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ANNEXURE TO TENDER NO. DPS/MRPU/IGCAR/FAB/1448/TPT-1108

TECHNICAL SPECIFICATION OF 10TON CASK-DOLLY AND MONORAIL HOIST

1.0 Introduction:

The tender specification for design, engineering, preparation of fabrication drawing,

manufacture, supply, erection, testing and commissioning of 10Ton cask-dolly and its

associated 10Ton monorail electric wire rope hoist for handling cask.

1.1 Applicable drawings:

a) DFRP cask-dolly conceptual drawing: DFRP/23000/4000

b) Rail fixing details for cask-dolly: DFRP/23000/4001.

c) DFRP 10Ton Monorail hoist: DFRP/23000/4002

2.0 Scope of Work:

a) Study of conceptual drawing and technical specification.

b) Visit to plant site (DFRP/IGCAR) for understanding of the cask-dolly functional

requirement, rail erection and associated 10Ton monorail electric wire rope hoist

erection with respect to site condition before submission of technical offer.

c) Preparation of manufacturing sequence and Quality Assurance Plan (QAP).

d) Preparation and submission of detailed design calculations for purchaser’s approval.

e) Selection of suitable mechanical standard items like gear box, single acting low height

hydraulic cylinder, rail for LT, spherical roller bearing, Journal bearing, track wheels,

rubber buffer etc, and obtaining approval from purchaser.

f) Selection of suitable electrical standard items like VFD motors, DCEM brakes,

pendant control, drum wound cable arrangement for trolley power feed arrangement,

limit switches, electric panel, VVVF drives, etc and obtaining approval from

purchaser.

g) Preparation of 2D part-drawing (i.e. fabrication drawing) with tolerance, drawing of

each module assembly and complete assembly drawing of the cask-dolly and

monorail hoist and submission for purchaser’s approval.

h) Obtaining approval of the purchaser for design, drawings and standard bought out

items before commencement of manufacturing / fabrication.

i) Fabrication of components as per approved drawings.

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j) Stage inspection of components during manufacturing and maintenance of all

inspection reports viz., linkable test certificates, material identification certificate,

LPE reports, RT/UT reports, dimension inspection reports.

k) Submission of all the required procedures for manufacture, erection, testing and

commissioning of 10Ton dolly and monorail hoist and approval from purchaser.

l) Inspection of bought out standard components and sub-assemblies and maintaining

inspection reports.

m) Testing of cask-dolly and associated 10Ton monorail hoist at supplier’s premises by

the purchaser as per QAP and test procedure.

n) Supply of essential spares as per this technical specification.

o) Safe transport and delivery at IGCAR, Kalpakkam.

p) Erection, commissioning and testing of equipment at DFRP/IGCAR site.

q) Submission of History dockets / inspection reports.

3.0 CASK-DOLLY

3.1 Description

The cask-dolly should be robust in design. The cask-Dolly shall be made out of formed/

fabricated channel / box sections using IS2062, Grade E250 (Fe 410W), Quality-B plates

as per drawing and technical specification. The dolly is mounted on trolley as per

drawing. The trolley moves over the rail mounted on the floor and shall be electrically

operated. The dolly is for aligning the cask and shall be mounted on the trolley platform

by wheels as per drawing.

Dolly platform are moved up down by low height hydraulic cylinder placed at four

locations under the platform for leveling and for cask alignment with cell-shielding unit.

The movement of Dolly over the trolley is also motorized.

Supporting table / collapsible platform shall be mounted on the floor with cell shielding

unit as per drawing and shall be aligned to the trolley platform. Hinge type arrangement

shall be provided in the table as per drawing.

3.1.1 Trolley

Cask-dolly is used to transport cask from cask handling area to cell area and vice versa.

Cask-dolly consists of Trolley and Dolly. The trolley is the base for mounting the dolly

and shall be electrically operated. It shall have long travel to cover 23m distance from

fuel handling area to receipt cell at DFRP. The trolley shall have electrical motor with

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gear box to drive the trolley to the specified speed. Festoon cable/spring loaded cable

drum supply with pendant control system shall be provided for the trolley. The speed for

operation of trolley to be 5m/min for main speed and 0.5m/min for micro speed.

3.1.2 Dolly

The dolly is mounted over the trolley on wheels and shall have transverse movement. The

dolly is meant for transverse / cross travel (CT) motion to align with the cell shielding

unit through a collapsible platform. The dolly has a top platform with low height

hydraulic cylinder for fine adjustment and leveling and for alignment of cask with cell

shielding unit. The dolly shall be motorized to enable the traverse/cross travel motion.

3.1.3 Collapsible platform / table

A hinged type collapsible platform acts like a bridge / connecting platform between the

cell shielding unit and trolley. The platform consists of a fixed and movable portion with

hinges. The fixed part of the platform is welded to the existing member of the cell

shielding unit (existing structure) at appropriate location. The movable portion of table

can be swiveled with respect to the hinge. The collapsible platform is rested on four legs

at suitable locations.

3.1.4 Rail erection at site

Rail shall be of ISCR140 as per IS3443 or square bar of equivalent mechanical properties

shall be erected as suitable to site condition with the approval of departmental engineer,

Refer Drg No: DFRP/23000/4001. The rails shall be fixed/supported only at the fixing

locations (EPs) provided in the layout.

3.1.5 Manual Operation

Provision for manual operation should be provided for trolley and dolly to bring the

system to safe position in-case of power failure.

3.2 Materials

Sl. No. Description Material

1 Structural Material IS2062, Grade E250 (Fe 410W), Quality-B.

2 Bearings Wheel bearings with min. factor of 2.5 over C/P loading

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ratio suitable for 10,000 running hours of SKF/FAG

make.

3 Rail & Wheel As per IS3177.

4 Gear & pinion As per IS3177.

The basic type of material for construction is indicated above. The supplier has the

freedom to choose/suggest alloys with required optimum properties with heat treatment to

enable high load bearing capacity so as to reduce the size/weight of each component. This

has to be carried out after getting the concurrence of purchaser.

Material tests: Material test shall be carried out as per applicable standards. Test reports

or linkable documents showing chemical composition and mechanical properties are

required for all materials. In case test reports are not linkable , testing of the material

shall be carried out by the supplier at his own cost from mutually agreeable laboratories.

Material of construction shall bear identification marking to assure that all material can be

identified during all stages of fabrication in the supplier shop.

3.3 Cask-Dolly specification

i) Type of Equipment Cask-Dolly

ii) Capacity 10 Ton

iii) Qty 1 no.

iv) Trolley wheel gauge 2500mm(span) – fixed

v) Trolley wheel base 1120mm (can be varied as suited to site

condition)

vi) Class of Duty Group classification M5 as per IS3177

vii) Design ambient

temperature

40ºC

viii) Dolly top platform size Sq.1240mm

ix) Trolley overall dimension 2900 x 1252mm

x) Max. level of platform

top from finished floor

level

Restricted to 580mm.

xi) Trolley rail Rail section as per IS3443 (ISCR140) or

square bar of equivalent mechanical

properties. Length of rail to be laid is

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23m. Fish plate to be fastened to either

side of rails for a length of 23m at 1m

interval.

xii) Max. projection of

Trolley from center line

of wheel

150mm

xiii) L.T wheel drive Motorized

xiv) Trolley L.T speed 5m/min(main) & 0.5m/min (micro)

xv) Trolley L.T using VFD

motors

Drive integration details with trolley

wheel to be provided.

xvi) Trolley L.T brakes and

Dolly brakes

2 x DCEM disc.

xvii) Top platform up / down

motion

By Single acting, low height, light weight

Hydraulic cylinder (Jacks) of vanjax,

enerpac or equivalent make-4nos

xviii) Dolly movement

mechanism & speed

Motorized, 1m/min & 0.1m/min.

xix) Gear box type High efficiency compact inline planetary

Drives

xx) Operation Push button pendant with Cable

connected to one corner of trolley.

Emergency OFF push button to be

provided on pendant.

xxi) Wheel bearing housing

type

Conventional type

xxii) No. of wheels 4 nos. for trolley and 4 nos. for dolly

xxiii) Power feed arrangement

to Trolley

Spring loaded drum wound cable with

plug arrangement.

xxiv) Bay length 23meters.

xxv) Power supply required 415/410 V, 3 phase, 50Hz A.C

xxvi) Control Voltage 110 V A.C

xxvii) Total weight of Cask-

Dolly

2.8 Ton (approx.)

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3.4 Technical specification of Cask-Dolly

i) Motors

Squirrel cage induction motors as per IS325, crane

duty, class F insulation, S4 duty, 150 starts & stops/hr,

40% CDF. IP55 protection, B5, TEFC. Make - Bharat

Bijlee / ABB / Seimens / Kirloskar.

ii) Brakes

DCEM/Thruster fail safe disc brakes mounted behind

motor. Normally ON type. Brake rating – min. 1.5

times the motor torque as per IS 3177. Manual release

to be provided. Make – Cutler-Hammer, Pethe,

EMCO Dynatorq.

iii) Track Wheel

Double flanged type, cylindrical tread. Spherical

roller bearing type.

iv) Electric panel and

VVVF drives

Electrical panel to be mounted at convenient location.

Seimens / Telemechanic or equivalent make.

VVVF drive shall be provided for very smooth / jerk

free movement during starting and stopping. ABB/

SEW / Schneidar /Siemens make.

v) Rubber Buffer To be provided for LT and CT motion.

vi) Limit switches Heavy duty, IP55 protection. 2 way long lever limit

switches for transverse motion (C.T). Cuttler-Hammer

make or seimens.

vii) Cables Copper flexible cables to be considered conforming to

latest IS9968 & IS1554. All cables to be copper

flexible, 1.1 kV grade, FRLS PVC insulated and PVC

sheathed, EPR cables.

viii) Painting Three coats of Amercoat90S to be applied not

exceeding 200micron dft. Color: Golden yellow /

Pearl grey.

All the hardware items/components required for complete and proper functioning of the

control systems either mentioned or otherwise required are deemed to be provided by the

supplier. Necessary interlock mechanisms and back rigging shall be provided wherever

required.

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3.5 Fabrication

3.5.1 Fabrication shall be carried out as per approved fabrication drawings. All the parts shall

be fabricated/machined and assembled to tolerances mentioned in the approved drawing.

3.5.2 The manufacturing process and workmanship of the various parts of the equipment shall

be such that the parts shall be interchangeable from one unit to another. The various fits

should confirm to the values given in the drawings. The equipment shall be rigid in

construction and operation shall be smooth. The surface finish wherever not specified in

the drawing shall be N7.

3.5.3 Tolerances

i) For machined dimensions, wherever tolerances are not indicated general tolerance shall

be as per IS 2102 (part 1) tolerance class designation ’M’ & IS 2102 (part 2) general

geometrical tolerance ‘K’ for straightness, flatness, parallelism and perpendicularity.

ii) For unmachined dimensions, ISO 2768-M shall be followed.

iii) Rail alignment tolerance shall be as per ASME NOG-1-2004.

3.5.4 All weld joints shall be checked by dye penetrant test for root and final pass of welding as

per ASTM E165. The acceptance criteria shall be as per ASME Sec VIII, Div-1.

3.5.5 Forming materials: Materials shall be formed to the required shape as per IS811.

Forming procedure to be submitted to purchaser for approval.

3.5.6 Welding:

i) Electrodes for welding carbon steel parts shall be as per E7018 of SFA-5.1, ASME Sec

II Part-C.

ii) Welding procedure and welder qualification shall be as per ASME Sec IX.

Welding procedure specification, Procedure qualification report and welder performance

qualification report should be furnished and get it approved by the purchaser prior to start

of fabrication. Welding procedure qualification and welder performance qualification

shall be carried out in the presence of IGCAR representative.

3.5.7 There is NO FREE ISSUE OF MATERIAL envisaged under this tender.

3.6 Inspection and Testing

Contractor should submit the manufacturing sequence for fabrication of cask-dolly and

Quality assurance plan (QAP) with stage inspection schedules before starting of

fabrication.

3.6.1 Inspection shall be carried out at various stages i.e. right from procurement of raw

material to end product to ensure the quality of the component/product.

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At every stage of manufacturing, the contractor should ensure that proper dimensional

control is employed. The purchaser will be at liberty to do dimensional inspection of all

parts if required. In arranging out such inspection the contractor shall provide all

assistance, cooperation, all instruments and manpower if asked for and make

arrangements to carry out such operation. The contractor should submit in duplicate the

inspection reports showing individual dimensions and testing reports for all the

components for purchaser’s scrutiny and records.

3.6.2 In addition to certain stage inspection of individual components the contractor will do all

that is necessary to attain proper assembly of full item and check for proper alignment.

3.6.3The purchaser will have free access to the manufacturer’s premises or the premises of his

sub-contractors for the purpose of inspection of raw materials, semi or fully finished

components of the equipment during any stage of manufacture.

3.6.4 Inspection of raw materials, consumables and bought out items: Visual inspection,

correlating of material test certificate/Laboratory testing/identification marks on material

according to test report.

Stage inspection: Visual inspection, fit-up, dimensional check, root and final pass DPT.

Final inspection:

Dimensional check, functional test of cask-dolly on rail at shop and as well as at site after

erection.

The cask-dolly shall be cleared for dispatch only after satisfactory inspection at supplier’s

site.

3.6.5 Functional testing:

At shop:

The manufacturer shall make a complete assembly of all the parts of cask-dolly at his

shop and shall be simulated by providing equivalent plates/supports structure. Smooth

movement of the cask-dolly for the full length of travel for to and fro motion shall be

demonstrated ten times.

At site:

Cask-dolly shall be tested at site till smooth performance is achieved. However, the final

acceptance will be given only after successful demonstration of all the functionality of

each part of the system and all mechanical operations mentioned in this specification. The

Load test shall be carried out as per IS3177.

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3.6.6 Test Failure:

In the event of any test failure of the components to meet specified inspection or test

requirement, the manufacturer shall immediately notify the purchaser. The manufacturer

shall obtain permission from the purchaser before any repair is undertaken. If the repairs,

including design modification, are likely to affect the result of the tests or work

previously completed, appropriate re-inspection and re-testing shall be carried out. The

repair shall be carried out by the manufacturer as per the approved procedure.

3.7 List of essential spares for cask-dolly

i) Trolley - wheel (2nos.), bearing (4nos.), shaft (1 no.)

ii) Dolly - wheel (2nos.), bearing (4nos.), Shaft (1 no.)

iii) Gear box (1no.)

iv) Limit switches (2nos.)

4.0 MONORAIL ELECTRIC WIRE ROPE HOIST

4.1 General

This section describes the technical specification for design, preparation of fabrication

drawing, manufacture, supply, erection, testing and commissioning of 10Ton monorail

electric wire rope hoist as per IS3938 and as per technical specification and tender

drawing (Dwg no. DFRP/23000/4002) for handling cask (load) at DFRP, IGCAR.

4.2 Description

Electrically operated hoist shall be a complete unit with monorail, travelling trolley,

hoisting motor, rope drum, wire rope, chain pulley for cross travel, necessary gearing,

sheaves, brakes, hook, pendant push button, contactor panel, all wiring, limit switches,

end stops, buffers, earthing terminals and other accessories to make the equipment

complete in all respect.

4.3 Specification

i) Capacity 10 Ton SWL

ii) Qty. 1 no.

iii) Lift height 4500mm

iv) Span 3780mm

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v) Type of hoist Monorail electric wire rope hoist

vi) Class of duty Class-2 as per IS 3938.

vii) Design ambient

temperature

40ºC

viii) CT movement Manual by Chain pulley

ix) Hoist Motorized with push button on pendant.

x) Hoist Speed 5m/min & 0.5m/min

xi) Monorail height 5377mm

xii) Power supply 415V, 3Phase, 50Hz, A.C

xiii) Power conductor PVC shrouded copper bus bar / flexible trailing

cable.

xiv) Length of travel 1900mm

xv) Hook approach 1220mm from civil column face and 740mm from

other side. Ref. dwg. no. DFRP/23000/4002.

xvi) Control voltage 110V, A.C

4.4 Technical specification

i) Rope drum Seamless pipe construction as per ASTM-SA106

or welded pipe with 100% radiography and

acceptance criteria as per ASME Sec. VIII Div-1.

ii) Wire ropes 4/2 falls as per IS2266 with minimum factor of

safety 6.

iii) Hook details Standard trapezoidal section shank hook as per IS

3815. Higher tensile steel hook confirming to

grade-3 of IS1875. Thrust bearing of SKF/FAG

make to be provided.

iv) Brakes DCEM fail safe disc brakes.

v) Hoist Low head room electric wire rope hoist.

Please note, STAHL make electric wire rope hoist

will meet the requirement mentioned in this

specification.

vi) Monorail column centers 3780 x 4800mm

vii) Monorail columns 4nos. (column towards cable tray side shall be ‘Z’

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shape to avoid fouling)

viii) Monorail Beam/Supporting

beams

Fabricated out of suitable rolled sections as per IS

800/807 with stiffeners.

ix) Type of gear box Compact, Inline planetary gearbox

x) Limit switches Heavy duty, IP55 protection

xi) Hoist power feed

arrangement

Through festoon cable arrangement mounted on

Co-burn track, festoon chain, buffer stops,

mounting brackets.

xii) Painting Three coats of Amercoat90S to be applied not

exceeding 200micron dft. Color: Golden yellow /

Pearl grey.

4.5 Inspection and Testing

Load testing of the hoist shall be carried out as per IS3938.

Inspection and testing of the hoist shall be carried out at supplier’s premises and at

purchaser’s premises as per the applicable code/standard mentioned in this specification.

4.6 List of essential spares for Hoist

i) Wheel, bearing, shaft – 2nos each.

ii) Gear box – 1 no.

iii) Limit switches – 1 no.

5.0 Applicable Standards and Codes

The design, manufacture and testing of the cask-dolly and hoist shall strictly conform to

the codes and standards listed below with latest revision wherever applicable.

a) IS3938: Electric wire rope hoists.

b) IS807: Code of practice for design, erection and testing of cranes and hoists.

c) IS800: code of practice for general construction in steel.

d) IS2062: Hot rolled low, medium and high tensile structural steel.

e) IS2266: specification for steel wire ropes for general engineering purpose.

f) IS3815: Forged and Heat treated alloy steel/carbon steel for lifting hook.

g) IS3177: Code of practice for electric overhead travelling cranes and gantry cranes

other than steel work cranes.

h) IS3443: Specification for crane rail section.

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i) IS325: Three phase induction motors – specification.

6.0 Time Schedule

Scrutiny of purchaser’s conceptual drawing and based on that design, submission of

design report along with the drawing in duplicate to the purchaser for the approval within

One month from the date of issue of purchase order.

Purchasing of raw material, manufacture, offering the unit for testing, supply of finished

equipment, erection and commissioning of cask-dolly and monorail hoist within Five

month from the date of approval of shop drawings.

10Ton cask-dolly and associated 10Ton monorail electric wire rope hoist shall be

commissioned and tested at DFRP, IGCAR within Six months from the date of receipt of

purchase order.

The contractor should submit a fortnightly report on the progress of work in duplicate for

information and purchasers record.

Once the time schedule is approved the contractor should strictly adhere to it and do all

that is necessary to deliver the unit in time.

7.0 Packing and Transportation

After carrying out the tests at the manufacturing works as specified in this tender

specification, the equipment covered in the contract shall be carefully disassembled into

major completed subassemblies and then properly packed, suitably crated and protected

from damage during transport, transit and storage at site. In this regard, the supplier shall

prepare drawing / procedures for packing and transportation of the subassemblies of cask-

dolly & monorail hoist from supplier’s premises to the purchaser’s site and submit to the

purchaser for approval. The details of dividing into sub-assemblies shall be clearly

indicated and the movement of all the parts to be arrested. Felt of minimum 10mm

thickness shall be provided between component and wooden saddle wherever supported.

The packing shall include adequate cushioning, blocking, bracing, anti-skidding, hoisting

and tie down provisions with the approval of the purchaser. All machined parts shall be

protected with antirust grease. The supplier shall do the packing and dispatch after

obtaining written shipping release from purchaser. Wherever parts are packed in boxes, it

shall be clearly marked with the parts number of contents and quantity.

Supplier shall be responsible for any damage to the equipments during transport, transit

and storage at the site. The supplier shall provide barrier such that during transportation

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and storage, the entry of collection of water in the equipment is prevented. Any short

supply inside the intact package cases shall be supplied without any extra cost.

The components shall be packed, safe crated, safe transported and delivered at DFRP site

at free of cost by the contractor for erection. Also the essential spare parts mentioned here

in this specification are to be supplied.

8.0 Erection, Testing and Commissioning of cask-dolly and monorail electric wire rope

hoist at DFRP/IGCAR site

The supplier shall erect, test and commission the cask-dolly and monorail electric wire

rope hoist, as per IS3177 and IS3938 respectively, at DFRP/ IGCAR site. General list of

activities to be carried out by supplier at IGCAR site:

i) Handling, transportation, unloading, storage and shifting to site for installation.

ii) Erection of trolley, dolly, collapsible table/platform, rails, monorail supporting

columns & beams, hoist etc at DFRP, IGCAR.

iii) Laying of electrical cables and making end connections between the various

equipments and respective control panels.

iv) Overall functional testing of cask-dolly and hoist at full load as per specification.

The supplier shall submit a detailed plan for the above listed activities and carry out these

activities after obtaining the approval of purchaser. The supplier shall take care of all the

industrial safety measures as stipulated in Atomic Energy (Factories) Rules, 1996.

Electricity and loads for testing will be provided at free of cost by department during

erection, testing and commissioning of cask-dolly and associated monorail hoist at DFRP

site.

9.0 Guarantee

9.1 Supplier shall guarantee that the goods furnished by him shall be in accordance with the

requirements of technical specifications.

9.2 Supplier shall provide the warranty that the goods are new and of high Quality and that the

goods are free from defects in design, materials or workmanship was applicable and

warranty shall cover for a period of 12 months (Twelve) from the date of satisfactory

handing over the equipments to the purchaser at the site.

9.3 If within the expiry of the above stipulated warranty / guarantee period, the subject goods

or any part thereof are found defective because of Workmanship or materials, supplier

should repair at his own expense.

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10.0 Documentation

Complete documentation with respect to design reports, as built drawing, material test

certificates, dimensional inspection reports, NDT reports, etc to be made by supplier.

Following documents are required to be submitted to the purchaser along with the

delivery.

i) Three sets of design reports.

ii) Three sets of as-built drawings.

iii) Three sets of History dockets which includes stage-inspection reports & material test

reports, etc.

11.0 Schedule of Quantities

Schedule of Quantities

Sl.

No Item Qty

Unit

rate in

Rs.

Total

Amount

in Rs.

a) Design, engineering, preparation of fabrication

drawing, manufacture, supply and testing of 10Ton

cask-dolly including supply of rails as per drawing

and technical specification.

1 no.

b) Erection of rails, testing and commissioning of

10Ton Cask-Dolly at DFRP/IGCAR site as per

drawing and technical specification.

1 no.

1

c) Supply of essential spares for cask-dolly 1 no.

a) Design, preparation of fabrication drawing,

manufacture and supply of 10Ton Monorail electric

wire rope hoist at DFRP, IGCAR as per drawing and

technical specification.

1 no.

b) Erection, testing and commissioning of 10Ton

monorail electric wire rope hoist at DFRP, IGCAR

site as per drawing and technical specification.

1 no.

2

c) Supply of essential spares for monorail hoist 1 no.

TOTAL

Note:After publishing the tender, if there is any change in specification, it will be

published as corrigendum in the MRPU portal.

Accessories, Breakup costs etc. if any, may be quoted online in the ‘Price Bid

Alternate Offer’ form.