PE-TS-362-501-A001

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TECHNICAL SPECIFICATION FOR

TG HALL EOT CRANE

2X800 MW YERMERUS STPP

Specification no.: PE-TS-362-501-A001Rev. 00Date: J un 12

Sheet 1 of 1

INDEX

S.N. DESCRIPTION PAGES

1.0 Project Information 4

2.0 Project Technical Data Sheet for 2X800MW YERMERUS STPP

9

3.0 Painting Specification (Annexure I ) 1

4.0 Crane Clearance Diagram Drg. No (PE-DG-362-501-A001) for TG hall crane

1

5.0 Write up for Load test procedure of Liftingbeam in Bidders works

5

6.0 BHEL standard QAP 11

7.0 Ref quality plan for Lifting beam 2

8.0 Scope of O&M service to be provided by thebidder

2

9.0 Specific Confirmation 3

10.0 Documents to be submitted along with offerAnnexure C.

1

Note:1.0 The Standard Technical Specification PE-TS-STD-501-A002 Rev 03 shall

be applicable for this project.2.0 Any contradiction between project specific specification PE-TS-362-501-

A001 & Standard specification PE-TS-STD-501-A001 Rev03, the data

given in project specific specification will be followed.

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RAICHUR POWER CORPORATION LTD

PROJECT INFORMATION

SHEET 1TITLE

1.0 Owner : Raichur Power Corporation Ltd22/23, Sudarshan Complex,IInd floor, Sheshadri Road,Bangalore560 009Karnataka, India

2.0 Consultant : M/s Evonik Energy Services (I)Pvt. Ltd.,A-29, Sector 16Noida-201301(UP), India

3.0 Project Title : 2x800 MW Yermarus Thermal

Power Station

4.0 Location : YermarusRaichur DistKarnataka State, INDIAIt is situated at about 8 Kms fromRaichur on the Raichur-HyderabadState Highway-13 and 12 kmsaway from Bank of river Krishnaand about 5 kms from Raichur

Thermal Power Station

5.0 Nearest Railway : Chicksugur Railway Station whichis about 2 kms from site.

6.0 Nearest Airport : Hyderabad around 200 kms

7.0 Nearest Port Chennai around at about 470 kmsfromsite.

8.0 Latitude and Longitude : Latitude 16 16 55.9N

Longitude 77 20 38.6E

9.0 Elevation above mean sea level : 350-375 meters

10.0 Climatic Conditions

(a) Ambient Temperature

i. maximumtemperature

: 45o C

ii. minimum temperature : 6o C

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PROJECT INFORMATION

SHEET 2TITLE

iii. Design Temperaturefor all Electrical/MechanicalEquipment

: 50o

C Ambient

(b) Relative Humidity

i. Maximum during monsoon : 85%

ii. Minimum : 20%

iii. Average : 65%(c) Rainfall

Annual average rainMax. for one dayMax. intensityPeriod

::::

720 mm115 mm38 mm/hr

J une to September

(d) Wind Speedi. Prevailing wind

direction: West, South-East, North-West,

South-Westii. Maximum mean wind

speed

: 15.9 Kms / hr

(4.42 m/s)

iii. Average : 9.61 Km/hr(2.67 m/s)

11.0 Wind LoadCalculations for wind effect shall be in accordance with IS:875- (Part-3)latest revision taking into account the following :

(a) Basic wind speed of 39 m/sec as given in Fig.1 of the code.

(b) Factor K1 shall be taken as 1.06

(c) Terrain category shall be 2 and corresponding values shall betaken for K2

(d) Factor K3 shall be taken as 1.0

12.0 Wind Loading for Stack(a) For wind pressure as per clause 11.0 above(b) For RC stacks as per IS: 4998

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PROJECT INFORMATION

SHEET 3TITLE

13.0 Seismic data (as per IS:1893 latest issue)

(a) Zone : Zone III (as per IS:1893- latest )

(b) Importance factor (I) : 1.75

14.0 Auxiliary power supply : Auxiliary electrical equipment to besupplied against this specificationshall be suitable for operation on

the following supply system.

(a) For motors rated above1500 kW

: 11000V, 3 phase, 3 wire, 50Hzmedium earthed AC

(b) For motors rated 175KWand above and below1499KW.

3300V, 3 phase, 3 wire, 50Hzmedium earthed AC

(c) For motor rated 174 kWand below

: 415, 3 phase, 3 wire solidly earthedAC

(d) For motor control centre : 415V, 3 phase, 3 wire solidlyearthed AC

(e) DC. motor starters, DCsolenoids, DC alarm,control and protections

: 220 V DC, 2 wire, unearthed DC

(f) AC control & protectivedevices

: 110 V 1 phase, 50Hz, 2 wire ACsupply. The single-phase 110V ACsupply shall be derived by

Contractor by providing 415V/110Vcontrol transformers of adequaterating with MCCB /MCB on both theprimary and secondary sides.

(g) Uninterrupted powersupply

: 240 V, 1 phase, 50Hz, 2 wire ACsupply from UPS system for I&C(including indicator recorders) andUCMS only

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PROJECT INFORMATION

SHEET 4TITLE

(h) AC solenoids,indicators/recorders,space heaters (for motorsrated 30KW and above)

: 240V 1 phase, 2 wire, 50Hz ACsystem with effectively earthedneutral. The power supply shall bederived by CONTRACTOR byproviding 415V/ 240V transformerof adequate rating with MCCB/MCBon primary/secondary sides.

(i) Winding heating ofmotors below 30kW

: 24 V 1 phase,50Hz, AC with onepoint earthed. This shall be derivedby CONTRACTOR by providing

415V 3 phase, 3 wire, AC supplythrough an adequately rated step-down transformer of adequaterating with MCCB / MCB onprimary/secondary sides.

(j) Solid state controls(including solenoidvalves)

: 24 V DC, 2 wire, supply fromBattery chargers for instrumentationsystem only.

(k) Lighting fixtures : 240 V, 1 phase, 2 wire, 50Hz

system.

(l) Lighting fixtures andspace heaters in panels

: 240 V, 1 phase, 2 wire, 50Hzsystem.

(m) Construction supply : 415 V, 3 phase, 4 wire, 50 Hz ACsupply with neutral lead solidlyearthed.

(n) The above voltages may vary as follows :

All devices shall be suitable for continuous operation over the entirerange of voltage and frequency indicated below without any changein their performance.i. AC supply : Voltage variation 10%

Frequency variation 5%Combined voltage & frequency

variation 10%ii. DC supply : Voltage variation +10%

-20%

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S.N.

1.0

2.0

3.0

4.0

5.0

5.1

5.2

6.0

7.0

`8.0

8.1

13

De

Design,and tecranestandanumbe

Numbe

Craneclassifi

Suitabl

outdooduty

Capacit

Main h

Ratedtonnes

OverloaSWC

Aux. H

Rated S

OverloaSWC

Span

Operati

CRANE

PERFO

Cranefull load

Main H

Aux. Ho

Crab trspeed

Crane tspeed

TECHNCIAL0/30T CAP TYERMERUS

scription

, fabricatioting of thconfirm td / cod

r of crane/s

cation

fo

r or indoo

y

ist

SWC

d Test loatonnes

ists

WC tones

d Test loatones

on from

RMANCE

speed wit

ist

ist **

velling

avelling

DATA SHEEG HALL EOTSTPP ( 2X80

IS: 3177

As per

M5 for(part-5)-

r

r

Indoor

As per

C

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1.6 (TG

7.5

15.0

30.0

T FORCRANES0 MW )

1999 (reaffi

able 1

echanical a993

able 1

3

As per a

abin +pend

ed M/Min

all crane)

DOC.

REV. 0

Page 1

Technical

ms 2006) &

nd Electrica

130T for T

(125%

0T (for TG h

(125% o

tached cran

ent push bu

(

(

(

O.PE-TS-3

DAT

of 10

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IS 807

l as per IS:

hall crane

of SWC)

all crane onl

SWC)

e clearance

ton +radio

reep spee

.16(10% ofthru VVVF.7510% of maithru VVVF.510% of maithru VVVF.010% of maithru VVVF

62-501-A00

E: 4/6/12

807-2006 a

y)

diagrams

emote cont

M/Min

main speedrives)

speedrives)

speedrives)

speedrives)

nd 13834

ol

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8.2

8.3

8.4

9.0

9.1

9.2

9.3

9.4

13

Lift in

Main H

Aux Hoi

Hook A

Hand

COMPDETAIL

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Type

Methodfabricati

Materialto IS:

Rope d

Material

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Type of

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Factor

Type of

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Material


eters

ist

st

pproaches

rail pipes

NENTS

ofon

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rums

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s provided

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etails

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ction

f safety

core

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The liftinreach th

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As per a

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Identical

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T FORCRANES0 MW )

g rope shallzero level.

tached cran

tached cran

ached cran

B Mediumf1100 mmg 1500 mmk)

d

elded

Gr. B

is t

s pipe ASTress relieve

ach hoist

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flexible plo

5.25 as pe

Steel/ Fib

Main hoi

F

DOC.

REV. 0

Page 2

be of suffi

e clearance

e clearance

clearance

lass of IS: 1and 600 mwith provisi

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and Left han

IS:

gh steel / 6

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re

t

e 410 WB I

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of 10

ient length

diagram

diagram

iagram

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266

x 36 constru

: 2062 Gr.

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62-501-A00

E: 4/6/12

to permit th

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ction, Galva

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Steel / Fibr

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/

hook to

om rail atcing nothigh and

IS: 2062

nised

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9.5

9.5.1

9.5.2

9.5.3

9.5.4

9.6

A.0

13

DiametEquival

in mm o

Typeprovide

Coupli

Couplin(betweegear bo

Type

Guards

Couplinbox and

Type

Guards

Couplinbox and

Type

Guards

Shafting

Design

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Type of

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n Root

of guar

g & Shaftin

g detailsn motor and)

nd Enclosur

g details (gewheels)

nd Enclosur

g details (gerope drum)

nd Enclosur

(Output)

f shafts

ent ofon

ubricant

x details

otions

mountingx

ation

gears

f lubricatio/ splash

brication)


fs

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ds

g

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s

r

s

r

s

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f

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/

T FORCRANES0 MW )

ot be lessd main she

Fab

Aux.

ross Trave

Main Hoist

Flexible ge

H

ical

DOC.

REV. 0

Page 3

than 62%ve diameter

ricated from

Hoist

Flexible g

Pro

l

Flexible g

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red couplin

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NA

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O.PE-TS-3

DAT

of 10

f.

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diameter

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ross Travel

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ided

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ared type

ided

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ided

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ase

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62-501-A00

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plate

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ng Travel

ux. Hoist

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l

han 62%sheave

ravel

micro

A

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B.0

9.7

9.8

13

Differenand pini

Material(gear/pi

Casing

Travel

Typegear bo

Classifi

Type of

Type(greasepump lu

Differenand pini

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Casing

Wheels

Material

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Type

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Specificconfor

Arrangelubricati

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Type

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otions

f mountinx

ation

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brication)

ce in Gon hardnes

s (gear

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s

s provided

ationing to

menton

ooks

ng capacity


a

Main Ge

F

CT

Vertical

Helical

/

a

/ Main Ge

F

f

Ramshoswivelin

130 T f

T FORCRANES0 MW )

ars En 9/ 55

Hardabricated F

CT m

NA

NA

ars En 9/ 55

Hardabricated F

Cross tr

4 nos.

MH

rn shank wig type as pe

of IS: 57

or TG hall a

DOC.

REV. 0

Page 4

Min 2

C8/ IS2707

ess confor410w IS: 2

icro

M5

Splash L

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ess confor410w IS: 2

vel

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ith safety latr latest editi49

per IS 574

O.PE-TS-3

DAT

of 10

BHN

r. 1or 2. Pi

ming to IS:62 Gr B &

LT

Vertical/

Horizontal

duty

Helical

brication

BHN

r. 1or 2. Pi

ming to IS:62 Gr B &

EN 9 (55 C

50 BHN

flanged

7-1999

ase

hn

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ed

30T f

62-501-A00

E: 4/6/12

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Long trav

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n with safeting type asition of IS: 1

or TG hall a15560

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o

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A

/EN 24.

d

l

latcher latest

5560

per IS:

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9.9

A.0

B.0

9.10

9.11

9.12

10.0

10.1

13

Material

Brakes

Hoist M

Type of

Numbemotor

Braking

Travel

Type of

Numbemotor

Braking

Bearin

Type

Method

lubricati

Bearing

Bridge

Type &

Vertical

Type oto end c

Rails-B

Type / s

Standaconfor

Material

Motors

Hoist M


otions

brake

provide

capacity

otions

brake

provide

capacity

s

on

life

girder

Quantity

Deflection

f connectioarriage

ridge girde

ection

ding to

otions


/

1

/

1

f

Rails sewelded b

T FORCRANES0 MW )

Class 2 / IS:

MH

1+1

50%

CT

1+1

25%

An

Grease

10,0

Box type

LT rail

tions as pery thermit w

Suit

MH

DOC.

REV. 0

Page 5

: 1875

MH micro

EHT+

NA

NA

CT micr

EHT+

NA

NA

ifriction ball

lubrication

00 working

2 nos, Mat

Span

By fitted bol

IS: 3443 Grlding & fusi

IS:

Rail

ble for ambi

MH micr

O.PE-TS-3

DAT

of 10

Cla

A

DCEM

1+

150

o L

DCEM

1+

125

/ roller beari

ith separat

ours.

erial: IS 206

/ 900

ts

ade 50 C 12n welding

443

Steel

ent tempera

A

62-501-A00

E: 4/6/12

s IA or 3/ IS

A

1

%

L

1

%

ngs

pumps

2 Gr. A / B

CT rail

. J oint to be

ture of 500

H

: 1875

micro

NA

NA

micro

NA

NA

butt-

AH micro

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10.2

13

Type

Enclosu

Numbe

Voltagefrequen

Class o

Rated c

Rating

Class o

Numbehour

Travel

Type

Enclosu

Numbe

Voltagefrequen

Class o

Rated c

Rating

Class o

Numbe


re

s furnished

, phase ancy

protection

apacity (KW

insulation

of sta

otions

re

s furnished

, phase ancy

protection

apacity (KW

insulation

of sta

DATA SHEE

G HALL EOTSTPP ( 2X80

SC, sInve

T

415V +variation

IP 55

) Selectedmaximufrequenc

Motor naover theduty poi

Cl

ts

SC, sInve

T

415V +1

Combine

) Selectedmaximufrequenc

Motor naover the ipoint.

ts

T FORCRANES0 MW )

itable forter duty

EFC

1

0%, 3 Ph,= 10% abs

motor ratincontinuou

y variation,

meplate ratiinput powert.

lass F for s

CT

itable forter duty

EFC

2

0%, 3 Ph, 5

d voltage &

motor ratincontinuou

y variation,meplate ratinput power

lass F for

DOC.

REV. 0

Page 6

NA

NA

NA

0 Hz, 5 %lute

should havload dema

emperature

ng at 50 oCrequiremen

40

q. cage mot

that of

150 st

CT micr

NA

NA

NA

0 Hz, 5 %

frequency v

IP

should havload dema

emperatureng at 50 oCrequirement

40

sq. cage mo

to that o

150 st

O.PE-TS-3

DAT

of 10

SC, suiInvert

TE

Combine

e minimumd includingrise and oth

hall have atof driven e

CDF

rs with tem

class B

rts / hr

o

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riation =10

55

e minimumd includingrise and othshall haveof driven eq

CDF

tors with te

f class B

rts / hr

62-501-A00

E: 4/6/12

table forer duty

FC

1

voltage &

argin of 15voltage ander factor.

least 15%uipment at

rise limited

LT

itable forter duty

FC

4

% absolute

argin of 15voltage ander factor.at least 15uipment at

p rise limite

NA

NA

NA

requency

% over

arginated

to

LT micro

NA

NA

NA

% over

marginated duty

d

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11.0

12.0

13.0

14.0

15.0

13

hour

Spacerequire

Limit s

Type

Numbe

ControlEnclosu

Power(DSL)

Type

Length

Control

Material

Numbelocation

Degree

MasterControl

Numbe

Voltagerating

Locatio

Cable

Material

Size

Type

Voltage

Voltage


eaterent

itches

provided

voltage/re

conductor

panel

s and

of Protectio

lers

of steps

& curre

grade

drop


Mai

RotarG

1

CT:(Fest

One

Mai

t

Min. 2.5

Cable f

T FORCRANES0 MW )

For

hoist

y gear +avity

+ 1

LT: PVC

Flexible traioon type) E

S

R

ach for MH,

Hoist

5

Powe

Copper

mm2 for Cu.

rom main is

DOC.

REV. 0

Page 7

motors abo

Aux. Hois

Rotary ge+Gravit

1 + 1

110 V

shrouded

ling cable mP insulated

itable for e

olled sheet

AH, CT an

IP

Aux Hois

5

110

In c

FRL

11

lating switc

O.PE-TS-3

DAT

of 10

ve 30 KW r

tCroTrav

rLever

2

/ IP 54

u conducto

ounting on rCu conduct

tire bay len

teel 2mm si

LT located

54

** CroTra

4

/10 A

abin

PVC

0 V

(1.5M abo

62-501-A00

E: 4/6/12

ting

sel

Lon

type Le

r bus bar.

etracting suor as per IS:

th

ze

on bridge pl

ssel

Lon

Control

Copper

Min. 1.5 m

e operating

g Travel

er type

2

port9968

tform

g Travel

4

2

floor) to

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16.0

17.0

18.0

19.0

20.0

21.0

22.0

23.0

24.0

25.0

13

Contac

Switch

Fuses

Overlo

PortablExtingu

Type a

Locatio

Power

Transfo

Control

Lighting

Illumin

In cabin

Over Br

Under b

For in

crane c

Ventilat

Buffer

Numbe

Type


ors

s

d relay

e Fireisher

d size

upply

rmer

tion

idge

ridge

spection

mponents

ion


motor

AC 4 d

AC

Te

415 V,

40Wlamp

4 nos 6

4 nos 4

f One (1)

wire guainspectio

Springbring t

T FORCRANES0 MW )

terminal shae

uty for rever

23 for moto

perature co

One i

3 phase, 3len

lorescent fi 1 each, 2n

W Bulk-he24

00 W HPSV

ortable 40

rd) hand lan of crane c

On

Cross Tra

4

loaded/ hyhe loaded cpeed at a d

DOC.

REV. 0

Page 8

ll be so sizexceed 3% o

sing applicaappli

application,

H

pensatedprev

5.0 kg ,

n cabin** an

ire supply agth with cha

Qty /

2 X 100 %

One /

ture + Bulkos. 24V 5

d fittings wi- 5A - 3 pin

lamps

(SLS lamp

p with min.omponents

(1) no. Ele

el

raulic type rane to resteceleration r

O.PE-TS-3

DAT

of 10

that the vorated voltag

ion. AC 3 dation

AC 22 for o

C

i metallic wintor.

CP type

d Three on

t operating flge over swi

ating

/ 415/110V

15/240V

ead fitting 3 pin ind

h incandesindustrial so

with enclos

alf span len

tric fan in c

bber bufferrom speedate not exce

62-501-A00

E: 4/6/12

ltage drop de.

ty for non r

ther applica

th single ph

ridge

loor at centritch.

ith 60W incustrial sock

ent lamps acket

d type batt

gth flexible

bin.

Long Travel

4

. To be desif 50 % of theding 5 m/s

es not

versing

ion.

sing

of bay

ndescentt.

nd 4nos.

ry and

able for

ned toe rated.

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26.0

27.0

28.0

29.0

30.0

31.0

13

Typerequire

bridge.

Positionpoint

Emerge

Typeplatfor

Length

Providesides

Operat

Type of

Area aclear he

Operat

Warnin

Positioncontroll

Type ofHoists/operati

Paintin

Whetheoperati

Liftingbforoper


f platford on th

of acces

ncy escape

of accesto cabin

d on bot

rs Cabin

constructio

d minimumight

rs seat

gong

ofrs

control forCT/LTn

r tandemn required

eamandslinationtande

DATA SHEE

G HALL EOTSTPP ( 2X80

C

s

s

2

Footoperate

23

T FORCRANES0 MW )

hequered pl

500/1850 m

operated Brfrom insid

In

Sha

5T capacity l

DOC.

REV. 0

Page 9

te platform

From

Rung lad

By St

Full sp

Y

Closed ty

m with a cle

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ss gong su. Suitable fo

at 3

ront/ side of

Through

ll be as per

Y

ifting beam

O.PE-TS-3

DAT

of 10

6 mm thick

cabin

er at ends

ircase

n length

es

e with AC

ar head roo

ng type

pended outr 240 V AC.5 m

operators c

VVF drive

nnexure I b

S

ith slings s

62-501-A00

E: 4/6/12

s per IS :35

of 2000m

side the cabof noise leve

hair

elow

hall be provi

02

.

in andl 95 dBA

ded

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PAIN

A)

Sur

Pri

Fini

Tot

B)

Sur

Pri

Fini

Tot

COLO

13

TING SP

Structural

ace prepa

er

sh Coat

l DFT

Electrical

ace prepa

er

sh Coat

l DFT

R SHADE

S. No

D

1 C

2 Bas

3 H

4 E

s

5 Pa

m


CIFICAT

ation : De

( S

: Red

Mini

: Synt

Mini

: 125-

Control P

ation : Se

: Zinc

Mini

: Synt

Mini

: 110 -

Item

scription

ane Struct

ttom blocsembly

oks

d carriage

eep

nels and

tors


ON FOR

greasing a

1/ ST 2 /

xide Zinc

um DFT

etic ename

um DFT 3

45

nel

en tank pr

phosphate

mum DFT

etic ename

um DFT

145

Color

re Golde

as per

Goldeas per

Golde

as per

Golde

as per

Steel

Purch

T FORCRANES0 MW )

OUBLE

d Mechani

T 3 as app

chromate a

30 per co

l (Alkyd m

5 per co

cess

Alkyd me

25- 35 p

l (Alkyd m

0-25 per

Shade

n yellow, s

IS-5

n yellow, sIS-5

n yellow, s

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ser.

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cal cleanin

licable)

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edium) as p

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edium) as p

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ade 356

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ade 356

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ired by

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DAT

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with wire

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er IS: 2932

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er IS: 2932

Remarks

With blac

With 100

black zebr

With blac

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ES

brush or h

medium)-

- 2 coats,

- 3 coats,

strip

m wide

a strip

strip

nd tool.

2 coat ,

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2X800MWYERMERUSTGHALLCRANEOF130/30TCAPACITYINTANDEM

WriteuponLoadTestingLiftingBeamTestingatManufacturersWorks

Thiswriteup briefly describes the procedure for carrying out the load testing of lifting beam at

manufacturersworksbythesuccessfulbidderforthesaidproject.Intentionhereisnottoelaborate

onstep

by

step

procedure

for

testing

of

lifting

beam

but

to

broadly

outline

the

type

of

load

test

for

theliftingbeamrequiredtobecarriedoutbythebidder.Loadtestingofthebeamcanbecarriedby

anyofthefollowingthreealternatives.Briefprocedureforloadtestingoftheliftingbeamwithallthe

threealternativesismentionedisasunder:

ALTERNATIVEI

a)Liftingbeamassembly(lowerandupper liftingbeam)shallbehungsuitablyfromastructure

capableofholdingtheloadforwhichtheliftingbeamisdesigned(235T)withmargins,atthe

pointsfromwheretheliftingbeamissupposedtobeheldwiththehooksduringactualcrane

operation in tandem.Actual liftingpinsshallbeused forhanging the liftingbeam.Suitable

wireropes/chainsshallbeusedforhangingtheliftingbeamthroughpinstothestructure.

b)Loadshallbeappliedon the lower liftingbeamexactlybelowtheabovementionedhanging

arrangementwith thehelpofhydraulicjackofsuitablecapacity.Durationofapplicationof

loadshallbe30minutes.

c)Loadcellsshallbefixedbelowthehydraulicjacktoascertaintheloadapplied.

d)Deflectionoftheliftingbeamshallbemeasuredatthecentreandnoteddownunderloaded

condition.

e)After30minutes, the load shallbe removedand thedeflectionof the liftingbeamshallbe

measuredatthecentreagaintofindoutthepermanentdeflection,ifany.

f)Maximum deflection in the lifting beam should not exceed the allowable deflection as per

relevantIS/equivalentstandard.

g) Load testingof the liftingbeam atmanufacturersworks shall be acceptable inhorizontal

conditionalso(incasethebidderdoesnthavearrangementforverticaltestingofthebeam).

However, insuchcases,necessaryfixtures/arrangementsshallhavetobearrangedbythe

bidderto

demonstrate

testing

of

beam

under

similar

condition

of

loading

as

will

be

seen

by

thebeamduringactualtandemoperationofthecranes.

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ALTERNATIVEII

a)Liftingbeamshallbeplacedonelevatedpedestalsinsteadofhangingfromthefixedstructure,

as mentioned in the alternative I above and the load shall be applied with the help of

hydraulicjackfrombelow.

b)AllotherrelevantconditionsshallremainsameasmentionedinalternativeIabove.

ALTERNATIVEIII

a) Liftingbeam shallbeplacedon theelevatedpedestalsasmentioned inalternative IIabove.

However the load shall be applied from the top of the lifting beam. Either dead load or

hydraulicloadcanbeusedforthispurpose.

b)IncasebidderpreferstogowithAlternativeIII,biddershallberequiredtotestthelowerlifting

beamalsointhesimilarfashionastheupperliftingbeam.c)Allotherrelevantconditionsshall

remainsameasmentionedinalternativeIabove.

(BiddersSignaturewithSeal)

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MANUFACTURER'SNAME&ADDRESS

SL. CHARACTERISTCS CLASS TYPEPF QUANTUM REFERENCE ACCEPTAN

NO. CHECK OFCHECK DOCUMENT NORMS

1 3 4 5 6 7 8

QP NO : PETSSTD501A001

REV :

DATE :

MANUFACTURINGQUALITYPLAN

COMPONENTS&

ITEM:

OPERATION

4

d filletwelds Sizeandsurfacedefects Major Visual 100% ComponentDrg.

Component

Drg.

Major DPT 10%RANDOM

ASMESecVIII

Div1

ASMESecV

Div1

Append8 Append8

e DimensionsforGirder,end Major Dimensional 100% VendorMfg.Drg. VendorMfg.

carriageropedrumetc. Measurement

Camber,Verticality,bend

etc

f Heattreatmentofropedrum S tressrelieving Major ReviewofSR 100% ASMESecVIII,Div I ASMESecVIII,

I

chart

3 Gearboxcasing

a Material Surfacecondition Major Visual 100% ComponetDrg. ComponetD

Chemical&mech Major Measurement 100% ComponetDrg. ComponetD

Correlationwith 100% IS:2062 IS:2062T.C.Checktest

inabsesnceofT.C.

Correlation

b welding Welding&Dimensionalconformity Major Measurement 100% ComponetDrg. ComponetD

c Heattreatment stressrelieving Major ReviewofSRchart 100% Compone ntDrg./ ComponentD

ASMESecVIII,Div

I

ASMESecVI

Div Ifor

procedure.

4 PLATFORMS Dimensionalconformity Minor Measurement 100% ComponentsDrg. Components

5 L.T.FRAMES Dimensionalconformity Minor Measurement 100% ComponentsDrg. Components

6 HANDRAILINGS Dimensionalconformity Minor Measurement 100% ComponentsDrg. Components

7 CABIN Dimensionalconformity Minor Measurement 100% ComponentsDrg. Components

LEGEND :

MANAFACTURER/ CONTRACTOR C:BHELCQS

** M:MANAFACTURER/SUBCONTRACTOR

INDICATE"P"PERFORM"W"WITNESSAND"V"DOCUMENTREVIEW

D* RECORDSINDETIFIEDWITH'TICK'( )SHALLBE ESSENTIALLY

INCLUDEDBYCONTRACTORINQADOCUMENTATION

SUBCONTRACTOR

finalinsectionoffabricated

componentslistedinSr.1

above

Format: QS-01-a1-P-9/F1/R1 BHEL-QAP

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1 3 4 5 6 7 8


REV :

DATE :


COMPONENTS&

ITEM:

OPERATION

4

N:CUSTOMER REVIEWEDBYSIGNATURE


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1 3 4 5 6 7 8


REV :

DATE :


COMPONENTS&

ITEM:

OPERATION

4

8 Currentcollerctorarms Dimensionalconformity Minor Measurement 100% Mfr.Catalog Mfr.C at al og

9 DSLGuard Dimensionalconformity Minor Measurement 100% ComponentsDrg. Components

10 Rails Dimensionalconformity, Minor Measurement 100% G.A.drg./IS:3443

Vendore

T.C./Appd.Data

Sheet

G.A.drg./IS :

Vendore

T.C./Appd.Da

SheetChemical&hardness Major Checkchemical&

hardness

One/Cast IS3443 IS:3443

11 MECHANICALCOMPONENTS

A a) wheels

i) Materials Chemicalscomposition and Major Corelationwith 100% Mfg.drg./IS :1570 Mfg.drg./IS :1

MechanicalProporties. mfr'sTC /BS 970 /BS 970

ii) Machined a) Dimensions Major Measurement 100% Component

Drawing

Component

Drawing

b) Hardness Mechanical 100% ApprovedData

Sheet/Mfg.Drg.

ApprovedDa

Sheet/Mfg.

c) UT NDT 100% ReferNote:6 ReferNote6

d) DPT NDT 100% 8 App8

b) Gears,Pinions,Shafts, i) ChemicalsComposition Major Correlationwith 100% Component

Drawing,

Component

Drawing,

Axlesetc &heattreatment,Mech mfr'sTC BS:970/IS:1570 BS:970/IS:

1570

Properties. Checktestin ApprovedData

Sheet

ApprovedDa

Sheet

absenceofTC

ii)UT(afterproofmachining) Major checkforUT 100% A SMESecV ReferNote6

(above50mmdia)

iii) Hardness Major checkfor 100% Mfg.drg.& Mfg.drg.&

Hardness ApprovedData ApprovedDa

iv) Dimensions Major Measurement 100% Component

Drawing

Component

Drawing

V)D.P.Testonteeth Major NDT 100% ASTME165 NoCrackand

of

i nd ic at ion

LEGEND :

MANAFACTURER/ CONTRACTOR C:BHELCQS `

SUBCONTRACTOR

D* RECORDSINDETIFIEDWITH'TICK'( )SHALLBE ESSENTIALLY

INCLUDEDBYCONTRACTORINQADOCUMENTATION


INDICATE"P"PERFORM"W"WITNESSAND"V"DOCUMENTREVIEW


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1 3 4 5 6 7 8


REV :

DATE :


COMPONENTS&

ITEM:

OPERATION

4

N:CUSTOMER REVIEWEDSIGNATURE


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1 3 4 5 6 7 8


REV :

DATE :


COMPONENTS&

ITEM:

OPERATION

4

B Pulleys,Brakedrums,coupling&othermajorsteelcastings&forging

i) Materials Physical/Chemical/Hardness Major Corelationwith 100% Components

Drawing

Components

Drawingexceptpulleys. mfr'sTC

ii) Machined a) Dimensions Major Measurement 100% Components

Drawing

Components

Drawing

b) DPT ingrooveafter Major NDT 100% ASTM E165 No.crack/Lin

machiningforpulleysonly. indication

C Gearboxassy&idlerunning Checkforoilleakage,Noiselevel, Major Visual& 100% Vendorstandard Smoothrunn

no

backlash,riseintemp.after2 Measurement oilleakage,N

Hrs.ofrunning. 85dbat1Mt

Max.Temp.

40Cabovea

D a) Topblcok,bottomblock dimensionalconformity Major Masurement 100% Assemblydrawing Assembly

drawing

b) Hook i)Chemicalcomposition,Heatt re at me nt , M aj or C he mi cal& 100%

Mechanicalpropertiesonintegeral Tensile

testbar

ii)UTonrawmaterialofhook Major UT 100% ASMEsecv Annex1

(Attached)

iii)Forgingoperationofhook Major Visual 100% IS:5749/IS:15560 IS:5749/IS:15

iv)Proofloadtest Major Mechanical 100% IS:5749/IS:15560 IS:5749/IS:15

v)UT&MPIafterproofloadtest Major UT &MPI 100% ASMEsec v Annex1forU

(UTonshankportiononly) Nocrack&li

indication(Fo

E Ropedrumassembly Die mnsionalconformity Major Measurement 100% Component

Drawing

Toleranceas

drg

LEGEND :

D* RECORDSINDETIFIEDWITH'TICK'( )SHALL

BE ESSENTIALLY

INCLUDEDBYCONTRACTORINQA

DOCUMENTATION


MANAFACTURER/ CONTRACTOR C:BHELCQS

SUBCONTRACTOR

INDICATE"P"PERFORM"W"WITNESSAND

"V"DOCUMENTREVIEW

Material:ClassIIIS:1875

Profile:IS:IS5749/IS15560


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1 3 4 5 6 7 8


REV :

DATE :


COMPONENTS&

ITEM:

OPERATION

4

N:CUSTOMER REVIEWEDBYSIGNATURE


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1 3 4 5 6 7 8


REV :

DATE :


COMPONENTS&

ITEM:

OPERATION

4

12 E le ct ri calcomponents

a) Motors( =

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1 3 4 5 6 7 8


REV :

DATE :


COMPONENTS&

ITEM:

OPERATION

4


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PROJECT : 2

QP. NO. :

BHEL DRG. NO.:

Rev. 0

DATE :

1 3 4 5 6 8 92

REFERENCE

DOCUMENT

SR.

NO.

CLASS

MANUFACTURING QUALITY PLAN

QUANTUM OF

CHECK

COMPONENT &

OPERATIONS

ITEM: 235T LIFTING BEAM

ASSEMBLY FOR 130/30 D/G EOT

CRANE

MANUFACTURER NAME & ADDRESS

FORMAT OF

RECORD

TYPE OF

CHECK

CHARACTERISTIC

PACKAGE :-T

CONTRACT

7

ACCEPTANCE

NORMS

b)

Surface defect & size Major Visual 100% Component Drawing inspection

report

DPT 10% at random Free from linear

indication

inspectio n

report

iii) Visual & dimensional Major Dim ensional &

measurement

100% Individual component

drawing

inspectio n

report

3) Visual &

Dimensional .

Major

.

.

Visual &

Dimensional

check

100% GA drawing of lifting

beam / IS 3177 & Tech.

Specification.

interrnal

inspection

report.

4) AS per approved QAP

5)

Visual

Major

Visual

100%

Load Test Procedure

Inspection

Report

LEGEND: FOR CUSTOMER USE

Contractor"C" CONTRACTOR(BHEL)

"N" CUSTOMER ( NTPC )

INDICATE "P" PERFORM, "W" WITNESS AND "V" VERIFICATION AS

" CHP" SHALL IDENTIFIED IN COLUMN " N "

NOTE: ITEMS NOT COVERED IN MQP, MAY BE CLEARED ON BASIS

OF "CERTIFICATE OF CONFIRMANCE"SIGNATURE

sub-contractor

REVIEWED

Final assembly of

Lifting Beam

Inspection of

fabricated lifting beam

Component Drawing

Fillet Weld

Individual component

drawing

INCLUDED BY CONTRACTOR IN QA DOCUMENTATION

Manufacturer/ "M" MANUFACTURER/ SUBCONTRACTOR

RECORDS IDENTIFIED WITH 'TICK ( ) SHALL BE ESSENTIALLY

GA drawing of lifting

beam /IS 3177 &

Tech-Specification.

Load Test at

manufacturers' works

as well as Site

Load Test Procedure

IS:3658

Review of QA

Documents

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2X800 MW YERMERUS STPP, 2 NO'S 130/30T TG HALL EOT CRANE

OPERATION AND MAINTENANCE SERVICES FOR 2 YEARS SHALL

INCLUDE BUT NOT LIMITED TO FOLLOWING

1.0 For Operation of the Crane

An experienced crane operator shall be available as and when required by BHELfor at least 16hrs a day, daily.

2.0 For Maintenance of the Cranea) Break-Down Maintenance

i) In case of any break-down of the crane during the contract period,service engineer shall be made available at site within 72 hrs.

ii) All the critical spares and consumables, as deemed necessary by themanufacturer shall be made available at the site. No delay in crane

maintenance shall be allowed by BHEL due to non-availability ofrequired spare at site.

b)Preventive Maintenancei) Following work should be carried out quarterly

Bridge and Trolleywheel assy

Checking for wear, flat spots and cracks in flange. Ensuredrive wheels are of the same diameter.

Runway Checking alignment and elevation of gantry track. Checkingrail clamp bolts.

Machine Bolts Checking all foundation bolts of Electrical and Mechanicalequipments for tightness.Structural Bolts Checking for tightness. They should also be checked after

the first month of operation.Flexible Couplings Checking pins and teeth for wear, cleaning and greasing.Cross-shaftPlummer Blocks

Dismantling cap. Cleaning and checking oil seals and to bepacked with fresh grease.

Trolley Collectors Checking of cable trolleys / cabling / chain. Ensuringconnection of trolley wheels is kept through entire length ofspan.

Brakes All Brake assembly will be checked for loose connection,

earthing connection, linings for wear, leakages andadjustments to ensure brake is not rubbing the brake drumduring operation. Greasing pins and operation adjustment ofbrakes.

ResistorConnections

Checking, tightening connections at grid joints and at cableterminations.

Control Station Clean out control cabinets. Checking of all connection atpush buttons, master controllers contact tips, cams andterminals.

Control Panels All Control Panels will be checked for loose connection andcleaning the contactor contacts, if required will be replaced.

Electrical Motors All motion motors connection will be checked for loosecontacts in terminal box loose crimping of wire lugs, loose

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contacts on slip ring assembly with carbon brush. Earthingsconnection with motor.

Safety Switches All limit switches will be checked for desired operation andlimits. Emergency switches will be checked.

Main Collectors Checking of worn collector shoes, sag in main runway wiring,ensuring contact is kept through entire length runway

properly.Electricalconnections

Checking throughout electrical equipments for looseconnection such as selector switches, junction boxes, minisolator switch etc.

Lubrication All gear box and thrusters oil level will be checked. Allbearings, couplings grease will be checked.

Testing After completion of checking and required rectification, trolleywill be checked for idle operation, for brake operation, limitswitch operation & safety switch operation. All motorcurrents will be checked on no load.

ii) Following work should be carried out annually.

Gear Boxes Oil seals will be checked, if required will be replaced. Gearand pinion teeth will be checked. Drain the oil cleaning gearbox and refill fresh oil.

Motor All motors insulation test and meager test will be carried out.Resistance Box All resistance boxes step resistance value will be checked.

iii) Besides the quarterly and annual preventive maintenance schedulementioned above, operator shall carry out any daily, weekly, monthlymaintenance schedule as deemed necessary and shall operate the craneonly when the fitness of the crane for operation has been ensured.

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SPECIFIC CONFIRMATION / COMMENTS REQUIRED FROM

BIDDER

SPECIFICATION: PE-TS-362-5

TITLE: DOUBLE GIRDER EOT CRANE FOR TG HALL VOLUME-II B SECTION-C

PROJECT: 2X800 MW YERMERUS STPP

S.N. DESCRIPTION REPLY / COM

1.00 MECHANICAL1.01 Bidder to confirm that the Data sheet attached along with project

specific Technical Specification No. PE-TS-362-501-A001 Rev. 00 are

acceptable without any deviation. Bidder to confirm the same.

CONFIRMED

1.02 In case of any deviation, the same has been furnished in the separate

Deviation schedule attached along with the Technical Specification.

Bidder to note that deviation mentioned elsewhere will not be taken

cognizance of in any case. Bidder to confirm the same.

CONFIRMED

1.03 Bidder to note that QAP indicated in the standard technical specification

PE-TS-STD-501-A001 R03, is the minimum requirement. Finalisation of

the same shall be as per final approval by BHEL/CUSTOMER. Bidder

to confirm

CONFIRMED

1.04 Bidder to confirm that there is no deviation from the Crane Clearance

Diagram no. PE-DG-362-501-A001 Rev 01A . Bidder to specifically

note that in no case any deviation from the Crane Clearance diagrams

given by BHEL shall be accepted. Bidder to confirm the same.

CONFIRMED

1.05 Bidder to confirm that there is no deviation from the makes of various

sub vendors items as given in annexure-I Makes of Sub-vendors

Items , volume II-B, section-C. of standard technical specification PE-

TS-STD-501-A001 Rev. 03 Bidder shall confirm the compliance

CONFIRMED

1.06 The material offered is equal or better in grade than specified. Bidder

shall confirm the compliance

CONFIRMED

1.07 Bidder to note and confirm that there will be no price implication for

variation in Span, Lift and baylength upto 500 mm. Bidder to confirm

CONFIRMED

1.08 Bush as a antifriction bearing shall not be used. Bidder shall confirm

the compliance

CONFIRMED

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BIDDER




1.09 Bidder to specifically note that there is specific requirement of the

painting for this particular project. Bidder to confirm the compliance to

the attached Painting specification.( Annexure I)

CONFIRMED

1.10 Bidder to confirm that in case of award of order, Hook drawing shall be

submitted to BHEL within one week of receiving the LOI. Bidder also to

submit Unpriced Purchase Order copy of Hook within 15 days from LOI

. Bidder to confirm

CONFIRMED

1.11 Bidder to confirm that in case of award of order, Motor Sizing

calculations shall be submitted within 15 days time of receiving the LOI

by the bidder. Bidder to confi rm the same.

CONFIRMED

1.12 Bidder to note that lifting beam has to be sourced from BHEL approved

suppliers only. Also the testing of the lifting beam at manufacturers

works shall have to be carried out by the bidder as per BHEL approved

QAP. List of sub-vendors and reference MQP (to be finalized during

detail engineering) for Lifting beam testing at manufacturers works, are

being furnished along with the specification. Bidder to confirm

acceptance.

CONFIRMED

2.00 ELECTRICALS

2.01 CABLES

a All CONTROL AND POWER cables shall be as per BHEL specification.

Bidder shall confirm the complianceCONFIRMED

b Makes of cables shall be as agreed in between BHEL / Customer during

contract stage and approved make shall only be supplied. Bidder shall

confirm the com liance

CONFIRMED

c Cable required between isolating switch / change over switch and DSL

included in the scope. Bidder to confi rm the same.CONFIRMED

2.02 MOTORS

a Class of insulation of Sq. cage motors shall be "F" and the temperature

rise to limited to class "B". Bidder shall confirm the compliance CONFIRMED

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BIDDER




b Motor size shall be subjected to the approval of motor calculation.

Bidder shall confirm the compliance CONFIRMED

c The successful bidder shall submit the data sheet -C of LV motors

during detailed engineering and the same is subjected to customer

approval without any cost implication on account of the same.Bidder

shall confirm the compliance

CONFIRMED

d The minimum requirementindicated in the BHEL's Standard QAP shall

be complied for Electrical Items. Bidder shall confirm the compliance CONFIRMED

e Bidder to confirm that there is no technical deviation on "Electrical

portion of StanderdTechnical specification" and "Data sheet of Electrical

portion". Bidder to confi rm the same.

CONFIRMED

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Annexure-C

VENDOR HAS TO SUBMIT ONLY FOLLOWING DOCUMENTS ALONG WITH THE OFFER,FOR TECHNICAL EVALUATION OF THE BID:-

1.0 Specific confirmation / Comments from the bidder as per BHEL Format.

2.0 NO DEVIATION CERTIFICATE Clearly mentioning that bidder hasconsidered No - Deviation from the technical specification provided byBHEL.

OR

DEVIATION Sheet, indicating clause wise technical deviation if any.

3.0 Unpriced format, duly mentioned Quoted against each Sl.no. below

each column.

Note1:- Any other standard document/ details furnished by the bidder i.e.Data sheet / Crane clearance diagram/ GA Drawing/ QAP etc. shall not betaken in to consideration for evaluation.

Note 2:- Bidder to note that if the bidder does not submit the documentsmentioned in Sl. No. 1.0 ,2.0, and 3.0 along with their offer then their offer isliable to be rejected.