaves shall be equipped with special roller type sheave anti-friction bearings and shall be fully guarded to prevent the rope coming off.

3.15.3 Grease lubricated sheave bearings should be provided with individual grease lubrication fittings and shall be easily accessible for maintenance.

3.15.4 All sheaves shall be identical; however, exception may be 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.

3.15.5 Sheave fleet angle shall not be more than 3.5˚.

3.15.6 All sheaves shall have guards, which are fit close 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 all bearings.

3.15.7 All the upper block sheaves shall be mounted above the trolley platform for ease of maintenance and inspection.

3.15.8 Sheaves grooves shall be machined smooth and support wire rope uniformly at least 136˚ angle of contact over its circumference.

3.16 WHEELS & RAILS:

3.16.1 Bridge and trolley track wheels shall be of forged steel or cast steel with cylindrical straight tread and shall confirm as per section 8.5 of IS:3177.

3.16.2 The face width of the rail the wheels are determined on the basis of rail size and possible lateral displacement of wheels during operation considering all misalignments.

3.16.3 All wheels shall be of forged type, double flanged with straight tread, with 12˚ taper flanges and shall be grounded to equal diameter in pairs

3.16.4 The minimum hardness of the wheel rim shall be maintained between 300 and 350 BHN with minimum depth of 10 mm. Steel used for wheels shall not contain more than 0.060 per cent of either sulphur or phosphorus. The wheels shall be mounted in such a manner as to facilitate easy removal and placement.

3.16.5 Design and construction of the wheels and rails shall match the requirements of the drive mechanism and shall be properly coordinated with parameters of the drive system being supplied.

3.16.6 The wheel diameter and rail sizes shall be suitably selected so as to meet the requirements of wheel loading for the specified duty class of crane. Necessary sizing & contact stress calculations as per IS:4137 shall be submitted.




SHEET : 17 OF 56

3.16.7 The rail fasteners shall be suitably machined to ensure full contact with the rail flanges. The bridge and trolley track wheel bearings shall be anti-friction roller bearings and shall be carried on specially designed bearing support blocks of ‘L’ type design (commonly known as ‘L’ type bearing housings).

3.16.8 The required runway rails along with rail clamps and other accessories for mounting the rail on the PURCHASER’s structure shall be provided. Runway rails shall have adequate strength and rigidity. Hardness of the rail shall be marginally lower than wheel hardness.

3.16.9 Rails are required to transmit vertical down and horizontal loads due to operation, and shall confirm to the IS:3443

3.17 BEARINGS & BEARING HOUSINGS

3.17.1 All bearings of the gearing shall be anti-friction type. Angular contact ball or taper roller bearings shall be used wherever necessary. The bearing shall correctly locate the shafts while allowing for thermal expansion of the shafts.

3.17.2 Provision shall be made for service lubrication of all bearings.

3.17.3 Bearing enclosures shall be designed to exclude dirt and prevent leakage of oil or grease.

3.17.4 Rated life of ball and roller bearings shall be not less than total life in working hours of the total system. Life of the bearing shall be calculated in accordance with manufacturer’s recommendations. Refer section 8.7 of IS: 3177.

3.17.5 Bearing mountings fits, tolerances and clearances shall be as recommended by the bearing manufacturer.

3.17.6 All antifriction bearings and bearing housings shall be of SKF/ FAG/Timken make, which are interchangeable with corresponding size of the bearings.

3.17.7 Design shall be such that there is no ingress of dust or grease does not leak out. Drip pans shall be provided to accept accidental leakage and drippings.

3.17.8 Bearing housings shall be split on the shaft centre line to permit removal of the shafts.

3.18 COUPLINGS

3.18.1 All couplings shall be designed to suit the maximum torque that may be developed, refer section 8.9 of Is: 3177

3.18.2 Couplings between motors and gear box shall be Flexible full/half geared couplings. Make of couplings shall be of FENNER / ELECON / SHANTHI.

3.18.3 Flexible Couplings between gearbox and rope drum for hoists

Drum/ Barrel couplings of M/s Malmedie, Germany shall be used for Main hoist and Aux hoist. Selection criteria, service factor (as per ISO-M8 class), Torque rating, drawing shall be submitted for approval.

3.18.4 Flexible Couplings between gearbox and rope drum for hoists ( For dual load path/ twin drive)




SHEET : 18 OF 56

Suitable type of coupling (rating Class-4 of IS4137) shall be used between Gearboxes and Rope drum for Main Hoist such that incase of any failure in one gearbox, the drum can be driven from other load path. Aux. hoist shall be provided with Drum/ Barrel couplings of M/s Malmedie, Germany

3.18.5 All Couplings selection shall be based on the manufacturer’s rating and applicable service factors for heavy duty cranes compared to the applied torque on the coupling and as per IS4137. Consideration shall be given to motor starting torque, gear ratio, dynamic effects, brake torque etc.

3.18.6 Motor shafts shall be connected to gear extension shafts through flexible / shock absorbing couplings. Geared couplings shall be used between gearbox output shaft and intermediate shaft or end shaft and also for connecting intermediate lengths of long travel and cross travel shafts. Between intermediate shaft and end shaft and between end shaft and wheel axle, any other special coupling which can give better and more reliable service may be used after obtaining specific approval of the SDSC SHAR.

3.18.7 Wherever necessary gear couplings as per IS: 12405 shall be used between connecting shafts. Positive locking by means of gib headed keys or end stopper plates shall be provided. To prevent axial displacement for all couplings, keys shall be so fitted and screwed that they cannot work loose in service.

3.19 SHAFTS, AXLES & KEY WAYS

3.19.1 Unless otherwise stated, materials of construction of shafts/axles shall be as per 45C8 forged steel or alloy steel.

3.19.2 Torsional deflection of the shafts at torque corresponding to 1.33 motor rated torque during acceleration shall not exceed 0.10deg./meter of shaft length

3.19.3 Wherever components of considerable amount of inertia is directly mounted on the high speed shaft (e.g. brake drum, couplings, etc.), they shall be balanced dynamically to minimize vibrations.

3.19.4 Provision shall be made to prevent the sliding of the keys from their respective key ways during operation. Wherever feasible, gib head keys shall be used.

3.19.5 Design of the shaft is to minimise stress concentration at the changes of diameter, and hence shall be provided with chamfers, fillet radii or relief grooves as applicable. Wherever practicable, keys and keyways and splines shall confirm to the relevant Indian standards.

3.19.6 Keys and Keyways shall confirm to IS 2048 /2291 /2292 /2293 as applicable. Splines and serrations shall be involute or straight-sided form. Straight-sided splines shall comply to IS 2327 / 2610 as applicable.

3.19.7 Material of keyways shall be C45C8 or alloy steel.

3.19.8 Proper fits and tolerances shall be used between key and keyways, such that key should not get loosened in service life. Key end arrestors shall be provided.

3.19.9 Shaft support on plumber blocks of SKF/FAG/Timken make only.

3.20 GEARBOXES




SHEET : 19 OF 56

3.20.1 Gearing shall be as per IS:3177

3.20.2 Each main hoist drive shall be provided with a planetary gearbox with driven by two motors. Crane duty, horizontal foot mounted parallel shaft helical planetary gearbox shall be used.

3.20.3 Helical parallel shaft, Crane duty, gearboxes, shall be used for CT & LT drives. LT drive shall be of vertical foot mounted gearboxes.

3.20.4 Travel drive gearbox ratings for bending strength and pitting resistance shall be based on 2 times rating of AC motor.

3.20.5 Make of Gearboxes Heavy duty, and crane duty gearboxes of Elecon / Shanthi/ GREAVES (Premium transmission) / Flender/ DB-Radicon / Sumitomo / Renold only. Other make & Own make gearboxes are not acceptable. Bidder shall confirm the acceptance.

Tender will be rejected for not meeting this requir ement .

3.20.6 Torque & power rating of Gear Boxes / Pinions / Gears / Shafts

Gearboxes selection shall consider starting torque of motor (i.e., 2 times the Full load torque ) of selected motors.

The gearing shall be designed for strength, durability, and momentary high overloads which includes the loads imposed during starting, braking and failure of components.

Due consideration shall be given for braking torque in selection of Gearboxes.

3.20.7 The stresses in all components of hoisting machinery and gearboxes should not exceed 60% of yield point of the material for the component under break down conditions (POT) of motor.

3.20.8 In design of gearboxes, due consideration shall be given to creep speed and also ramping down of rated speed (rpm) to zero speed through VVVF drives.

3.20.9 Drawings and dimensional details of gear boxes, selection criteria, power rating & torque rating calculations, bearing details, data sheets from gearbox manufacturer shall be submitted for SDSC SHAR approvals during design engineering phase

3.20.10 Main hoist gearboxes for both options shall be designed & manufactured as per class ‘4’ duty of IS:4137.

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

3.20.12 All pinions shall be integral with shafts.

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

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

3.20.15 Gear teeth shall be cut in metric module system. All gear teeth shall be profile ground to smooth with less error & for low noise while running.

3.20.16 All gear boxes shall be totally enclosed and splash or forced lubrication system shall be provided. Gearboxes shall have sufficient heat radiation area to maintain lubricant at temperatures below maximum operating temperature




SHEET : 20 OF 56

3.20.17 Vertical Gearboxes shall have an oil pump lubrication system when vertical gearing exceeds of two reductions. Tubing/ Piping for gearbox lubrication shall be provided with SS316/SS304 and must be properly clamped. No hoses shall be used. Visual indicator for oil flow shall be provided in line.

3.20.18 Gearboxes shall have fill and drain connections, BREATHERS, lubricant level indicator, and shall have good accessibility for checking, maintenance and oil filling.

3.20.19 For all gearboxes lubrication shall be ensured even at creep speed of motor and from the initial start of motion (i.e. main or creep).

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

3.20.21 Fabricated gearbox housings shall be made of minimum 10 mm thick steel plate. All fabricated gearboxes shall be duly stress relieved.

3.20.22 Gearbox cover shall be split horizontally at each shaft centre line and fastened and arranged so that the top half can be removed for inspection and repair without disturbing the bottom half.

3.20.23 Radial clearance between the gear box inner surface and the outside diameter of the gears shall be at least 1 1/4 times the depth of the largest gear tooth inside gear box or 20 mm whichever is higher.

3.20.24 No oil leakage is allowed from gearboxes. Oil drip pans shall be provided around the gearbox.

3.20.25 Sufficient clearance need to be maintained between gear of one stage to pinion of next stage of non-meshing sets to avoid interference.

3.20.26 The noise level at gear box must not more than 75-80 dBA measured at a distance of 1m from the direct vicinity of the gear box. This is very important for all the gearboxes, and any gearbox making more noise is liable to be rejected.

3.20.27 Reliable oil seal arrangement i.e., preferably double stage oil sealing arrangement shall be provided for shafts of gearboxes.

3.20.28 Open gears should not be used.

3.20.29 Gears in the speed reducer unit for bridge drive, all hoists and trolley drive, shall be enclosed in substantial housing and shall operate in oil bath. The oil shall have additives of approved quality and shall be of approved viscosity at standard temperature (say 60°C). The housing shall be of suf ficient design not to permit a temperature in excess of 90°C of the oil bath and s hall be adequately supported. Housing cover shall be easily removable without disturbing gear assembly.

3.20.30 All gears shall be of hardened and tempered alloy or carbon steel with machine cut teeth shell be in metric module system.

3.20.31 Gears shall have tooth form and modules as recommended in IS:3681 and they shall be adequately designed to withstand shock load and vibration and shall not be excessively noisy in operation. The ratings of gears shall be established as per IS:4460




SHEET : 21 OF 56

3.21 LIFTING HOOK BLOCK ASSEMBLY

3.21.1 The lifting hook block assembly shall be point hook / Ramshorn with adequate capacity and shall be of forged steel construction. Each hook shall be supported on ball or roller thrust bearing and shall rotate freely on its bearing by manual operation. The lifting hooks shall have a safety latch.

3.21.2 A gravity actuated pendulum type verticality indicator shall be incorporated to the hook blocks.

3.21.3 450 t hook shall be Crosby make only of Mckissick duplex hook.

3.22 BRAKES

3.22.1 Non flame proof type electro hydraulic thruster drum brakes shall be of suitable rating to stop the crane within a very short distance and in a safe and smooth manner. They should be equally effective in both directions. The thruster brakes shall be operated by electro hydraulic thrusters. The brakes shall apply automatically when power to drive motor is cut-off or fails.

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

3.22.3 Double-shoe type service brake shall be provided for each motion of the crane. These brakes shall be directly applied automatically to the motor shaft when power supply to the drive motor is cut-off or fails. The brakes shall be equally effective in both directions of rotation. Two brakes each rated for 2 times of motor rated torque/ suitable capacity shall be provided for all motions of both hooks.

3.22.4 Service brake for hoist motions shall be adequately sized to arrest and hold at rest any load up to and including test load at any position of the lift. For hoist motion, redundant brake is required to be provided and the capacity shall be such that each brake can satisfactorily meet the requirements of the braking.

3.22.5 Brake drum shall be positively locked in position so as not to prevent lateral movement by means of retainer plates or any other means.

3.22.6 Thrusters shall have reserve of at least 30% stroke length available for necessary adjustment as well as provision for adjustment of time for upward and down ward travels of the piston.

3.22.7 All brakes shall have smooth braking capability to decelerate in safe manner to avoid any derailment even when applied at maximum speed. The braking action of hoist motion shall be such that there shall not be any jerks for the objects being lifted at main speed.

3.22.8 Brake is normally closed under spring force. The brakes shoes shall be of hinged type. Brake levers shall be forged or fabricated or cast steel. Hinge pins shall be of hardened alloy and shall be lubricated. These hinge pings shall be provided with steel bushes at bearing point.

3.22.9 Brake drums shall be of forged or cast steel. Drums shall be completely machined and dynamically balanced. Width of the brake drum shall be 5 to 10mm more than the width of the brake shoes. Hardness of brake drum shall be 38-43Rc.




SHEET : 22 OF 56

3.22.10 The brakes should be provided with brake release mechanism, for releasing the brake during maintenance.

3.22.11 Brake for Hoist motion shall be selected such that the braking distance for lowering motion shall be as IS:4137 with one brake at full rated speed. Necessary calculations shall be submitted in this regard during design phase.

3.22.12 Manual release mechanisms shall be provided to permit drive movement during power stoppage. Manual release shall be of self-reset type, and operative only when held manually in the release position.

3.22.13 No oil leakage is allowed from thrusters disk brakes. Oil drip pans shall be provided under thrusters.

3.23 EMERGENCY MODE OPERATION

3.23.1 An emergency stop pushbutton shall be provided in the intrinsically safe pendent. On operation of this emergency push-button, all electro-hydraulic brakes shall be applied immediately to all motions and drives shall be stopped.

3.23.2 Each hoist motion shall be provided with self-contained, sturdy, automatic braking system to prevent over speeding of the hoist. These over speed brakes may be mechanical load brake type, AC regenerative or DC dynamic type as per standard of the manufacturer.

3.24 GUARDS

3.24.1 All exposed couplings, shafts, gear wheels, pinions, drives etc. shall be safely encased and guarded.

3.24.2 Guards of an approved design, which will push forward or off the rail track any object (such a person’s foot or arm placed across it), shall be attached to each of the end carriage for both LT & CT.

3.24.3 The sheaves of hook blocks shall be guarded to prevent trapping of hand between a sheave and the in-running rope

3.24.4 Protective guards to live electrical / conductors shall be provided. However, a trailing cable arrangement with cable trolley is only preferred.

3.24.5 Effective means of guiding the wire ropes over the sheaves shall be provided wherever required, so as to prevent dismounting of rope from the sheave grooves even when a slack rope condition is developed.

3.24.6 All openings in foot walk flooring, for access of bottom chord platform, if any and to other inspection platforms shall be provided with covers having suitable locking means to avoid any accidental opening.

3.24.7 Guards shall be strong enough to take person weight ~100kg.

3.24.8 Toe guards shall be provided for all openings, on trolley and on Bridge platforms




SHEET : 23 OF 56

with minimum of 100mm.

3.25 PLATFORMS / WALKWAYS & LADDERS

3.25.1 Access walkways of minimum 1.8 mtr clear inside width with hand railings on both sides of bridge girders for the full span length for inspection and maintenance of the crane shall be provided. Walkways shall be of chequered plate or non-slip steel surface of minimum 6 mm thick. Walkways shall be of rigid construction and designed to sustain a distributed live load of not less than 3 KN/m2.

3.25.2 Walkway platform shall be complete with hand railings, posts and toe plate all around. The hand railings shall consist of 32 mm NB pipe in two (2) tiers. Top pipe shall be at about one (1) m and middle pipe shall be at about 450 mm height from the walkway platform level. Posts shall be spaced at 1.5 m maximum. Toe plate shall be 6 mm thick and shall project 100 mm above the walkway platform.

3.25.3 Ladders shall be of staircase type. Ladders shall be provided from catwalk to end carriage and to LT platform in all four corners.

3.25.4 Ladder shall be provided to reach the walkway platform from the operating floor. Ladder shall be at least 450 mm clear width with 20 mm diameter rungs spaced at 300 mm centres and shall be equipped with safety cages when the ladder is more than three (3) m high.

3.25.5 One ladder for access from the crane girder walkway to long travel walkway on each side of crane span shall be provided.

3.26 REPAIR CAGES

3.26.1 Repair cages shall be provided on the inside of the end carriage for attending to the current festoon cable 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 1000mm wide and shall be such that two persons can work comfortably in the space provided. The floor of the repair cages shall be about 1500mm below the LT wheel centres except the one which current festoon cables & trolleys are mounted, where it shall be suitably adjusted.

3.26.2 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.

3.27 LUBRICATION

3.27.1 Semi-Centralised grease lubrication unit with motor operated pump and hand operated grease pump as standby shall be provided for all anti-friction bearings. One unit shall be provided on bridge platform for line shaft anti-friction bearings and another unit shall be provided on trolley for top sheave and drum anti-friction bearings.

3.27.2 All other anti-friction bearings shall be lubricated manually by hand operated




SHEET : 24 OF 56

grease pump through respective grease nipples. Accessibility shall be such that parts can be safely lubricated from the walkways or ladders.

3.27.3 Bearing shall be enclosed in suitable housing with proper holes and plugs to prevent any ingress of dirt and to permit easy lubrication of the bearing.

3.27.4 Lubrication chart shall be provided indicating all lubricating points, type of lubricant and recommended frequency of lubrication.

3.27.5 Splash type lubrication shall be incorporated and adequate lubrication of the gears shall be ensured. Oil level required in the housing shall be clearly marked. A large oil filter cum breather shall be provided together with a drain plug. No oil should be leaked from any part of the crane.

3.27.6 Wheel bearings shall be provided with suitable gearing points on both the sides of wheel and shall be made approachable.

3.27.7 Trunion of wheel bogies shall be provided with suitable greasing points for both sides of the pins.

3.27.8 Suitable provision shall be provided for lubrication of hook and sheave bearings.

3.27.9 Suitable drip pans shall be provided as required to collect oil and grease which may drop from operating parts. All drip pans shall be accessible for draining and cleaning.

3.27.10 Adequate provision / arrangements shall be made to prevent lubricants falling from the crane.

3.28 RUNWAY / TROLLEY RAILS

3.28.1 The rail section shall be as per IS: 3443.

3.28.2 The rails shall be made continuous by welding standard lengths. Welding shall be done as per standard procedure approved by Third party inspection agency and SDSC-SHAR

3.28.3 Rails shall be clamped to the girders with double bolt clamping plates. The rail clamps shall be spaced not more than 450mm apart. Rail clamps shall be of Make: M/s GANTREX only.

3.28.4 The scheme of securing the rails to the gantry girder/ bridge structure shall be with galvanised clamps, bolts and nuts and shall be perfectly aligned.

3.29 PARKING BRAKE

3.29.1 A parking brake of suitable design and construction shall be provided for the bridge travel motion.

3.30 BOLTS & NUTS

3.30.1 All bolts, nuts, washers etc. used in the crane for structural and for mechanical systems shall be galvanised as per IS:1367 part 13.

3.30.2 Maximum combined stresses induced in the fasteners by normal operating loads (but not including pre-tensioning loads) shall not exceed 20% of the ultimate strength of the fasteners.

3.30.3 Bolts in rotating parts shall be locked with double lock nuts. All couplings & brake




SHEET : 25 OF 56

drums shall be provided with “Fit” type bolts.

3.30.4 High tensile galvanised bolts shall be baked to relive Hydrogen entrapped.

3.31 TOLERANCE ON CRANE STRUCTURES

3.31.1 Top flanges shall be as flat as possible and the cross cambers over the central width of 150mm shall not exceed 0.6mm with the convex surface upwards. Crane girder with a concave surface over the central width of 150mm will not be accepted.

3.31.2 Webs will be flat and straight and shall not vary from the intended line by more than 2mm measured at the top flange.

3.31.3 Deviation from straightness of gantry girders shall not exceed 3 mm in 32 m length of the girder in plan. Vertical camber shall not exceed +3mm/-0mm in 32 m length.

3.31.4 The following tolerance shall be used:

Overall depth of crane girders : ± 2 mm

Span over LT wheels : ± 4 mm ( maximum)

Diagonal on wheels : ± 5 mm ( maximum)

LT wheel alignment : ± 1 mm ( maximum)

Tilt of wheels or balancer : ± 1/1000 maximum (horizontal & vertical)

Trolley wheel gauge :±2mm for gauge up to 2.5mm (max)

: ±3mm for gauge above 2.5mm

3.31.5 Difference in height between trolley rails (#) in relation to the trolley gauge (s) shall be within the following tolerance:

S,mm #, mm

Upto 2500 3mm

Above 2500 5mm

3.31.6 Crane Girder:

Differences in levels between crane girders on either side of the building: ±5mm

Deviation in crane rail level at any point from true level :±4mm

Differences in crane rail actual levels between any two points 2m apart : 2mm

along rail length

Deviation in crane rail axis from centre line of web : ± 3.5mm

Deviation in crane rail gauge : ±5mm

Deviation in alignment of crane rail plan : ±1mm

measured between any two points apart




SHEET : 26 OF 56

4.0 ELECTRICAL REQUIREMENTS

4.1 GENERAL ELECTRICAL SYSTEMS

4.1.1 Incoming Power specification & availability.

a) The incoming source is of 3 Phase with neutral solidly grounded system. The crane electrical equipment shall be designed for satisfactory operation for 3 phase, 415V±10%, 50Hz ±5%, 240V±10% for single phase

b) The incoming source panel to the crane power is located at 4 m level. A main isolator switch has to be provided at 86 m. Level. (around 250 mtr cable length) The bidder’s Scope of supply includes (i) incoming power cables from 4 m level to the crane isolator panel (ii) isolator panel at 86m level (iii) cabling from isolator panel to crane main incoming panel at drive room(82 m) including cable laying and termination.

c) The isolator panel is at 86m. Consisting of Isolating switch with R,Y,B LED indication lamps.

d) Each motor has to be provided with 3 pole isolating switch gear, HRC fuses, contactors with thermal overload relays and other VVVF drive components required for satisfactory control of motors. The isolating switch gears and contactor shall be rated at least 40-50% more (nearest standard size) than the motor full load current.

e) The main incoming panel shall be of IP 54 protection and VVVF drive panels as per standard are to be located at 82m level with sufficient working space all around with adequate cooling system.

f) Main incoming panel at 82m level shall be with ACB with under voltage, over current and earth fault protection. The breaker shall have mechanical key protection with emergency pushbutton projection at outside.

g) The incoming panel shall be provided with R,Y,B indication lamps, with digital volt meter, ammeter and other standard metering/indications.

h) CFL / LED Lights inside the control panels for maintenance purpose shall be provided with door interlocks.

i) The ACB may be provided with hinged protective transparent acrylic sheet for inadvertent manual operation.

4.1.2 Power & Control Panels.

a) The isolator panel, incoming panel and drive panels etc, shall be designed for 3 phase, 415V±10%, 50Hz ±5%, 240V±10% for single phase. The power panel shall be rated for 50kA short circuit capacity as per standard.

b) The panels are treated in 9 tank process or better and powder coated painted with approved and standard shade and special consideration to withstand saline environment. Dust and vermin proof panels shall be IP 54 or better protection.

c) These panels are compartmentalised panel(s) for housing the control gear comprising contactors, timers, isolators switches, HRC fuses, moulded case




SHEET : 27 OF 56

circuit breakers all brought upto terminal blocks, etc. inside the panel and push buttons, indicating lamps, operating handles, etc. brought out on the panel door.

d) Sheet Steel used shall be cold rolled and at least 2.0mm thick and properly braced to prevent wobbling.

e) Panels shall be provided with hinged door(s) with padlocking arrangement and suitable brackets/channels shall be provided.

f) All doors, removable covers and plates shall be gasketed all around with neoprene gaskets. All accessible live connections shall be shrouded and it shall be possible to change individual fuses, switches, MCBs without danger of contact with live metal.

g) All live parts shall be provided with at least phase to phase and phase to earth clearances in air of 25 mm and 20mm respectively.

h) Adequate interior cabling space and suitable removable cable glands shall be provided. Necessary number of cable glands shall be supplied and fitted screwed-on type and made of brass.

i) Two earthing terminals shall be provided to all panels to suit the earthing conductor.

j) All panels are floor mounted, front operated type with bottom cable entry.

k) All the Panels housing electronic components shall be provided with cooling systems with redundancy to limit the temp inside to the safe limit.

l) Bus bars shall be insulated and of copper and shall have adequate cross-section to carry the required continuous currents such that the operating temperature of the busbars does not exceed as per standard.

m) The panel layout, engineering, power and control wiring shall be as per industry standard and as per BIS.

n) Strip type space heaters of adequate capacity shall be provided inside each cabinet. Heaters shall be complete with rotary type ‘ON-OFF’ switch, HRC fuse on phase or a single-pole MCB with overload and short circuit protection, link on the neutral and a thermostat to cut off the heaters at 45 Degree Celsius and shall have continuously settable range from 30 to 90 degree Celsius

4.1.3 Electrical switch gear & components.

a) All electrical switchgear and components shall be designed for 3 phase, 415V±10%, 50Hz ±5%, 240V±10% for single phase. The components shall be rated for short circuit capacity as per standard and operation duty as required for crane operation.

b) ACBs/Switches / MCBs / MPCBs /MCCBs shall be hand operated, air break, heavy duty, quick make, quick break type conforming to applicable standards with remote control feature.

c) The rating of switch shall be so chosen as to get complete protection by associated O/L relay or fuse under all normal/abnormal conditions such as full load, overload, locked rotor, short circuit etc. MCBs / MPCBs /MCCBs shall be provided with overload/short-circuit protective device.




SHEET : 28 OF 56

d) Various protection systems shall be fully coordinated in the circuits.

e) Switch handle shall have provision for locking in both fully open and fully closed positions.

f) Fuses generally shall be of the HRC type, having a rupturing capacity of minimum 80 kA.

g) Current and voltage transformers shall be dry type of suitable rating and VA burden.

h) The pushbutton actuators and selector switches shall be of highly reliable for rugged operations at field. The rating shall be as per standard.

i) Indicating lamps of the Clustered Coloured LED type with coloured Lens as per standard.

4.1.4 Control & Aux.Power Supply

a) All AC control power requirement shall be derived from the main power by using appropriate transformers with standard protection and redundancy.

b) All DC control power requirement shall be derived from the main power by using appropriate power supplies with standard protection and redundancy.

c) Pendant control shall be through intrinsically safe circuits using standard and branded instrinsic safe units.

d) Separate circuits with switches, fuses etc. of adequate rating shall be provided for control of space heater, through thermostat and panel illumination etc.

4.1.5 Relays / Auxiliary Contactors

a) Necessary auxiliary release for alarm, time-delay relays, and voltage relays as required for control and protection shall be mounted inside the cabinet. Relays shall be equipped with externally reset, positive action operation indicator. Voltage relays shall have sufficient thermal capacity for continuous energization, using external resistors if necessary.

b) Auxiliary relays shall be rated to operate satisfactorily between 80% and 110%of the rated voltage.

c) Each relay shall be provided with at least two potential free contacts (1NO+1NC).

4.1.6 Labels and diagram plate.

a) Every equipment mounted in the cabinet shall be provided with individual labels with equipment designation/rating. Also, the cabinet shall be provided on the front & Rear side with a non-rusting label engraved with the designation of the cabinet.

b) All power & control and data/signal cables shall be clearly labelled through out their length at suitable intervals.

4.1.7 Drawings and data & catalogues

As part of the proposal, the BIDDER shall furnish the following drawings and data for scrutiny.




SHEET : 29 OF 56

a) Configuration of Electrical system

b) Write up giving details of redundancy, safety, protection, operational details

c) Overall layout of Power/Control cabinet general arrangement drawing showing dimensioned views, cable entry location and mounting details.

d) Design/Selection data with margins available

e) Bill of material listing equipment designation, make, model type, rating etc. of the various equipment mounted on the control cabinet

f) Technical catalogues all major items like motors,VVVF drives,& aux systems, brake systems, cables, cable drag chain systems.

g) One set of drawings, catalogues, drawings, technical manuals have to be supplied along with delivery of items and three sets of commissioning documents consisting of

i. Hard copies of as built drawings, layout, power and control drawings, technical manuals , O&M documents, PO copy , design details, factory/site acceptance test results, warrantee certificates etc

ii. VVVF Softwares/ parameters, licence, passwords, O&M manuals etc

iii. Operating handles, locks, keys etc 4.2 DRIVE MOTORS

4.2.1 Motors shall conform to the latest applicable standard of IEC-34/IS-325 for Crane duty applications.

4.2.2 All crane motors shall be totally enclosed fan cooled type (TEFC).

4.2.3 Motors shall be of increased safety category. All motors shall be of squirrel cage, Inverter duty type motors for VVVF drive and crane duty applications .

4.2.4 The motor current rating shall be arrived at such way that the motor shall draw 80% of the full load rating current while operating at designed speed and load at nominal voltage of 415V,50Hz,AC supply at incoming source panel.

4.2.5 The degree of protection for the motor enclosure and terminal boxes shall be IP-54 or better.

4.2.6 Space heaters shall be provided for all motors of rating 30 kw and above motors. Heaters to be automatically ‘OFF’ when the motor is switched ‘ON’. Stator winding will be connected to a 24 V single phase, 50hz, AC supply for heating and elimination of moisture. Space heaters shall have adequate capacity to maintain motor internal temperature above dew point to prevent moisture condensation during idle period. The space heaters shall be placed in easily accessible positions in the lowest part of the motor frame.

4.2.7 Each motor shall have two earthing terminals.




SHEET : 30 OF 56

4.2.8 Motors shall be suitable for bi-directional. Motors shall suit the duty Class S5 / as per standard for the application, cyclic duration factor 40% and number of starts per hour 300.

4.2.9 Motors shall be of IE1 for VFD and IE2 for non VFD as per IS 12615.

4.2.10 All motors terminal box shall be suitable for Copper cable connection.

4.2.11 Motor insulation shall be Class F or better with temperature rise limited to Class B tropicalized by coating with non-hygroscopic coatings, suitable for operation in saline , humid & hot environment.

4.2.12 The minimum permissible voltage at Motor terminals shall be 85% of the rated voltage during motor starting.

4.2.13 Motors shall be capable of starting and accelerating the load with the applicable method of starting, without winding temperatures reaching injurious levels, when the supply voltages is in the range of 85% of the rated motor voltage to maximum permissible voltage.

4.2.14 The temperature rises shall not exceed the value indicated in BIS.

4.2.15 The motor shall have the capability to meet the empty hook handling speeds mentioned.

4.3 VARIABLE VOLTAGE VARIABLE FREQUENCY DRIVES

I. Variable Voltage Variable Frequency (VVVF) Drive control shall be provided for all motors of motions of cranes.

II. The design, material, construction, manufacture, inspection, testing and performance of AC drives shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. The equipment shall also conform to IEC 146 or equivalent and the latest applicable standards. The drives shall be selected such that the de-rated current rating (50°C) shall be more than the rated full loa d current of the respective motor.

III. The crane shall have precise control/movement to align the parts for integration with variable speeds (VVVF Drive control).

IV. The Main & auxiliary hoisting and cross travel & Long travel drives shall be provided with VVVFD for varying the speed to achieve creep speed and inching operation.

V. Dual drive control system (VVVF Drive control) with synchronization shall be provided for main hoist motions. In case of failure of one drive system, the crane should be operable within the power and speed limits of good drive.

VI. Additionally Redundant spare drives in fully wired condition are to be provided for (1) Auxillary hoist, (2) Cross travel & (3) long travel motor circuits. In case of any failure of any drive for p articular motion, the redundant drive can be manually selected so that th e operation can continue immediately.




SHEET : 31 OF 56

VII. Twin or four control drives are to be provided for LT drive with a mechanism of speed synchronization on both sides of LT. In case of multiple drives either for CT or LT, speed synchronisation shall be provided. In such cases individual drive shall be designed to take the full load.

VIII. If two or more motors are provided for travel motion they may be controlled by common VVFD drive with an overload relays in each motor circuit. All the master controllers shall be provided with zero position interlock.

IX. VVVF drives shall generally conform the following also

a) Electro-magnetic compatibility as per EN 61800- 3/IEC 1800-3.

b) Conformation of European Union / under laboratory certification.

c) At least one size higher than the motor rating (more than 125%).

d) In built thermal overload protection. Provision to connect thermostats embedded in the motors.

e) Push buttons only for required speed selection

f) Radio interference filter.

g) In-built relays to indicate drive health and trip status.

h) Safe stop function, to ensure that the drive will only start.

i) Input current THD shall be limited to less than 5%. If required, necessary harmonic filters shall be incorporated

j) Control and signal cables shall be of screened type, laid separately and not to be bunched with power cable.

k) In case of any stoppage in emergencies, the system shall switch off main power supply and shall be capable of holding the load continuously.

l) Proper interconnection to limit switches for all the travels and hoist in both the directions.

m) When switched off, there shall be no residual power in the systems due to VVVF equipments.

n) For hoist, necessarily encoders shall be used for feedback to achieve closed loop speed control.

o) Provision for front panel parameter inputting and remote monitoring and resetting.

p) All necessary protections as per standard like overload, over /under voltage, short circuits, high temp, undesirable operating conditions and interlocks.

q) Multiple drives shall be configured such a way that all systems are suitably synchronised and subsystems like motors, break systems, DBRs etc shall perform the desired operational requirements and reliability.

4.3.1 DYNAMIC BRAKING RESISTOR




SHEET : 32 OF 56

a) Each hoist motion shall be provided with self-contained, sturdy, automatic braking system to prevent over speeding of the hoist.

b) Dynamic braking Resistors shall be adequately protected to prevent contact with live parts.

c) Dynamic braking Resistors shall be provided with terminal boards equipped with brass or copper terminal studs

d) 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

e) Dynamic braking connecting resistor temperature of any exposed portion of the resistor enclosure shall not exceed the limits set by standards

4.4 CABLES

4.4.1 LT Power Cables (Fixed type)

Power cables for 415V AC and 240V AC system are 2 core / 3 core /4 core (depending on the application), 1100V grade cross-linked polyethylene (XLPE) insulation, core identification by colour coding, extruded PVC compound type ST-1 inner sheathed, Galvanised steel wire/flat for multicore cables and extruded overall FRLS PVC outer sheathed, generally conforming to IS:7098 (Part I).

Design Criteria for Power Cable Sizing

a) Power cable sizes shall be selected on the basis of current carrying capacity, short circuit rating, permissible voltage drop and standardisation of cable sizes.

b) Power cables shall carry the full load current of the circuit continuously under site conditions considering the various derating factors like ambient air temperature, grouping, etc. The design ambient air temperature shall be considered at 50˚ C.

c) Power cables shall withstand the fault current of the circuit for the duration not less than the maximum time taken by the primary protective system to isolate the fault.

d) Voltage drop from transformer secondary to motor terminals during starting of motors will be limited to 15% of the rated voltage.

e) The voltage drop in feeder cables between source panels to motor terminals shall be limited to 3% during full load running condition.

4.4.2 Control Cables (Fixed type)

Control cables shall be 1100 V grade, multi core, minimum 1.5 sq. mm cross section, stranded copper conductor having extruded PVC compound Type A/XLPE insulated, extruded PVC compound type ST-1 inner sheathed, galvanised steel wire armoured and extruded overall PVC FRLS outer sheathed generally conforming to IS1554/7098 Part-I/Part II. In situations where accuracy




SHEET : 33 OF 56

of measurement or voltage drop in control circuit warrants, higher cross sections as required shall be used

4.4.3 Instrumentation cables (Fixed type)

The instrumentation cables shall be annealed, tinned stranded copper conductor of size 0.5 sq mm, extruded PVC compound Type A insulated, twisted into pairs, overall screened (I1 type) for digital signals, individual and overall screened (for I2 type) for low level analog signals, individual triplet and overall screened (type I3), extruded PVC compound type ST-1 inner sheathed, Galvanised Steel strip armoured and overall sheathed with FRLS PVC. The insulation shall be strippable manually as well as by mechanical stripping devices without damage to the conductor.

The outer sheath of FRLS PVC compound shall meet the following performance requirements:

4.4.4 Trailing cables

The trailing Power/control/signal cables shall highly flexible/multi strand annealed tinned copper conductor, Elastomer type IE1 insulated, Elastomer Type SE4 sheathed conforming to IS-4289 Part-1.

( Cable Chain Drag System Igus brand or reputed)

a) All trailing moving cables shall be protected by suitable size and designed cable chain drag system of reputed brand through out the crane movement.

b) All cables on crane top and drive room to crane etc shall be laid on a suitable size closed cable trays.

4.5 EARTHING

4.5.1 The earthing conductor shall be designed for 50 kA for duration of 1 second.

4.5.2 In case required separate earthing may be derived for signal/control application.

4.5.3 The earthing system conductors and accessories shall be of GI/copper of suitable size.

4.5.4 Earthing of Electrical equipment on cranes and travelling machines.

4.5.5 Every 3 phase electrical equipment shall have minimum of two earth connections.

4.5.6 A dual earth bus bar system shall be provided within the crane/machine to which all electrical equipments/Structures as per standard shall be connected at least at two places.

4.5.7 The size of the earthing leads shall be decided based on the type of equipment and structure to be earthed and shall be provided generally as per IS-3043 and also with a view to minimise the number of sizes.

4.5.8 SDSC-SHAR will only provide ground riser at 4mtr level location for grounding. Further connection from this riser to EOT system for earthing will be in bidders scope.




SHEET : 34 OF 56

4.5.9 Any specific grounding requirement other than the above power earth, may be brought out in the offer

4.6 CRANE PENDANT

4.6.1 Crane shall be operable from any floor using plug-in type light weight pendent (two spare pendent should be supplied).

4.6.2 SVAB crane shall be operated from pendant control at 22 platform levels at different elevations. The platforms are located at elevations of 0.0 m, 4.0 m, 7.0 m, 11.0 m, 15.0 m, 19.0 m, 23.0 m, 27.0 m, 31.0 m, 35.0 m, 38.0 m, 42.0 m, 47.0 m, 51.0 m, 55.0 m, 59.0 m, 63.0 m, 67.0 m, 70.0 m, 74.0 m, 78.0 m and 82.0 m. Also in 2 nos in SAT & 1 no. in NAT tower location.

4.6.3 For pendant operation, intrinsically safe junction boxes and plug sockets shall be provided on either sides of the platform level. Three numbers of portable trolley type, intrinsically safe, multi-pin plug-in type light weight pendants shall be provided along with a lead cable of 30 m length to plug the same at any of the plug sockets at various platform levels. Light weight pendants with interlock arrangement shall be provided.

4.6.4 An emergency stop pushbutton shall be provided in the intrinsically safe pendant. On operation of this emergency push-button, all electro-hydraulic brakes shall be applied immediate to all motions and drives shall be stopped.

4.6.5 Pendant interlock arrangement shall be provided, so that at any given instant crane can be operated using only one pendent.

4.6.6 Push button actuators shall be spring return type with 2 NO+2NC.

4.6.7 Suitable locking facility shall be provided between the socket and plug such that no instance the plug can come out of the socket inadvertently.

4.6.8 FRLS control cables from the crane/drive room shall be brought out and connected to suitable junction boxes with multi pin plug sockets and hinged covers to be provided at two sides of all floor levels.

4.6.9 All apparatus and circuits contained inside the pendant push button station, junction boxes, plug sockets, etc, shall be intrinsically safe and shall belong to the category ‘ib” as per IS: 5780. The degree of protection offered by the enclosure to the pendant push button station shall be IP:54 or better as per IS:2147.

4.6.10 The trolley type Pendant push button station shall comprise the following push buttons and indicating lamps all combinations of crane operations.

4.6.11 Remote display of VVVF drive parameters and Reset facility shall be provided in the Pendant station.

Slno Description

1 Supply On /off selector switch

1 Control pendant manual control keyway switch On / off selector switch

2 Control on (manual control key on) Red lamp on




SHEET : 35 OF 56

3 Control off (manual control key off) Green lamp on

4 Two way selector switch for selection of Main hoist drive Drive A / Drive B

5 Three way selector switch for selection of Main hoist motor

M1 motor / M2 motor / M1&M2 motor

6 Bell / Horn on crane bridge on / off Push button Push button 7 Emergency Push button Push button

8 Main Hoist Normal up Push button

9 Main Hoist Creep up Push button

10 Main Hoist Normal down Push button

11 Main Hoist Creep down Push button

12 Auxiliary Hoist Normal up Push button

13 Auxiliary Hoist Creep up Push button

14 Auxiliary Hoist Normal Down Push button

15 Auxiliary Hoist Creep Down Push button

16 Long travel Normal North Push button

17 Long travel Creep North Push button

18 Long travel Normal South Push button

19 Long travel Creep South Push button

20 Cross travel Normal East Push button

21 Cross travel Creep East Push button

22 Cross travel Normal West Push button

23 Cross travel Creep West Push button

24 Main hoist Motor-1 fault indication Yellow lamp on

25 Main hoist Motor-2 fault indication Yellow lamp on

26 Auxiliary Hoist fault indication Yellow lamp on

27 Long Travel fault Indication Yellow lamp on

28 Cross Travel fault indication Yellow lamp on

29 Manual control keyway switch for no Load Double speed selector On / off

30 Any other standard pushbutton / indications

4.7 LIGHTING AND MISCELLANEOUS ACCESSORIES

4.7.1 LIGHTING FIXTURES

Lighting fixtures shall be of flame proof fitting. Gr II B category .Flood lights shall be of Metal Halide or LED type fixed under the crane bridge so that the lamps illuminate the load being lifted to a lux level of 250 at the lowest level as per the original layout of the facility.




SHEET : 36 OF 56

Few lights fittings shall be also provided on the top to illuminate the crane top.

4.7.2 SOCKETS

Flame proof socket Points Gr II B 16 amp single phase 2 Nos and 32 amps 3 phase 2 Nos shall be provided on the top of the crane.

4.7.3 LIMIT SWITCHES

Heavy duty limit switches, suitable for crane applications should be provided and Activation of hoist limit switches shall put off power supply to the control system

Automatic reset type of limit switches shall be provided to prevent over-travel for each of the following motions:

a) For Over-hoisting and over –lowering motions of the main hook and the auxiliary hook.

b) Long travel motion.

c) Cross travel motion.

4.8 ON THE SITE TRAINING FOR ELECTRICAL & VVVF DRIV E SYSTEM O&M

Supplier has to impart necessary training on electrical system including VVVF drives by the competent either from the OEM or experienced engineers of supplier to the authorised Departmental staff for minimum period of 7 working days especially Operation and maintenance aspects.

5.0 SAFETY FEATURES Safety of the article handled is foremost important and the same has to be ensured while configuring and designing systems. Failure of any system should not allow the crane to misbehave. Adequate control logic, protection schemes, interlocks shall be incorporated in main and sub systems of electric circuits.

(a) Protection & Interlocks shall be generally provided for:

i. Over/under voltage or frequency input power conditions

ii. Phase unbalances and phase sequences

iii. DC power systems

iv. Over current/over temp conditions with audible & visual indication

v. Crossing speed limits in all motions with audible & visual indication

vi. End limits for all movements

vii. Operational errors from the pendant.

viii. Pendant operated audible alarm to alert the commencement of crane operation

ix. Jerk free inching operations for minute and accurate handling of articles.




SHEET : 37 OF 56

(b) Mechanical safety devices such as end stopper, wheel stops etc. to limit the movement of trolley as well end carriage.

(c) All Brakes to be applied to all motors when over speed of rope drum is sensed.

(d) Limit Switches For Hoisting Motion

The hoist motions are fitted with three contact rotary shunt limit switch, coupled to the hoist drum through a gearbox. The limit switch contacts are arranged to give hoist slow down, hoist stop and lower top. Activation of the slowdown contact restricts the motion speed to approximately 20% of full speed. All contacts are self-resetting by operating the hoist motion in the opposite direction.

(e) Limit Switches for Cross and Long Travel Motion

Trolley and end carriage travel are provided with lever type shunt limit switches for slow down and stop contacts for the motion in both directions. Activation of the slowdown limit switches restrict the motion speed to approximately 20% of full speed. All limit switches are self-resetting by operating the motion in the reverse direction.

(f) Four (4) non-fusible air break isolating switches of adequate rating (not less than 15 amps) are fitted at the four corners of the crane so as to be accessible while standing on the crane platform. These are wired up in series with the emergency stop to open the main power contactors.

(g) Gravity operated pendulum type limit switches are provided for Main & Auxiliary hook. Resetting of this limit switch will be done at electrical room located at EL+82m.

(h) Limit switches are provided in access ladder gates to prevent start of crane when gates are in open condition.

6.0 HEALTH MONITORING SYSTEM FOR GEAR BOX’s IN MAIN & AUXILLARY HOIST

6.1 Health monitoring system is to be quoted separately in the price bid format.

6.2 Health monitoring system of the gear boxes to be provided for all gear boxes in main hoist and auxiliary hoist.

6.3 It shall consist of display of state of Lubricating oil, debris in oil, temperature of oil & bearings, vibration of the gear box etc.

6.4 Relevant proposed scheme to monitor gear box health status shall be submitted along with technical bid for evaluation.

7.0 LOAD TESTING OF CRANE AT VENDOR SHOP

7.1 Load testing of crane at Vendor site is to be quoted separately in the price bid format. However load testing of crane at SDSC-SHAR is in the scope of supplier only.

7.2 Along with no load tests of crane at supplier’s site, full Load testing of crane can be carried out as per IS.




SHEET : 38 OF 56

8.0 PERFORMANCE AND LAYOUT REQUIREMENTS

8.1 Performance Requirements

8.1.1 The equipment is normally expected to operate continuously.

8.1.2 Fluctuations in Power Supply Conditions

Although the rated frequency is 50 Hz, it is expected that reduced frequencies will prevail over sustained periods of time owing to possible shortage of power in the region. All motor driven auxiliary equipment and accessories shall be capable of continuously delivering the rated outputs for a voltage variation of ± 10% and frequency variation of ± 5% occurring separately or combined voltage and frequency variation of ±10%.

8.2 Layout requirements

8.2.1 Hook approaches for main and auxiliary hooks shall be as indicated in the crane clearance diagram with adequate space around the equipment.

8.2.2 Access walkways with safety hand railing shall be provided along the full span length on both sides of the crane bridge girders.

9.0 TOLERANCES ON CRANE DIMENSIONS & PERFORMANCE TE STS

9.1 Tolerances on crane dimensions and manufacturing:

9.1.1 Bidder shall ensure that the crane shall be manufactured as per the tolerances specified below. Final inspection reports shall be submitted in drawing format.

1 Span over LT wheels + 4mm maximum 2 Diagonal on wheels ± 5mm maximum

3 Parallelism of Girders < 1/1000 of wheel gauge (measured at every 1m interval)

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

5 Verticality of End Carriages < 1mm (measured at every 1m interval)

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

7 LT wheel alignment ± 1mm (maximum)

8 Difference in height between trolley rails

<1/1000 of wheel gauge maximum at 1m interval

9 CT Rail alignment w.r.t Girder centre

±1 mm (measured at every 1m interval)

10 Tilt of wheels ( both horizontal & vertical)

< D/ 1000mm where D = diameter Of wheels

11 CT/LT displacement wheel <2mm (measured at all wheels) Wheel alignment




SHEET : 39 OF 56

12 CT / LT wheel diameter variation

less than 0.1 mm in diameter of wheel

13 Squareness of Girders to End carriages

within 1.60mm ( for wheel base of ~4000mm)

14 Hoisting speed +10% -5% of specified speed. 15 Lowering speed +20% -5% of specified speed 16 Travelling speed +10% -5% of specified speed.

9.2 Performances Test

9.2.1 Performance tests shall carried out to prove the guarantees indicated as above.

9.2.2 The BIDDER shall conduct shop and site tests on the cranes to meet all technical specifications.

9.2.3 Control interlock and sequential operation of the control schemes shall be demonstrated both at shop and at site.

9.2.4 100% radiographic test shall be carried for butt welds in tension zone.

9.2.5 Energy consumption of motors at different motions while handling safe working loads at the rated speed shall be demonstrated.

10.0 SURFACE PREPARATION & PAINTING

10.1 Complete Crane structure shall be painted as per the instructions given below.

10.2 All the shop-fabricated items shall be grid blasted, primer painted.

10.3 The site fabrication items also shall be gridblasted and primer painted before erection.

10.4 After completion of the erection, all the damaged primer painted area shall be rectified.

10.5 After primer painting, the total surface shall be final painted with sufficient number of coats using acrylic aliphatic polyurethane finish paint, having a DFT of 40 microns.

10.6 All box girders, before closing, shall be painted with primer and finish paint inside the girders.

10.7 Preparation of surfaces

10.7.1 All surfaces to be painted shall be clean, dry and free from oil, grease, dirt, dust, corrosion and weld spatters.

10.7.2 Any other surface contaminant except tightly bonded residues of mill scale rust is permissible to a limit of not more than 5% of whole surface and a maximum of 10% on any particular square inch area.

10.7.3 Surfaces that may become inaccessible after erection or installation or both, shall be prepared and painted while still accessible as per the same procedure mentioned.

10.8 Grid Blasting




SHEET : 40 OF 56

10.8.1 The entire surface of all the fabricated materials is to be grid blasted as per near white quality of steel structures painting council (SSPC) standard of SA 2.5 of SIS 055900.

10.8.2 The surface profile after blasting shall be between 37-65 microns and should be of jagged in nature.

10.8.3 Hand cleaning by chipping and scraping followed by wire brushing / abrasive wheels is allowed for items where surface preparation is difficult by sand blasting after taking approvals from purchaser / TPIA. All surfaces shall be degreased using a suitable solvent to remove oil & grease and shall be dried off before painting

10.9 Painting Scheme

10.9.1 Immediately after gird blasting, one coat of inorganic zinc silicate primer shall be applied to a dry film thickness (DFT) of 65 microns (minimum), followed by a final coat of 40 microns of acrylic aliphatic polyurethane finish paint. Colour code will be inalized by purchaser after award of contract.

10.9.2 All paint and primer shall be of standard quality and procured from approved manufacturers. The tenderer shall provide “Elcometer” / Paint thickness measuring gauges free of charge and shall measure the thickness of paint in the presence of the representative of the purchaser at random locations selected by him.

10.9.3 Machine finished surfaces shall be protected against corrosion by a rust inhibiting coating that can be easily removed prior to erection or which has characteristics that make removal unnecessary prior to erection.

10.9.4 Field painting shall only be done after the structure is erected, levelled, plumbed, aligned and welded / connected in its final position, tested and commissioned. However, touch-up painting for making good to any damaged shop painting and completing any unfinished portion of the shop coat shall be carried out by the Tenderer at free of cost. The materials and specification for such painting in the field shall be in accordance with the requirements of the specification for shop painting.

10.9.5 Painting shall not be done in frosty or foggy weather or when humidity is such as to cause condensation on the surfaces to be painted. Before painting of steel, which is delivered unpainted, is commenced, all surfaces to be painted shall be dried and thoroughly cleaned from all loose scale and rust.

10.9.6 All field rivets, bolts, welds and abrasions to the shop coat shall be spot painted with the same paint used for the shop coat. Where specified, surfaces which will be in contact after site assembling shall receive a coat of paint (in addition to the shop coat, if any) and shall be brought together while the paint is still wet.

10.9.7 Bolts and fabricated steel members, which are galvanized or otherwise treated, shall not be painted.

10.9.8 Paints shall be stored under cover in airtight containers. Paints supplied in sealed containers shall be used as soon as possible once the container is opened.




SHEET : 41 OF 56

10.9.9 While painting the new structures, the already finished floors and structures shall not be spoilt. If there is any spillage of paint on the floors or members on the finished structures, the tenderer has to clear and provide the painting to the spoiled areas.

10.9.10 Paints shall be checked for shelf life to meet the requirements before application. Proper action shall be taken well in advance prior to actual usage.

10.10 Paint Specifications

c) Inorganic Zinc Silicate Primer:

• Two part, self cured

• Dry temperature resistance to 400 oC

• Minimum shelf life of 12 months

• Excellent abrasion resistance

• Minimum coverage of 9 sq m./litre at 65 microns (minimum)

• Volume of solids 60% (minimum) by weight and 80% of zinc in dry film by weight

• No mud cracking at an applied thickness of 75 microns.

(b) Air drying Acrylic Aliphatic polyurethane finish paint.

• As per approved manufacturer’s specifications.

• Colour code will be finalised by department after award of contract.

11.0 START-UP SPARES, MAINTENANCE TOOLS AND RECOMME NDED SPARES

11.1 SPARES & MAINTENANCE TOOLS

11.1.1 The BIDDER shall include in his scope: (a) Start-up Spares, Maintenance tools as necessary and (b) Recommended spares. A detailed list of Recommended Spares shall be furnished by the BIDDER

11.1.2 The spares supplied shall be directly interchangeable with parts for which they are intended for replacement.

11.1.3 The spares shall be treated and packed for long storage (minimum 5 years) under the climatic conditions prevailing at the site.

11.1.4 The BIDDER shall indicate the service expectancy periods for all the spare parts in terms of hours of operation under normal operating conditions after which replacement will become necessary.

11.2 START-UP SPARES & MAINTENANCE TOOLS

11.2.1 The Start-Up Spares are those spares which will be required during start-up and commissioning of the equipment / systems until the equipment/systems are handed over to the SDSC-SHAR after completion of performance testing

11.2.2 The prices of the Start-Up Spares and tools shall be included in the lumpsum supply price of the total system. An adequate stock of Start-Up Spares and




SHEET : 42 OF 56

maintenance tools shall be available at the site such that the start-up and commissioning of the equipment / systems, performance testing and handing over the equipment/ systems to the SDSC-SHAR can be carried out without hindrance or delay. All Start-Up Spares which remain unused after the taking over the plant shall remain the property of the SDSC-SHAR. BIDDER’s quoted lumpsum price for the supply of the equipment shall be inclusive of the cost of Start-Up Spares

11.3 RECOMMENDED SPARES

11.3.1 BIDDER shall furnish in his bid a list of Recommended Spares with unit prices. The SDSC-SHAR reserves the right to buy any of the Recommended Spare parts as considered necessary by him. The prices of Recommended Spares shall be consistent with those of Start-Up Spares.

11.3.2 The Recommended Spares shall include the following.

a) Spares to be stored for three years trouble free operation.

b) Any strategic spares or consumables which the BIDDER recommends the SDSC-SHAR to hold to avoid delay in return to service following a breakdown. Justification for such holdings shall form part of the tender submission

11.3.3 Spares held off-site by the Manufacturer in his works shall not be included in Recommended Spares list. BIDDER can however indicate the details of such spares normally held by him.

11.3.4 The price of the Recommended Spares shall be kept firm up to twelve (12) months from the expiry of the validity of the offer for main equipment. Purchase of these spare parts will be covered by a separate order or an amendment to the contract and will be normally considered for ordering only after the receipt of the complete information such as instruction manuals/general arrangement and spares identification drawings, etc. for the equipment from the Bidder to enable the SDSC-SHAR to finalise the exact requirements. Subsequent to placement of order for Recommended Spares, Bidder shall furnish details/dimensional drawings for all such spares.

11.3.5 The BIDDER shall guarantee to the SDSC-SHAR that before going out of production of spare parts for the equipment furnished he shall give at least twelve (12) months advance notice to SDSC-SHAR so that the latter may order his requirement of spares in one lot if he so desires.

11.4 LIST OF START-UP SPARES & MAINTENANCE TOOLS

Following are the list of minimum number of start-up spares per EOT crane to be included in the BIDDER’s scope

Sl.no Description Quantity

MECHANICAL SPARES

1 Linings for Brakes

a) Main Hoist (for each brake) 2 Pairs




SHEET : 43 OF 56

b) Aux. Hoist (for each brake) 2 Pairs

c) Cross travel (for each brake) 2 Pairs

d) Long travel (for each brake) 2 Pairs

2 Bearings

a) For each motor 1 Complete Set

a) For each gear box 1 Complete Set

b) For each rope sheave 1 Complete Set

d) For each wheel 1 Complete Set

3 Thrustor Brakes

a) Main Hoist ( Fully assembled Brake) 1 Complete Set

b) Aux. Hoist (Fully assembled Brake) 1 Complete Set

4 Oil Seal

a) Gear Couplings 3 Sets

b) For each Gear box 3 Sets

5 Pinions

a) Long Travel pinion 1 Piece

b) Cross Travel pinion 1 Piece

6 Set of Gaskets of all sizes wherever applicable 3 sets

7 Rubber Bushes for Flexible Coupling 3 sets

8 Rope Guide

a) Main hoist 1 Pair

b) Aux. Hoist 1 Pair

9 Brake Spring

a) Main hoist (for each brake) 1 Pair

b) Aux. Hoist (for each brake) 1 Pair

c) Cross travel (for each brake) 1 Pair

d) Long travel (for each brake) 1 Pair

10 Suitable Hydraulic jacks for lifting Crane bridge / trolley for wheel maintenance

1set

ELECTRICAL SPARES

11 Fuse links 3 no.s each category.

12 MCB,, MPCB etc 1 no. minimum or




SHEET : 44 OF 56

10% of total qty.

13 Contactors 1 no. minimum or 10% of total qty.

14 Over load relays 1 no. minimum or 10% of total qty.

15 Encoders 1 no. minimum or 10% of total qty.

16 Intrinsic safe relays 1 no. minimum or 10% of total qty.

17 Power supply Units 1 no. minimum or 10% of total qty.

18 Push buttons 1 no. minimum or 10% of total qty.

19 VVVF drive related

a) Spare replaceable control cards 1 each for all types of drives.

b) Drive command relay boards 1 each for all types of drives.

20 Limit Switches

a) Hoist 1 No

b) Cross / Long travel 1 No

c)Rotary limit switch 1 No

d)Gravity limit switch 1 No

Maintenance tools

21 Complete set of ring spanners 1 set

22 Complete set of open end spanners 1 set

23 Complete set of Screw drivers 1 set

24 Complete set of Adjustable spanner 1 set

25 Insulated plier 1 set

26 Wrench Spanner 1 set

27 Grease Gun 2 Nos.

28 Oil gun 2 Nos.

29 Hand lamp 1 No.

30 Line tester 1 No.

31 Tool Box 1 No.




SHEET : 45 OF 56

12.0 INSPECTION & TESTING DURING MANUFACTURING & TE STING OF

CRANE

12.1 Designs / Drawings approvals & certificate from SDSC-SHAR before crane manufacture. Crane & its sub-components shall be manufactured and inspected as per the approved drawings only. All inspections / test reports shall be made with respect to approved drawing only.

12.2 The contractor shall conduct all tests required to ensure that the equipment furnished shall confirm to the requirements of the specification and in compliance with the requirements of the applicable codes in the presence of SDSC-SHAR representative and Third party inspection agency.

12.3 Manufacturing stage inspection and testing shall be carried out as per QAP. Supplier shall hold the manufacturing at specified “HOLD” places and call for inspection. The Schedule of Inspections shall be strictly adhered to and shall be witnessed by TPIA and/or ISRO. All the critical inspections and load testing shall be done in the presence of Third Party and SDSC-SHAR.

12.4 Raw material identification for structures, wheels, hoist mechanisms, Gears, load pins etc., shall be done by Third party inspectorate and/or department. Raw material test certificates, traceability of materials with identification marks shall be made available during identification.

12.5 All Butt Welded Joints (both compression & tension flanges / web joints) shall be subjected to 100% X-ray Testing and X-Ray Films to be produced for TPIA and/ SDSC-SHAR for evaluation and shall form part of the quality (QA) documentation submitted to SDSC-SHAR.

12.6 Inspection of Bridges, End Carriages, trolley, rails gauge, Wheels and measurement of Camber, mechanical assemblies checking as per QAP. Reports shall be made in drawing format.

12.7 Inspection of Span & Diagonal Dimensions (Minimum ~10Kg pull should be applied while checking), Checking bridge & end carriages squareness, Checking of Wheel Alignments, Mechanical drive Assemblies alignment and Pulley blocks alignment. Reports shall be made in drawing format.

12.8 The crane hook should be tested and certified by the dock labor board / govt. Approved test house for twice its SWL and test certificate should be provided.

12.9 The particulars of the proposed tests and the procedures for the test shall be submitted for approval before conducting the tests.

12.10 All materials, castings and forgings shall be of tested quality. Necessary test certificates shall be submitted.

12.11 The crane shall be subjected to full load & over load tests as per IS:3177 after complete assembly and wiring at site.

12.12 The crane shall be subjected to deflection test as per IS:3177.

12.13 The routine tests for the specified duty shall be conducted on the motors as per Indian standards IS:325 and IS:4029.




SHEET : 46 OF 56

12.14 If the hoisting drum offered is of welded construction, the seams of the same shall be fully radiographed.

12.15 Butt welds on structural members in tension shall be subjected to radiography. All other welds shall be DP tested.

12.16 Reports of all shop tests shall be submitted before dispatch of the subsystems to site.

12.17 Verification of BOQ and wiring & interconnections.

12.18 Verification of factory test / Other test certificates.

12.19 Verification Protection settings.

12.20 Verification parameter inputs of VVVF drives.

12.21 Verification of control and logic circuits.

12.22 Verification of Power circuits and adequacy.

12.23 Physical verification of electrical components and systems.

12.24 Load test also measurement of all electrical parameters, verification of safety/protection/operational specifications and VVVF drive performance etc as per standard.

12.25 Load test as applicable also measurement of all electrical parameters, verification of safety/protection/Temp rise/ cooling system/operational specifications and VVVF drive performance etc as per standard.

12.26 Over load test as applicable.

12.27 Functional operational verification and verification of design specifications such as brake effectiveness, noise, vibration etc

12.28 SHOP TEST

The crane shall be assembled and tested for satisfactory operation of all motions. The interference, if any, shall be rectified. No load performance shall be checked with reference to the specifications.

All drives in operation shall be tested at shop without load.

12.29 TESTS AT SITE

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 deflections of the bridge girders shall not exceed 1/1000 of span with 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




SHEET : 47 OF 56

on the extreme end of the crane span with smaller hook approach of the largest capacity hook.

c) Speed tests:

All the motions of the crane shall be tested with rated load and the rated speeds shall be attained within the tolerance limits indicated.

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

d) Performance tests:

The cranes shall be tested with rated load for performance of long travel and cross travel motions to develop the required acceleration.

e) Brake tests:

The hoist brakes shall be capable of braking the movement under conditions of full load and over load speed tests.

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 meters/min.

f) Insulation and other tests shall be submitted.

g) All test gadgets and instruments necessary for conducting tests at site shall be provided by the contractor and necessary calibration certificates shall be given for all test instruments.

h) The SDSC-SHAR will make arrangements for test loads.

13.0 ERECTION AND COMMISSIONING

13.1 Inspection and testing during/after erection shall be as per QAP.

13.2 Supplier shall submit detailed erection plan and procedure along with erection loads on building & also on parts being lifted shall be submitted for approval.

13.3 Supplier shall depute adequate qualified personnel i.e., Two Engineers/supervisor/ foreman, (one for mechanical and one for electrical), fitters, riggers, and electricians and helpers for carrying out quality erection work at our site within schedule.

13.4 Material (lifting equipment, lifting tackles, etc) required during erection are in Bidder’s scope. All lifting machines / tackles used shall be tested & certified as per standards before their usage for lifting crane.

13.5 Department shall provide suitable hooks on the roof in the facility for lifting of crane components. The capacity & location of hooks shall be given by manufacture during detail engineering. However the lifting machinery (power winch, pulley blocks, wire ropes, lifting gear, etc.,) and accessories are in the scope of supplier. All lifting machines/tackles’ Test certificates shall be furnished.

13.6 Initial filling of lubricants and spare parts required for commissioning at site shall be provided by the supplier.

13.7 Proving out for the Crane’s Capacity and Smooth Functioning of the Crane at




SHEET : 48 OF 56

Full load and over load shall be the responsibility of the supplier.

13.8 To be inspected and certified by “Competent Person/ Third party Inspection Agency “as per Industrial Laws and provide certification/clearance from Third Party Inspection Agency for final clearance & usage

14.0 CODES AND STANDARDS

14.1 All equipment, systems and works covered under this specification shall comply with all currently applicable statutes, regulations, standards and safety codes in the locality where the equipment will be installed.

14.2 In particular, the latest editions of following standards are applicable.

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

IS:1367 part13 Technical supply conditions for threaded fasteners Hot-dip galvanized coatings ( second revision)

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

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

IS:2062 Steel for general structural purpose.

ANSI/AWS D14.1

Code of welding practice for Industrial cranes, Mill cranes and other material handling equipment

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

IS:3681 Gears tooth form and modules.

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

IS 4460 : Parts 1 to 3 : 1995 Gears – Spur and Helical Gears – Calculation of Load Capacity

IS:1835 Steel Wires for Ropes

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

IS:2266 Steel Wire Ropes for General Engineering Purposes.

IS:2363 Glossary of terms relating to wire ropes.

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

IS:3443 Crane Rail Sections

IS:5749 Forged Ramshorn Hooks




SHEET : 49 OF 56

IS:3815 Point Hook with Shanks for General Engineering purpose

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

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

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

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

IS:325 Three Phase induction Motors.

IS:4029 Guide for Testing Three Phase induction Motor. ANSI/ASME B30.2 Safety Codes for overhead and Gantry Cranes.

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

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

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

IS 2148 : 1981 Flameproof enclosures for electrical apparatus

IS 2206 : Specification for Flameproof Electric Lighting Fittings

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

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

IS:1554 PVC Insulated (Heavy Duty) electric cables. IS:2208 HRC cartridge fuse links up to 650V. IS:2959 Contactors for voltage not exceeding 1000V AC or 1200V DC

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

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

IS:13703 Low voltage fuses for voltages not exceeding 1000V.

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

Specification for Low-Voltage Switchgear and Controlgear Assemblies – Part 1 to Part 3




SHEET : 50 OF 56

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 : Suppliers and Motor-Starters – Section 1 : Electromechanical Contactors and Motor Starters

IS 10118 : 1982

Code of Practice for Selection, Installation and Maintenance of Switchgear and Controlgear

Part I : General Part II : Selection Part III : Installation Part IV : Maintenance

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

14.3 Other national standards established to be equivalent or superior to the codes

and standards specified are also acceptable. The BIDDER shall furnish English translation of all standards specified in this specification, as and when demanded.

14.4 In the event of any conflict between the codes and standards referred to in the

specification and the requirements of this specification, the more stringent of these requirements shall govern.

14.5 Unless indicated otherwise, all codes and standards referred to in this enquiry specification shall be understood to be the latest version on the date of offer made by the Bidder.

15.0 MAKES OF BOUGHT-OUT ITEMS All bought out items shall be procured from the approved suppliers as given below:

Slno Item Makes

1 Wire ropes Usha Martin only.

2

All low voltage switchgear / control gear components including ACB, Isolators, MCBs, MPCBs, MCCBs, Switch disconnector fuse units, fuses, power contactors, control relays, push buttons actuators, OLR

Siemens




SHEET : 51 OF 56

3 VVVF drives and aux items Siemens

4 Selector switches and control components

Siemens / L&T/ ABB/ Schneider.

5 LED indication Lamps Siemens / L&T/ JAI BALAJI / VAISHNO

6

Inverter duty “increased safety” squirrel cage induction motors

CG / BHARATH BIJILEE / HM

7 Limit Switches BALIGA / SIEMENS / ABB / L&T / Schneider / BCH /CG

8 FRLS Power and control cables

NICCO / INCAB / RPG / CCI / FINOLEX / POLYCAB / KEI / IGUS / LAPP

9 Trailing cables & chain drag system

LAPP /IGUS

10 All flameproof items including Flameproof light fittings.

BALIGA / R STALL

11 Intrinsic safe Units P&F

12 Control panels SIEMENS /ABB/L&T/ Schneider / Rittal or as approved

13 Power panels SIEMENS/ABB/L&T/ Schneider / Rittal.

14 Flame proof Light fittings LED/MH

Baliga / R Stahl

15 Flame proof switch sockets & limit switches

Baliga / R Stahl

16 Electrical Aux items Aux items of the main items like VVVF shall be as

per the recommendation of main item supplier and as per the design of the OEM.

17 Thruster brakes BUBenzer, INVENSYS BROOK CROMPTON, WITTON KRAMMER, SIBRE, GALVI

18 Encoders Hubner / P&F

19 Gear boxes Elecon / Shanti / Greaves (premium transmission)/ DB-Radicon / Renold / Sumitomo / Flender.

20 450t Main hook Crossby only




SHEET : 52 OF 56

21 60t Auxiliary hook EEK / Hercules / RIZAR / Shilpa Udyog

22 Rails SAIL / IISCO / JINDAL / ARCELOR / TATA STEEL / ESSAR

23 Bearings SKF, FAG, TIMKEN

24 Couplings Fenner, Elecon, Shanthi

25 Drum / barrel couplings Malmedie, Germany

26 Paints Bombay paints, Berger paints, Asian paints

27 FASTENERS UNBRAKO / TVS

28 Third Party Inspection Agency TCE / LLOYDS / MN DUSTUR / MECON

29 Cranes wheels VALDUNES / SIBRE

Note: As far as possible single brand components shall be used. All models used shall be of latest but at least 2 years in the market and next 10 years’ service availability.

16.0 SPECIFIC REQUIREMENTS / INSTRUCTIONS TO BIDDERS

16.1 Bidders offers

16.2 In case of any deviations from the technical specifications, the BIDDER shall indicate the same in Schedule of deviations given in section F5 of this document. If no deviations are listed in the schedule of deviations, it will be considered that the BIDDER complies in total with the technical specifications. Any deviations indicated elsewhere other than schedule of deviations in the offer will not be accepted.

16.3 The BIDDER is advised to furnish all information called for in check list mentioned in Section F8 to be furnished along with the bid.

16.4 BIDDER is advised to quote for the complete scope. Partial response will not be entertained. In case of few items which do not directly fall under BIDDER’s manufacturing range and / or not available from indigenous source, BIDDER should take the responsibility upon themselves to procure them and supply to ensure that their offer is complete in all respects.

16.5 All bought out items supplied shall have capacities not less than those stated in this specification and necessary test certificates shall be furnished in this regard. However, if the BIDDER considers that higher capacity is required to meet guarantee requirements, he should offer the same and substantiate the same by calculations.

16.6 The BIDDER shall specify all the Design modifications which he considers are necessary for him to carry out in order to meet the guarantee requirements. The details of design modifications proposed to be carried out shall be attached as Annexure to the Schedule of Deviations from Technical Specifications.




SHEET : 53 OF 56

16.7 Any items which may not have been specifically mentioned herein but are needed to complete the equipment / system shall also be treated as included and the same shall also be furnished and erected, unless otherwise specifically excluded as indicated.

16.8 All tools and tackles required during various stages of execution of order right from manufacture at shop to the erection and testing at site shall be in the scope of the Contractor.

16.9 The BIDDER shall furnish one complete set of any special maintenance tools required for normal maintenance of equipment. The prices for the same shall be indicated in section-F1 Schedule of prices and delivery

17.0 RELIABILITY AND QUALITY ASSURANCE PLAN

The inspection procedures shall be categorized as follows:

(a) Category A: Stage wise and final inspection including review of documents by Department/ Third party inspection agency.

(b) Category B: Stage wise and final inspection including review of documents by the Contractor. Department/ Third party inspection agency shall perform final inspection and review documents.

(c) Category C: Final inspection and review of documents shall be carried out by the Contractor. Department/ Third party inspection agency shall carry out the final review of documents.

The minimum requirements for ensuring quality at various stages are spelt out below. However, the reliability and quality assurance plan shall be prepared by the vendor and will be reviewed & approved by Department / Third party inspection agency.

The following are the basic inspection requirements to be followed upon receipt of raw material:

Review of material test certificates Category C

UT of plates for thickness greater than 20mm Category C

The following are the minimum in-process tests that shall be carried out:

Welding procedure & welder / welding operator’s performance qualification Category C

100% MT / PT for flame cut edges for plate thickness exceeding 38mm. Category B

100% PT after back gouging Category B

100% MT / PT for fillet welds when both plates exceed 25mm thickness.

Category A




SHEET : 54 OF 56

100% MT / PT for fillet welds between tension flanges & webs. Category A

100% RT / UT for butt welds Category A

Heat treatment shall be carried out on the following:

For carbon steel plates where thickness exceeds 20 mm Category C

All other components as referred to in the drawings Category C

The following are the final inspection / tests that shall be carried out during various stages of manufacture, as applicable:

Visual and dimensional inspection of components / sub-assemblies Category A

Blue matching for bolted components Category A

Complete assembly of Crane at VENDOR’s shop and testing for performance requirements Category A

Complete Erection of Crane at site and testing for performance requirements. Category A

The schedule of tests stated above are indicative and not exhaustive in nature. CONTRACTOR shall carry out any other tests at shop / site as per directions of PURCHASER.

Quality Assurance Plan (QAP) for the Crane shall be prepared by the tenderer based on IS. However, QAP for procurement of forgings, castings and Bought out Items shall be furnished along with the tender, besides QAP for realisation of total mechanical system.

However, QAP sheets are given in Section-D of this document for guidance

18.0 DATA TO BE FURNISHED ALONG WITH BID AND AFTER AWARD OF

CONTRACT

The BIDDER shall ensure the following documentation are prepared and submitted to PURCHASER for his review / record

18.1 ALONG WITH BID

18.1.1 All documents mentioned in slno: 1.7.1 of Section A

18.2 AFTER AWARD OF CONTRACT

18.2.1 Design of load bearing structures shall be as per IS 807 and drive mechanisms as per IS 4137 and also as per technical specifications in to consideration.

18.2.2 General Arrangement (GA) drawing of crane to scale with dimensions, Bill of materials, bought out items, makes, weight breakups and wheel loads.




SHEET : 55 OF 56

18.2.3 GA Assembly Drawing of Trolley with all components.

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

18.2.5 GA drawing of Main Hoist drive shall be submitted.

18.2.6 General Arrangement drawing of wire rope reeving with dimensions and rope equalizer assembly.

18.2.7 Design & Constructional Drawings of Girder, end carriage, and trolley their connections with bill of materials.

18.2.8 Sub-assembly drawings for rope drum assembly, wheel assemblies, hook blocks etc.

18.2.9 GA drawings, details and selection criteria, design calculations for gear boxes with manufaturer's data sheets

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

18.2.11 Bridge Girder CT rail arrangement drawing to scale with BOM.

18.2.12 Sizing calculations for selection of Machine elements like wire rope, hook blocks, cross head, sheave pins, rope drum, couplings, wire rope pulleys, shafts, bearings etc.,

18.2.13 Calculation for bridge girder with deflection & camber, trolley frame, end carriage, with weight breakup.

18.2.14 Calculations for selection of wheels & wheel bearings.

18.2.15 Calculations for selection of CT & LT rails.

18.2.16 Calculations for drive shafts and plumber block bearings.

18.2.17 Quality Assurance Plan for total crane manufacture, erection & testing.

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

18.2.19 GA drawing, Hydraulic circuit, Electrical circuit, Calculations & selection of Emergency disc brake system of M/s SIME STROMAG, France.

18.2.20 Selection of keys, key ways & couplings.

18.2.21 Selection of bearings for EOT Crane.

18.2.22 Selection of sheaves & sheave pin with calculations.

18.2.23 Calculations for selection of wheel bogie connecting pins.

18.2.24 All the components of crane which are lifted for erection shall be design checked for erection / lifting loads and necessary Calculations shall be submitted.

18.2.25 Calculation for selection of motors, brakes, drives, cables and switch gear with manufacturer datasheets & Explosion proof certificates. All Motors' torque and speed curves shall be submitted for approval.




SHEET : 56 OF 56

18.2.26 Electrical circuit diagrams of EOT crane with individual drive circuits, control circuit, and with interlocks' circuits.

18.2.27 GA drawings of Protective Panel and other panel and inside components arrangements.

18.2.28 Electrical circuit, hydraulic circuit, and control circuit diagrams of Emergency disc brake system.

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

18.2.30 Lubrication arrangement of EOT crane with points indicated in drawing.

18.2.31 Bidder shall give the break-up weights of crane as mentioned below during final design : a) Weight of each bridge girder as assembled and ready for erection, with and

without mechanical and electrical components. b) Weight of each end carriage as assembled and ready for erection. c) Weight and name of individual heaviest mechanical components. d) Total weight of structural, mechanical and electrical components separately. e) Total weight of crane including electrical equipment. f) Weight of trolley structure ready for erection shall be provided. g) Total weight of trolley including electrical equipment

18.2.32 Quality Assurance Plan (QAP) to be submitted for review & approval.

18.2.33 Micro schedule for supply & erection indicating the date of completion of various activities so as to complete execution of the contract within the time frame stipulated in the LOI / Purchase order.

18.2.34 Progress Reports

18.2.35 Instrument data sheets.

18.2.36 The above list of documents is indicative and not exhaustive. The BIDDER / CONTRACTOR shall submit documents as specified in various sections of this specification and also as per the specific instructions of the PURCHASER

19.0 FINAL DOCUMENTS 19.1 CONTRACTOR shall submit the copies of operation and maintenance manuals

well before the despatch of the equipment. The manual shall be in sufficient detail with step by step instructions to enable others to inspect, erect, commission, maintain, dismantle, repair, reassemble and adjust all parts of the equipment. Each manual shall also include a complete set of approved as built drawings together with performance / rating curves / charts of the equipment, maintenance schedule and test certificates wherever applicable.

19.2 CONTRACTOR shall submit all the raw material test certificates, Ultrasonic testing of the raw material, Ultrasonic / radiography test certificates of all necessary welds, Stress relieving Charts, Hardness test certificates and Dimensional inspection reports of individual components.

19.3 Quality assurance documentation compiled for the project.

SPEC no: TATA CONSULTING ENGINNERS LIMITED SECTION: C

TCE: 7517A-D-EOC-003 MAIN HOIST DRIVE CONFIGURATION FOR 450t / 60 t EOT CRANE FOR SVAB SHEET : 1 OF 1

OPTION-1

450t Main Hoist Configuration, Dual Drive, Dual Load path with Planetary Gear box.

Rope drum

Top pulley block

Brake 2Brake 1

Planetary gear box 1

Motor 1

Motor 2

Brake 3 Brake 4

Encoder 1

Encoder 2

Motor 3

Motor 4

Encoder 3

Encoder 4

Planetary gear box 2

Brake 6Brake 5

Brake 7 Brake 8

Overspeed sensor

Rotary limit switch

Pedestal bearing

Drum / barrel coupling

Overspeed sensor

Rotary limit switch

Pedestal bearing

SPEC no: TATA CONSULTING ENGINNNERS LIMITED SECTION: D

TEC 7517A-D-EOC-003 QUALITY ASSUARANCE, INSPECTION AND TESTING PLAN FOR EOTCRANE SHEET : 1 OF 11

Legend 1. Third Party Inspection Agency (TPIA) 2. Vendor ( Suppliers) Siganture Date Place 3. Sub-Vendor Designation

# Components/ Operations

Characteristic to be checked Category

Type / Method of

check

Extent of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

Per

form

ed

Witn

esse

d

Ver

ified

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






Type / Method of

check

Extent of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

Per

form

ed

Witn

esse

d

Ver

ified


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, AH, 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

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.






Type / Method of

check

Extent of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

Per

form

ed

Witn

esse

d

Ver

ified


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 2 1

3 MECHANICAL

COMPONENTS

3.1 MH, AH , 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 1

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

3.2 Machined components for MH, AH , CT &LT Gear box

Hardness Dimensional conformity.


IS:2048

Component drawing

Supplier's IR

3.2.1 Gear box Dimensional conformity/ Inspection of machine surface of gearbox base.


IS:2048

Component Drawing.

Supplier's IR






Type / Method of

check

Extent of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

Per

form

ed

Witn

esse

d

Ver

ified


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

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






Type / Method of

check

Extent of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

Per

form

ed

Witn

esse

d

Ver

ified


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

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

4 BOUGHT OUT

ITEMS






Type / Method of

check

Extent of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

Per

form

ed

Witn

esse

d

Ver

ified


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

4.1.2 Machined Bolts & Nuts

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

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

Major Elec. test 100% IS 325 IS 325 Mfr's TC 3 - 1






Type / Method of

check

Extent of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

Per

form

ed

Witn

esse

d

Ver

ified


5.3 Brakes and

Break coil

Visual

Accessibility of parts.

Major Name plate details verification of TC

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

3 - 1


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


5.6 Cables Routine test Major Test One per size

BOM/spec. BOM/spec. Mfr's TC 3 - 1


6 ASSEMBLY OF

CRANE

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






Type / Method of

check

Extent of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

Per

form

ed

Witn

esse

d

Ver

ified


7.1 Main Hoist and Auxiliary Hoist

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

8.1 sDEFLECTION 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 ,AH & CT)

Load test Major Measurement of speed, voltage & Current Measurement

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


Supplier's IR & ISRO Format

2 1 -






Type / Method of

check

Extent of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

Per

form

ed

Witn

esse

d

Ver

ified


8.3 OVER LOAD

TEST (MH, AH & CT)

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




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

10

LOAD

TESTING

AFTER

ERECTION AT

SITE.

10.1

No Load Test

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

Major No wad test 100% Approved Drg and Specifications

Specifications IS 3177

Supplier's IR

2 1

10.2

Deflection test with full load

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



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

Load test Major Measurement of speed, voltage & current measurement









Type / Method of

check

Extent of check

Ref. Document

Acceptance Norm

Format of record

Agency

Remarks

Per

form

ed

Witn

esse

d

Ver

ified


10.4 Brake Test

Brake holding Test

Brake path test

Major Measurement 100% IS 3177 and specification

Specification IS 3177

Supplier IR 2 1

10.4 Over Load test 125% of Full Load (MH, A.H, CT & LT)

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




Examine for weld cracks etc.,

11 Painting

Sand blazing priner, Final paint.

Major DFT measurement

Random Specification Specificant Supplier IR

2 1

12 Safety features

Limit switch, Busters, stopper

Major No load test 100% IS 3177 Specification

IS 3177 Specificant

Supplier IR 2 1

13 Special requirements




EOT CRANE LOAD –SPEED, CURRENT AND VOLATGE CHARACTE RISTICS

CO

ND

ITIO

N

PARAMETER

LONG TRAVEL CROSS TRAVEL MAIN HOIST AUXILIARY HOIST

Forward Reverse Forward Reverse Forward Reverse Forward Reverse

Main Micro Main Micro Main Micro Main Micro Main Micro Main Micro Main Micro Main Micro

NO

LO

AD

Speed m/min

Current amps

R- Phase Y- Phase B- Phase

Voltage

SA

FE

W

OR

KIN

G

LO

AD

Speed m/min

Current amps


Voltage

25

% O

VE

R

LO

AD

Speed m/min

Current amps


Voltage

BR

AK

E

TE

ST

Brake Currents

Voltage

RA

TE

D

VA

LU

ES

Speed m/min

Current amps


Voltage

SPEC no: TATA CONSULTING ENGINNERS LIMITED SECTION: E

TCE 7517A-D-EOC-003 HOOK APPROACHES FOR 450t / 60 t EOT CRANE FOR SVAB SHEET : 1 OF 2

MAIN HOOK APPROACHES PLAN OF THE BUILDING

SPEC no: TATA CONSULTING ENGINNERS LIMITED SECTION: E

TCE 7517A-D-EOC-003 HOOK APPROACHES FOR 450t / 60 t EOT CRANE FOR SVAB SHEET : 2 OF 2

SECTIONAL ELEVATION OF THE BUILDING

SPEC.NO. TATA CONSULTING ENGINEERS LIMITED SECTION: F1

TCE 7517A-D-EOC-003 SCHEDULE OF PRICES

450T /60T EOT CRANE FOR SVAB

SHEET : 1 OF 2

SCHEDULE OF PRICES & GENERAL PARTICULARS

1. Bidders shall not alter the contents of this schedule of prices. If the bidder wants any additions / alterations, these shall be brought out separately in the format as given in this schedule of prices.

2. Equipment and material to be supplied and erected shall be in accordance with

section A, B, C, D & E of this specification.

3. The quantities indicated are an order of magnitude only. In case there is any variation in the quantities of items actually supplied and installed from the quoted quantities, the price of the same shall be adjusted based on the unit rates furnished by the bidder.

4. The quoted price shall be price in Indian Rupees for supply of material,

manufacture, inspection and testing at manufacturer’s works, packing, forwarding, transportation from place of manufacture to site, transit insurance, unloading / receipt at site, storage / handling at site, erection, testing, commissioning and carrying out performance test at site inclusive of all taxes and duties as applicable except sales tax on finished products, and service tax which shall be separately indicated in the price bid.

5. Total price towards Third Party Inspection (to be borne by the supplier) shall be

indicated separately in the price bid.

6. SDSC SHAR reserves right to place order or not for items mentioned in column number 10 to 15 mentioned in the price bid format. Supplier has to accept the rest of the order (i.e. without items mentioned in column number 10 to 15).


TCE 7517A-D-EOC-003 SCHEDULE OF PRICES

450T /60T EOT CRANE FOR SVAB

SHEET : 2 OF 2

(A) SCHEDULE OF UNIT PRICE Sl.no Item Qty. Cost in Rs.

1

Design, procurement of material, manufacture, inspection testing and control assembly of 450 / 60 t capacity EOT crane of 37.5 m span with dual drive dual load path with planetary gear box, VVVF drive controls at manufacturer’s works, packing & forwarding, & start-up spares as per specification enclosed with this tender but excluding taxes and duties.

1 set (lumpsu

m)

2 CST / VAT on total supply price (price mentioned in column no: 1) for 450t / 60t EOT crane with 37.5 span @_________applicable on above items.

3 Transportation of above 450 / 60 t capacity EOT crane of 37.5 m span from place of manufacture to site (Sriharikota) including transit insurance, unloading / receipt at site, storage / handling at site

1 set (lumpsu

m)

4 Taxes applicable on transportation price for (price mentioned in column:3) for 450 / 60 t EOT Crane @_________applicable on above items.

5

Erection and commissioning of above 450 / 60 t EOT crane of 37.5 m span including storage / handling at site, erection, testing, commissioning and carrying out performance test of Crane as per specification enclosed with this tender but excluding taxes and duties.

1 set (lumpsu

m)

6 Service tax on total Erection and commission price (price mentioned in column no:5) for 450 / 60 t EOT Crane @_________applicable on above items.

7 Any other taxes and duties

8 Third party Inspection charges for 450 / 60 t capacity EOT crane

9 Service tax on Third party inspection charges (price mentioned in column no:8) @_________applicable on above item.

10 Supply cost of Recommended Spares for two years of trouble free operations, if any (Optional)

11 CST / VAT on supply cost of Recommended spares (price mentioned in column no: 10) @____________ applicable on above item.

12 Supply & commissioning of Health monitoring system for all gear boxes in hoisting drives (Optional).

13 Taxes applicable on column no: 12.

14 Additional cost for load testing of crane at Suppliers site (Optional).

15 Taxes applicable on column no: 14.

Total Cost: (1+2+3+4+5+6+7+8+9+10+11+12+13+14+15)

SEAL OF THE COMPANY

SIGNATURE :

NAME :

DESIGNATION:

DATE


TCE 7517A-D-EOC-003 BID QUALIFICATION CRITERIA 450 / 60 t CAPACITY EOT CRANE

SHEET : 1 OF 3

BID QUALIFICATION CRITERIA FOR SUPPLY OF 450 / 60 t CAPACITY EOT CRANE

Bidders who are qualifying / meeting following Technical and financial criteria are eligible to participate in the bid for supply of 450 / 60 t capacity EOT crane. Bidder shall furnish all the information mentioned in the 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.

A. Technical Qualification Requirements:

The bidder shall meet the following technical qualifying requirements and shall submit relevant certif icates to establish his credentials.

1. The Bidder shall be an organization with long experience in having executed contracts for design, engineering, manufacture, supply, erection, testing and commissioning of Double girder EOT Cranes for last 10 years in India.

2. The firm shall have successfully completed Design, Manufacture, Installation, Testing and Commissioning of at least 1nos. of double girder EOT cranes of capacity of 350t and above and Span equal to 25m and above during last 7 years ending with 31.07.2014. Bidders have to provide relevant certificates from the Owners (end users) along with the submission of bid for consideration of bid document.

3. The firm should have successfully completed Design, Manufacture, and commissioning of EOT cranes with VVVF (VFD) drive & control systems at least 4 no of cranes and at least one crane of capacity not less than 200t in last 7 years.

4. The firm should have successfully completed the design, manufacture, installation, testing & commissioning of EOT crane of capacity around 100t and span around 20m and height of lift around 50m and above during last 7 years ending with 31.07.2014

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

6. The firm should have successfully completed Design, manufacture, and establishment of at least 05 nos. of EOT cranes (not less than 200ton capacity) with twin motor with planetary gearbox system for Hoist mechanism for last 10 years.

7. The firm should have a facility to carrying out control assembly with bridge girder and trolley with rope drum and demonstrate functioning of CT travel and speed of the rope drum etc for inspection and testing of 450 / 60 t capacity EOT crane with 37.5 m span at their factory.

8. The firm shall have facility for fabrication & machining of 3 meter diameter rope drum.

9. The firm should have successfully completed Design, manufacture, and establishment of high capacity EOT cranes (100t and above) to the satisfaction of reputed third party inspection agencies like M/s MECON, M/s M N Dastur, M/s TCE, M/s LLoyds.

B. Financial Qualification Requirements:

1. The Bidder should have annual turnover of not less than a value of Rs. 100 crores per year last three financial years ending with 31.07.2014



SHEET : 2 OF 3

2. Firm should have undertaken and successfully completed Single work of EOT crane not less than: Rs.15 crore value of works related EOT cranes at least in last 05 (Five) years.

3. IT/ TDS certificate shall be submitted with Loss & Profit for last three years

4. Bidder shall submit audited statement of financial status for last three years.

D. The following documents shall be submitted along with the Techno-

commercial bid for prequalification of Bidder.

1. Firm establishment certif icate and nature of work.

2. Details of work of similar type completed during the last seven years ending with 31.08.2014 ( for Sl. No.2 of A)

3. Satisfactory work Completion certificates from the clients, with the work o rde r cop ies ( f o r S l . Nos . 2 & 3 o f A )

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

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

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 200t and above / Span 20m and above) completed from last ten years with purchase order copies.

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

11. Structure and Organization chart.

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

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

E. Bid Selection Procedure and Process of Pre-Qualification

1. Short listing based on documents submitted, satisfying the all eligibility criteria given above by the firm or individual along with their Bid / application. (Non-submission of any document as given in above list within stipulated time leads to rejection of Bid).

2. Subsequently Bidder's competency, their technical achievements and financial status will be evaluated suitable for this project. Feedbacks from Bidder's clients will be verified.

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



SHEET : 3 OF 3

has established above mentioned capacity EOT cranes.

4. If required, visit will be made to their factory/ firm by technical team (ISRO or third party) for accessing the capability of manufacturer.

5. Scrutiny of all technical specification and supply conditions mentioned in techno-commercial bid.


TCE 7517A-D-EOC-003 SCHEDULE FOR GENERAL PARTICULARS

450/ 60 t CAPACITY EOT CRANE FOR SVAB

SHEET : 1 OF 4

Signature of the tenderer of accepting of specification mentioned above.

SCHEDULE FOR GENERAL PARTICULARS / VENDOR EVALUATION FORMAT

SR. NO.

DESCRIPTION

1.0 Name of Company

2.0 Address of Company

3.0 Type of Company (Proprietary/Pvt.Ltd/Public Ltd/Joint Venure/Consortium)

4.0 Registration number

5.0 Year of inception of the company

6.0 Registered address

7.0 Name & address of the office of the Chief Executive of the company

8.0 Name & Designation of the officer of the Bidder to whom all correspondence shall be made for expeditious technical/ commercial co-ordination.

Telephone number Fax number E-mail address

9.0 Locations of the Branches of Company (if any)

8.0 Annual turn-over of the company for the last three years

9.0 IT returns for the last 3 years

10.0 Major customers (Enclose copies of the Purchase Orders)

11.0 Any customers feedback on the services which is in writing (Pl. enclose copies)

12.0 Quality certification of the company

13.0 PAN Card Copy

14.0 The Profit & Loss Account details for the last 3 years which is duly audited and Submitted as part of the Annual Report




SHEET : 2 OF 4


15.0 Orders executed during last three years, capacity of EOT cranes, references are is to be mentioned. (Separate sheet can be attached).

16.0 No. of EOT cranes of capacity 200t and above and Span above 30m above manufactured during last 7 years.

17.0 No. of EOT cranes of capacity not less than 100t with SIEMENS VVVF drive & control systems produced in last 10 years.

18.0 No. of EOT Cranes capacity not less than 100t supplied with Emergency Rope drum caliper brake.

19.0 No. of EOT Cranes produced ( not less than 100t capacity) with twin motor with planetary gear box system for hoist mechanism for 10 years.

20.0 No. of Steel mill cranes ( not less than 100 ton capacity) produced for molten metal ladle handling in last 10 years

21.0 Shop floor area covered

22.0

No. of employees (Supplier shall mention contract personnel separately) Engineers Supervisors Technicians Quality control engineers Administrative Staff.

23.0

Handling facility available: Over head / Gantry Crane details (Capacity , span lift). Mobile Cranes.

24.0

Load testing facility Available: Maximum weight available. No. of weights Total test load available.

25.0

Welding / fabrication workshop (Type / capacity / quantity of machines shall be provided) MMAW machines GMAW machines Gas cutting machines Plasma cutting machines Welding Fixtures

26.0 Fixtures available for welding of griders of span more than 37.5 m.

27.0

Welding professionals: No. of Welders (MMAW), Qualification details, No. of Welders (GMAW), Qualification details, No. of Welders (TIG), Qualification details, Welders Qualified by:




SHEET : 3 OF 4


28.0 Details of welding Inspection Equipment & Welding inspector available with supplier (LPT, UT, MPT, X-ray, etc)

29.0

Forming facilities available ( with brief specification of each machine) Shearing Machine Cutting Machine Cutting Machine Bending Machine

30.0

Machining Facilities available ( with brief specification of each machine) Turning lathe (Conventional /CNC) Milling Machine (Conventional / CNC) Gear Cutting / Hobbing Machines Drilling Machines (conventional / CNC) Cylindrical Grinding Machine ( Conventional / CNC) Any other machines.

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

32.0 If third party Inspection Services are taken for manufacturing of EOT cranes give details.

33.0

Range of capacity of EOT cranes manufactured, till now ( list with brief specification, completion certificate, customer feedback , Customer contact details for getting feedback shall be provided).

34.0

Maximum capacity of EOT crane manufactured with dimensions, type, quantity, purpose. (list with brief specification, completion certificate, customer feedback , Customer contact details for getting feedback shall be provided)

35.0

Maximum dimensions of EOT crane manufactured with capacity, Span, quantity, customer and purpose of EOT Crane. (list with brief specification, completion certificate, customer feedback , Customer contact details for getting feedback shall be provided)

36.0 Special Purpose EOT cranes manufactured, if any, capacity, dimensions and customer.

37.0

Design Software’s available Drafting & modeling software packages FEM software Other softwares Design Engineers ( with qualification & experience)

47.0 Bid validity period

(Min. 4 months from date of bid opening)




SHEET : 4 OF 4


48.0 COMPLETION SCHEDULE

49.1 Period required for supply of equipment at site (from date of LOI)

___ months

49.2 Period required for erection, testing and commissioning of 450/60 EOT crane (from date of LOI)

___ months

SIGNATURE :

NAME :

DESIGNATION:

SEAL OF THE COMPANY DATE :


TCE 7517A-D-EOC-003 DATA TO BE FILLED ALONG WITH BID FOR SUPPLY OF

450 / 60 t CAPACITY EOT CRANE FOR SVAB

SHEET : 1 OF 9

DATA TO BE FILLED ALONG WITH THE BID FOR SUPPLY OF 450 / 60 t CAPACITY EOT CRANE

SR. NO.

DESCRIPTION TENDERS OFFER

1.0 Duty class as per IS:3177-1999; M5 Yes / No

2.0 Type of Girder: Double girder Yes / No

3.0 No. Of trolleys (crab): one Yes / No

4.0 Crane Structure : Shall be designed in accordance with IS:807 with its latest edition / revision

Yes / No

5.0 Crane shall be suitable for indoor Operation. Yes / No

6.0 Capacity of crane: 450 / 60 t Yes / No

7.0 Span : 37.5 m Yes / No

8.0 Lift for main hoist: 82 m Yes / No

9.0 Lift for auxiliary hoist: 82 m Yes / No

8.0 Main Hook Approaches for main hoist from centre line of building.

CT: minimum of 13.75m towards East

CT: minimum 12.2m towards West

LT: minimum 25.575m towards North

LT: minimum 25.575m towards South

8.1 Centre to centre distance between Main hook and Auxiliary hook: ≤ 2.9m

9.0 Operating speeds for Main Hoist

With load: 3 m/min

Without load: 6 m/ min

Creep with/ without load : 0.3 m/min

10.0 Operating speeds for Auxiliary Hoist

With load: 4 m/min




SHEET : 2 OF 9

SR. NO.




11.0 Operating speeds for CT & LT Hoist

With load: 4 m/min



12.0 Length of gantry girder for LT: 68.5 m

12.1 Level of gantry girder for LT:82m

13.0 Height of Crane from LT rail top: (i.e from LT rail to Rope drum flange).

14.0 Overall buffer to buffer distance:

14.1 Wheel base of the trolley:

14.2 Trolley gauge: (i.e. centre to centre distance of CT rails)

15.0 Main girder length from end to end including ladders : ≤ 39m

15.1 Confirm that main girder is made in single piece only and will be transported to SDSC SHAR from your works site.

Yes / No

16.0 Total weight of crane including electrical equipment. (approximately)

17.0 Total weight of trolley including electrical equipment. (approximately)

18.0 Weight of each bridge girder as assembled ready erection (approx.)

19.0 Weight of each end carriage as assembled ready erection (approx.)

20.0 Total breakup of crane weight to tally with individual weights given.

21.0 Confirmation for procurement of bought out items of approved makes as listed in our specification in 15.0 of section:B.

22.0 Main Hoist related




SHEET : 3 OF 9

SR. NO.


22.1 Main Hoist rope size and construction details: 35x7, IWRC Power form, regular lay, right hand, non-rotating type of 2160 tensile designation as per IS: 6938 / IS:2266

22.2 Make of Wire rope: Usha Martin

22.3 Condition of Wire rope: Hot dip galavanised

22.4 Number of rope falls considered for main hoist

22.5 Factor of safety for Main Hoist wire rope

22.6 Diameter of rope

22.7 No. of Rope drums: 1

22.8 Diameter of Main hoist rope drum : ≥ 3m

22.9 Tensile strength of Wire rope: 2160 N/mm2

22.10 Material of rope drum

22.11 Make of planetary gear box for main Hoist

22.12 Material of Sheaves:

22.13 Diameter of Sheaves for Main Hoist

22.14 HP of motor & duty cycle for Main Hoist

22.15 RPM of Main motor

22.16 Duty of Main motor : S5

22.17 Enclosures to the Main motor IP55 or not

22.18 IEC frame size

22.19 Permissible no. of starts per hour: 300

22.20 Make and type of motor:

(CG / BHARATH BIJILEE / HM)

22.21 Class of insulation stator and rotor: F

22.22 Temp. rise over the specified ambient.

22.23 Brakes, type, make and size:




SHEET : 4 OF 9

SR. NO.


(Bubenzer, INVENSYS BROOK CROMPTON, WITTON KRAMMER, SIBRE, GALVI)

22.24 Make and type of bearings:

(Ball & roller anti-friction; SKF, FAG & Timken make)

22.25 Type and make of main hoist hook : (Crossby make Rams horn type of Mickissick duplex model)

22.26 Is safety latch provided on the hook

23.0 Auxiliary Hoist Related

23.1 Auxiliary Hoist rope size and construction details: 35x7, IWRC Power form, regular lay, right hand, non-rotating type of 2160 tensile designation as per IS: 6938 / IS:2266

23.2 Make of Wire rope: Usha Martin

23.3 Condition of Wire rope: Hot dip galavanised

23.4 Number of rope falls considered for Auxill. hoist

23.5 Factor of safety for Auxiliary Hoist wire rope

23.6 Diameter of wire rope

23.7 No. of Rope drums

23.8 Diameter of Auxiliary hoist rope drum:

23.9 Tensile strength of Wire rope: 2160 N/mm2

23.10 Material of rope drum

23.11 Make of gear box for Auxiliary Hoist

23.12 Material of Sheaves:

23.13 Diameter of Sheaves for Auxiliary Hoist

23.14 HP of motor & duty cycle for Main Hoist

23.15 RPM of Main motor

23.16 Duty of Main motor : S5

23.17 Enclosures to the Main motor IP55 or not




SHEET : 5 OF 9

SR. NO.



23.19 Permissible no. of starts per hour: 300

23.20 Make and type of motor:


23.21 Class of insulation stator and rotor: F

23.22 Temp. rise over the specified ambient.

23.23 Brakes, type, make and size:


23.24 Make and type of bearings:

(Ball & roller anti-friction; SKF, FAG & Timken make)

23.25 Type & Specification for Auxiliary hook

23.26 Is safety latch provided on the hook

24.0 Trolley / Cross Travel

24.1 Trolley Wheel span

24.2 Trolley Wheel base

24.3 Material of wheels of Trolley

24.4 Number of wheels in trolley

24.5 Diameter of wheels in trolley

24.6 Maximum wheel load of trolley

24.7 Make of Gear Box for CT

24.8 Rail size for trolley run way

24.9 HP of motor & Duty cycle for CT

24.10 RPM of motor for CT

24.11 Duty of motor : S5 for CT




SHEET : 6 OF 9

SR. NO.


24.12 Enclosure to the CT motor : IP55


24.14 Make and type of motor for Cross travel:


24.15 Class of insulation:- Stator / Rotor: B

24.16 Temp. rise over specified ambient

24.17 Permissible no. of starts/ hour for CT motor: 300

24.18 Make, type and size of brake for CT Drive:


25.0 Bridge / Long Travel

25.1 Wheel Base for bridge

25.2 Wheel spacing

25.3 Material of wheels for LT

25.4 Diameter of Wheels

25.5 Number of wheels on each end of crane.

25.6 Maximum wheel load: 80t

25.7 Make of gear box for LT

25.8 Material of gears: Forged / Alloy / Carbon steel

25.9 Rail size for LT

25.10 Number of motors for LT

25.11 HP of LT motor & duty cycle

25.12 RPM of LT motors

25.13 Duty of LT motor: S5

25.14 Enclosures to the LT motor IP54




SHEET : 7 OF 9

SR. NO.


25.15 Make and type of LT motors:

CG / BHARATH BIJILEE / HM


25.17 Class of insulation for LT motor: Stator / Rotor B

25.18 Temp.rise over specified ambient

25.19 Permissible no. of stars / hour: 300

25.20 Make, type and size of brakes:


25.21 Make and type of Bearings: (Ball & roller anti-friction; SKF, FAG & Timken make)

25.22 Full length platforms on both girders.

25.23 Manually operated Parking brakes for LT

26 Control panels

26.1 Brief Description of control features: For all drives, control shall be using VVVF drives

26.2 Make, model & rating of VVVF control for speed control: (SIEMENS make only).

26.3 Control panel degree of protection

26.4 Operation using 3 nos of plug-in type intrinsically safe pendants.

26.5 Providing interlock for pendant such that at any time only one Pendant to operate.

26.6 Pendant plug points on both sides of the building at 22 level and near towers. Total (22 + 3 near towers= 25 nos. plug points)

26.7 One set of separate displays shall be provided for current, voltage and frequency in VVVF control drive panels. It shall be possible to select the display of hoist or CT or LT

26.8 Synchronisation mechanism shall be incorporated for all drives, if multiple motors are used for each drive.

26.9 Providing independent switches for main and micro speeds in




SHEET : 8 OF 9

SR. NO.


pendant for all motions

26.10

Incoming power panel will be provided by Department at 4m level. Party shall include in their scope all the cables required from 4m level to the crane, panel room at 82m level and pendent socket cable to all 22 levels on both sides.

26.11 Providing main isolation switch on one side only at 82m level.

26.12 Cable shall be fire retardant, low, smoke, armoured and tinned copper cable.

26.13 Wiring , trade name, and classification of wire insulation.

26.14 Earthing as specified: Double earthing shall be provided to all the motors, thrusters, panels, etc.

26.15 Lights as specified.

27.16 Trailling cables shall be festooned using Cable chain drag system of Igus brand or reputed make.

27.17 Protection switch gears as specified.

27.18 Limit switches shall be of totally enclosed with IP55 protection and with properly designed actuators.

27.19 Limit switches shall be readily accessible for adjustment and repair.

27.20 Limit switches shall be provided for LT and CT operations.

27.21

Each hoist shall be provided with two limit switches, one screwed type / rotary limit switch against over-hoisting and also in case of hook reaching floor level and the other a gravity operated hand reset type as a backup protection against over-hoisting.

27.22 Full load current of the motors shall be around 80% ±3% of the motor rated current.

27.23 Redundant brake for each motor in hoist motion

27.24

Final capacity of relays, contactors and cables shall have 50% capacity more than the capacities usually selected as per standard practice to avoid welding of contacts and over-heating of cables.

27.25 Electrical contacts shall be suitable for 300 starts / hour (AC4 duty)




SHEET : 9 OF 9

SR. NO.


28 Make and type of flexible coupling: Gear couplings

Fenner, Elecon, Shanti

29 Provision of repair cages considered

30 Gridblasting as specified

31 Painting as specified

32 Trolley & Bridge runway rails are in the scope

33 General arrangement drawings submitted


TCE 7517A-D-EOC-003 SCHEDULE OF TIME FOR MANUFACTURE, DESPATCH AND SHIPMENT TO SITE


SHEET : 1 OF 1

Signature of the Tenderer for accepting specification mentioned above.

SCHEDULE OF TIME FOR MANUFACTURE, DESPATCH AND SHIPMENT TO SITE

The Bidder shall indicate hereunder the time for manufacture, despatch and

completion of each equipment from the date of Letter of Intent (LOI)/ purchase order

(PO) as shown below.

Equipment

Time for manufacture

from date of LOI / PO

excluding control

assembly

Time for control

assembly, dismantling,

packing and ready for

despatch from Works

Time for

shipment to

site

Total time from

date of LOI / PO to

shipment to site.

The Bidder hereby undertakes to meet the above time schedule from the date of LOI

/ PO

SIGNATURE :

NAME :

DESIGNATION:



TCE 7517A-D-EOC-003 SCHEDULE OF TIME FOR MANUFACTURE, DESPATCH AND SHIPMENT TO SITE


SHEET : 1 OF 1

Signature of the Tenderer for accepting specification mentioned above.

SCHEDULE OF TIME FOR MANUFACTURE, DESPATCH AND SHIPMENT TO SITE

The Bidder shall indicate hereunder the time for manufacture, despatch and

completion of each equipment from the date of Letter of Intent (LOI)/ purchase order

(PO) as shown below.

Equipment

Time for manufacture

from date of LOI / PO

excluding control

assembly

Time for control

assembly, dismantling,

packing and ready for

despatch from Works

Time for

shipment to

site

Total time from

date of LOI / PO to

shipment to site.

The Bidder hereby undertakes to meet the above time schedule from the date of LOI

/ PO

SIGNATURE :

NAME :

DESIGNATION:


SPEC no: TCE 7517A –D-EOC-003

TATA CONSULTING ENGINEERS LIMITED SECTION: F7

450 /60 t CAPACITY EOT CRANE FOR SVAB SHEET : 1 OF 2

Sheet 1 of 2

SCHEDULE OF BIDDERS EXPERIENCE

The bidder shall furnish here under a list of EOT cranes executed by him to whom a reference may be made by the PURCHASER in case the PURCHASER considers such a reference necessary.

SL. NO.

Name & address of Client / Name & address of project

or plant (incl. tel.no., fax no., e-mail and name &

designation of person who can be contacted.

Purchase Order / Contact no. and

Date.

Brief details of

equipment / system covered

Scope of services

Contract price (Rs)

Scheduled date of

completion

Actual date of

completion

Reasons for delay in

completion, if

applicable.

REMARKS

SIGNATURE: : NAME : DESIGNATION: COMPANY :

COMPANY SEAL DATE :

SPEC no: TCE 7517A –D-EOC-003

TATA CONSULTING ENGINEERS LIMITED SECTION: F7

450 /60 t CAPACITY EOT CRANE FOR SVAB SHEET : 2 OF 2

Sheet 2 of 2

SCHEDULE OF BIDDERS PRESENT WORK The bidder shall furnish here under a list of EOT Cranes being executed to whom a reference may be made by the PURCHASER in case the PURCHASER considers such a reference necessary.

SL. NO.

Name & address of Client / Name & address of project or plant (incl. tel.no., fax no., e-

mail and name & designation of person who can be contacted.

Purchase Order / Contact no. and

Date.

Brief details of equipment

/ system covered

Scope of services

Contract price (Rs)

Scheduled date of

completion

Expected date of

completion REMARKS

SIGNATURE: : NAME : DESIGNATION: COMPANY :

Company Seal DATE :


TCE-7517A-D-EOC-003 CHECK LIST FOR BID SUBMITTING OF 450 / 60 t

CAPACITY EOT CRANE FOR SVAB

SHEET : 1 OF 2

CHECK LIST

Signature of the tenderer.

Sl no Description Response by supplier

1. All documents related to Prequalification criteria mention in Section F2 have been met and all related documents are enclosed in technical Bid

Yes / No

2. Are all the technical particulars as called for in the data sheets section A, B, C, D & E and commercial details as called for in schedule of prices filled up

Yes / No

3. Demand Draft towards the Tender fee and Earnest Money Deposit are enclosed in technical bid and scan copy is uploaded in e-procurement portal.

Yes / No

4. The detailed scope of work and technical specifications are understood and price was quoted accordingly.

Yes / No

5. Confirmation that the quoted prices are firm and fixed till the completion of scope of work.

Yes / No

6. Validity of Offer is 4 months (minimum). Yes / No

7. Vendor Evaluation Format is attached Yes / No

8. List of Customs Duty Exemption Certificate (CDEC) items are submitted for providing CDEC by Department.

Yes / No

9. List of Excise Duty Exemption Certificate (EDEC) items are submitted for providing EDEC by Department.

Yes / No

10. Service Tax 12.36 % or at the prevailing rates (If not mentioned it will be assumed that the price quoted are inclusive of taxes).

Yes / No

11. VAT/CST to be indicated in percentage (if not mentioned it will be assumed that the price quoted are inclusive of taxes).

Yes / No

12. Delivery Schedule is 20 months with milestones Yes / No

13. Accepted the Department Payment Terms Yes / No

14. Are General terms and Conditions of Contract for Supply & Erection included in proposal acceptable?

Yes / No

15. If not acceptable, are the deviations brought out in the "Schedule of Deviations" Yes / No

16. Are there any deviations from enquiry technical specifications? Yes / No

17. If there are technical deviations, are these filled in "Schedule of Deviations from Tech. Specifications"?

Yes / No

18. Warranty for the fully commissioned and accepted system is 12 months Yes / No

19. 10 % of the Order Value shall be submitted as Performance Security for the performance of the contract along with acceptance of order letter, which is valid till acceptance of the system.

Yes / No

20. 10 % of the Order Value shall be submitted as Performance Bank Guarantee, which is valid till completion of the warranty period plus 3 months claim period.

Yes / No

21. Liquidated Damages (Ref. Clause 26 of Section A.) are acceptable Yes / No

22. Last three years audited financial results are enclosed Yes / No

23. Registration certificate of the company is enclosed Yes / No


TCE-7517A-D-EOC-003 CHECK LIST FOR BID SUBMITTING OF 450 / 60 t

CAPACITY EOT CRANE FOR SVAB

SHEET : 2 OF 2

CHECK LIST

Signature of the tenderer.

24. All the forms in Section F1 to F8 are filled Yes / No

25. Are all data sheets A/B duly filled in and submitted in offer Yes / No

26. Technical documents / drawings are attached along with technical bid as para 1.7.1 of Section A

Yes / No