bid qualification criteria for supply of 250t/32t eot crane · bid qualification criteria for...
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BID QUALIFICATION CRITERIA FOR SUPPLY OF 250t/32t EOT CRANE
Bidders who are qualifying/meeting following Technical and Financial criteria are eligible to participate in the bid for supply of 250t /32t 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 with out seeking any further clarifications. I. Technical Qualification Requirements:
The bidder should meet the following technical qualifying requirements and
shall submit relevant certificates to establish his credentials.
1. The Bidder should be an organization with long experience in having
executed contracts for design, engineering, manufacture, supply, erection,
testing and commissioning of D o u b l e g i r d e r E O T Cranes & Hoists
Package for last 25 years in India.
2. The firm should have successfully completed Design, Manufacture, Installation,
Testing and Commissioning of at least 5nos. of double girder EOT cranes of
capacity around 200t and above and Span equal to 20m and above during
last 7 years ending 31.03.2014. 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 05 no of cranes and at least one crane of capacity not less than 150t in
last 10 years.
4. The firm should have successfully completed Design, manufacture and
establishment of fail safe mechanisms & controls like Emergency disc bake
on rope drum (actuated in case of failure in power transmission line), wire rope
spooling monitoring and redundant (double) wire rope reeving system at least
in 2nos. of EOT cranes in last 10 years.
5. The firm should have experience and knowledge in the Design and manufacture
of EOT crane with dual drive hoist (Twin load path). It is preferable to have
completed realization of such cranes.
6. The firm should have successfully completed Design, manufacture, and
establishment of at least 05 nos. of EOT cranes ( not less than 100ton capacity)
with twin motor with planetary gearbox system for Hoist mechanism for last
10 years.
7. The firm should have successfully completed Design, manufacture, and
establishment of at least 04 nos. of EOT cranes (not less than 100ton capacity)
for ladle cranes (hot metal handling cranes) for reputed steel mills for last 10
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years.
8. The firm should have facility for inspection and testing of 250t EOT crane at
their factory.
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 and M/s M N
Dastur.
10. Bidder shall furnish the details of their resources in factory like manpower,
machinery, quality system etc., for department to access their capability. Bidder
shall submit above information in the format given in “Questionnaire”
attached as Annexure to this BQR.
II. Financial Qualification Requirements:
The bidder should also meet the following financial qualification requirements:
2.1 The Bidder should have annual turn over of not less than a value of Rs. 10
crores. per year last three financial years ending 31-03-2014.
2.2 Firm should have undertaken and successfully completed following value of
works related EOT cranes at least in last 05 (Five) years :
Single work of EOT cranes not less than : Rs.750 lakhs.
(or)
Two works of EOT cranes, each not less than : Rs.450 lakhs (each)
(or)
Three works of EOT Cranes, each not less than : Rs.350 lakhs(each)
2.3 Bidder should possess a current Solvency Certificate from Nationalized Bank for
an amount of not less than 700 lakhs.
2.4 IT/ TDS certificate shall be submitted with Loss & Profit.
2.5 Bidder shall submit audited statement of financial status for last 03 years.
III. The following documents shall be submitted along with the application
for prequalification of Bid:
1. Firm establishment certificate and nature of work .
2. Detail of work of similar type completed during the last seven years ending
31.03.2014 ( for Sl. No.2)
3. Satisfactory work Completion certificates from the clients, with the work
order copies ( f o r S l . N o s . 2 & 3 )
4. Performance Report of EOT cranes established (with years of service) from
End users, with addresses and contact person with phone numbers.
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5. Documentary evidence (Technical details & drawings) for fulfilling special
technical conditions (Sl. no. 2, 3 4 & 5).
6. Copy of audited Balance Sheets for last three years
7. IT / TDS certificates for last three years.
8. Current Solvency Certificate.
9. List of EOT crane projects ( for capacity 100t and above / Span 20m and
above) completed for last ten years with PO copies
10. List, value, and work order copies of total projects under Execution with
Purchaser name and address.
11. Duly filled “ Questionnaire” (enclosed here with ) with signature, name,
phone no and company seal.
12. Structure and Organizational Chart
13. List of personnel with qualification & experience in the firm in the areas of
design, production, quality, safety, administration etc.,
14. List of Machinery & Equipments to be used for the work.
15. Any other relevant information which add value to above.
IMPORTANT NOTES :
1. Bidder shall furnish all the above details fully and explicitly. 2. Please note that the “BID” without above mentioned the documents/information in
support of the eligibility criteria will be summarily rejected.
3. NO further clarifications will be seeking in this regard.
IV. Bid Selection Procedure and Process of Pre-Qualification
Step - 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)
Step -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.
Step – 3 : Visit to sites/EOT Cranes by technical team (ISRO or Third party) where Bidder
has established above mentioned capacity EOT cranes. Step - 4 : If required, visit will be made to their factory/ firm by technical team (ISRO or
third party) for accessing the capability of manufacturer. Step - 5 : Mean while, technical Bids will be opened and scrutinized for meeting all
technical specification and supply conditions.
ISRO-SHAR reserves right to verify the information/data furnished by Bidder. If
the same is found as fault or with any deviation the bid will be rejected.
Only those Bidders who are found suitable & meeting all above qualification
Criteria/requirements will be finally qualified for opening the Price Bids for
evaluation.
Annexure to Bid Qualification
QUESTIONNAIRE FOR DESIGN, MANUFACTURE, TESTING AND ERECTION & COMMISIONING OF HIGH CAPACITY EOT CRANES
(INFORMATION TO BE PROVIDED BY BIDDERS) Name & Address of EOT Crane supplier: Phone : Mobile : Fax : Email : Sl. No.
Items/ Information Specification/ details of items Remarks
1. Type of Industry (SSU, Medium, Govt, etc.,)
2. Year of Establishment
3. Annual Turnover (in Rs. lakhs) for last three years year ending up to 31-03-14
3.1 Turn over – 2013-14
3.2 Turn over – 2012-13
3.3 Turn over – 2011-12
4.
Orders executed during last 03 years, capacity of EOT Cranes, references are is to be mentioned. (Separate sheet can attached for this)
a. 2013-14 b. 2012-13 c. 2011-12
5. Quality Certification of company (ISO, TUV, etc.,)
Annexure to Bid Qualification
6.
Nos. of EOT Cranes of capacity 200t and above and Span :20m and above manufactured during last 07 years ending 31.03.2014
7.
No of EOT Cranes of capacity not less than
100t with SIEMENS VVVF (VFD) drive &
control systems produced in last 10 years.
8. No of EOT Cranes of capacity not less than
100t supplied with Emergency Rope drum
caliper brake.
9.
No. of EOT cranes produced (not less than
100 ton capacity) with twin motor with
planetary gearbox system for Hoist
mechanism for last 10 years.
10. No. of steel mill cranes ( not less than 100 ton
capacity) produced for molten metal ladle
handling in last 10 years.
11. Shop floor Area Covered
12.
No of Employees (Supplier shall mention contract personnel separately)
a. Engineers b. Supervisors c. Technicians d. Quality control engineers Administrative staff
13.
Raw Material Sourcing: a. Steel Plates b. Rolled sections, Flats c. Forged Rods, Blanks d. Round bars (for Axles) e. Seamless pipes
14. Sources of Bought out components:
a. Electric Motors
Annexure to Bid Qualification
b. Brakes Flameproof c. Gearboxes d. Couplings e. Limit switches f. Wire ropes
15. Details regarding out sourcing, if any, of manufacturing and fabrication works.
16.
Handling facility available: a. Over head /Gantry crane details
(capacity, span, lift). b. Mobile cranes
17.
Load testing Facility Available: a. Maximum weight available. b. No. of weights c. Total test load available.
18.
Welding /Fabrication Workshop (Type/ capacity/ Quantity of machines shall be provided)
a. MMAW machines b. GMAW machines c. Gas cutting m/cs d. Plasma cutting m/cs e. Welding Fixtures
19. Fixtures available for Welding of Girders of span more than 20m.
Annexure to Bid Qualification
20.
Welding Professionals: a. No. of welders (MMAW) Qualification details Qualified by b. No. of welders (GMAW) Qualification details Qualified by c. No. of welders (TIG) Qualification details
Qualified by
21.
Details of Welding Inspection Equipment & welding inspector available with supplier ( LPT, UT, MPT, X-ray, etc) Any out sourcing can be mentioned.
22.
Forming Facilities available (with brief specification of each machine)
a. Shearing Machine b. Cutting machine c. Bending machine
23.
Machining Facilities available (with brief specification of each machine)
a. Turning Lathe (Conventional/CNC) b. Milling Machine (Conventional/CNC) c. Gear cutting/ hobbing machines. d. Gear Grinding machines e. Drilling Machine (Conventional/CNC) f. Cylindrical Grinding Machine
(Conventional/CNC) g. Any other machines
Annexure to Bid Qualification
24.
Details of Inspection facilities / Instruments available (Brief description & specifications shall be provided)
25.
If third party inspection services are taken for manufacturing of EOT Cranes give details.
26.
Range of Capacity of EOT Cranes manufactured, till now (list with brief specs, & customers shall be provided)
27.
Maximum capacity of EOT Crane manufactured with dimensions, type, quantity, customer, and purpose of EOT Crane.
28.
Maximum dimensions of EOT Crane manufactured with capacity, Span, quantity, customer, and purpose of EOT Crane.
29.
Special purpose EOT Cranes manufactured, if any, capacity, dimensions, and customer
30.
Design facility available: a. Drafting & Modeling software
packages b. FEM software c. Other Softwares d. Design engineers (with qualification
& experience)
31. Painting facility available
Annexure to Bid Qualification
a. Sand/ Abrasive blasting facility. b. Painting equipment c. Make of paints generally used.
32.
General stock level of Raw materials/brought out items in the factory:
1. Structural steel plates etc., 2. Alloy steel round bars 3. Bought out items 4. Paints, etc.,
33. Any awards or recognitions obtained through product excellence
34.
Collaborations with other reputed manufactures and OEMs with product details and Name of Principal supplier, country of origin etc.,
35. Any other relevant information in design, manufacture and testing of EOT Cranes
36. List of documents enclosed with this questionnaire
37. Any other information like to add (separate sheet can be attached)
Signature of competent person Name : Designation :
Date : Company seal :
SATISH DHAWAN SPACE CENTRE SHAR
SOLID PROPELLANT PLANT
Ref: SHPP 2013003090
TENDER SPECIFICATIONS OF 250t/32t EOT CRANE
Facility : Propellant Casting Facility
Sl.
No. Type of crane
Capacity
of crane
(ton)
Span
(m)
Height of
Lift (m)
Crane Travel
(m)
Duty
class of
crane
Quantity
( No)
1
Double Girder
Flame proof
EOT Crane.
250t / 32t 23.0 MH – 36m AH – 44m
~ 61.50 Class - II
of IS 4137 01
EOT crane shall be supplied, tested and commissioned as per the Technical Specifications, Terms & Conditions given in following pages of this document.
Ref : SHPP 2013003090
CONTENTS OF BOOKLET
Sl. No
Contents
Page No.
1
Full Technical Specifications cum Compliance statement, Terms & conditions of supply including codes and standards.
1 to 46
2 Annexure – 1A to 1D : Figures, EOT Crane Clearance diagram and dimensions.
47 to 51
3
Annexure – 2A : Location of VVVF Room and Plug-in locations for pendants in building.
52
Annexure – 2B : Schematic of Push Button operating station (Plug-in pendant)
53
4 Annexure – 3 : Quality Assurance, Inspection and Testing plan for EOT Cranes
54 to 65
5 Annexure – 4 : Details of EOT crane`s major components to be submitted by bidder along with quotation.
66 to 70
6 Annexure – 5: List of spare part to be supplied
71
TECHNICAL SPECIFICATIONS OF 250t/32t FLAMEPROOF EOT CRANE
SECTION – I
GENERAL SPECIFICATIONS
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:1
A
B
C
Contact Person :
FAX No :
Mobile No : Email :
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
Bidder shall completely fill the following format of technical specifications & supply conditions with the
mention of required details. Bidder can add more information and details, if required, by attaching seperate
sheets, by giving point no. of this format. Inadequate /incomplete, ambiguous, or unsustainable information,
against any of the clauses of the specifications / requirements shall be treated as non-compliance to
tender and quotation will be rejected. Generalized statements like crane shall be manufactured "as per your
specifications" or "as per IS standards" or "as per enclosed specification" is not acceptable and Bidder shall
submit all the specifications by filling in the following FORMAT only, otherwise it is not valid.
Deviations with respect to specifications given below are not acceptable. However Bidder can submit /
suggest improvements, if any, seperately by indicating the clause no. in this specifications.
Design, detailed engineering, manufacture, inspection, shop testing, supply,
erection, commissioning & performance proving of Heavy duty 250T/32T
capacity, Flame proof, Top running, double girder EOT Crane as per IS 4137,
IS 807 & relevant codes & standards.
Supply, erection & commissioning of Emergency Disc Brake unit for the main
hoist rope drum, wire rope spooling & monitoring as per the specifications
mentioned in this document. (in Single drive Option -2)
Bidder shall submit complete information asked in Qualification Criteria and Questionaire for qualifying for
bid with all informations, certificates and earlier references of manufacture should be enclosed. The offer
meeting all the requirements & conditions in all respects will only be considered for further processing.
SCOPE OF SUPPLY
The scope of work shall also include procurement of all materials including
importing of components (from other countries) required for completion of the
work, coordinated planning for manufacture, inspection, painting, load testing at
supplier works.
Main Hoist (250t hoist) shall be provided with dual rope reeving system i.e., two
independent wire ropes shall be provided with balanced reeving system.
Packing, marking, loading on Trucks/ Trailers and safe transportation of EOT
crane & other necessary parts / items / accessories from supplier site to SHAR
site .
V.NAME & ADDRESS OF
THE Bidder :
Supply & Erection of Bridge gantry rail along with its accessories for bay length
of around 61.5meter. ( Gantry girder is in the scope of Department /
Purchaser).
VVVF panels shall be erected in a separate room at ground level and cabling
must be done to the EOT crane at gantry girder height of ~30m as per clerance
diagram enclosed.
Supply & erection of Drag chain power cable system for EOT crane as per the
specifications mentioned.
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:2
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
1.9
2 Quantity of Cranes : 01 No. (One)
3
3.1 Application
This Heavy duty EOT crane is used for handling of
hazardous / dangerous materials like rocket motors,
propellant containers, delicate flight hardware etc., for
positioning and assembly during process operations.
Failure of EOT crane & its components during
handling may result in loss of life and property.
Hence Bidder shall design, manufacture and erect the
crane with emphasis on quality, reliability and safety
and shall ensure smooth & reliable operation of crane
with long service life.
1.11
Bidder shall quote seperate cost for following each option seperately in
Price Bid.
Option - 2 : Single Hoist Drive, Planetary gearbox, Two motors, with
Emergency Caliper brake on Rope drum (Single load path) : The single-
hoist drive shall have one planetary gearbox with two drive motors, two
holding brakes on each input shaft of gearbox and one emergency caliper
disc brake located at the rope drum. The rope drum disc brake to act
as a fail-safe brake which acts in the event of coupling/ geartrain failure and
hold the load by monitoring overspeed of drum.
Option -1 : Dual Hoist Drive with two gearboxes and single drum (Twin
Load path) : The dual-hoist drive shall have a single rope drum, two
pallel shaft helical gear trains ( on each side of drum), two drive motors (each
gearbox driven by one motor) and at least two holding brakes located on
input shaft of geartrain and realted couplings. This shall ensure two
independendant load paths for main hoist drive and each of two independant
load paths shall be capable of driving & holding the rated load.
Erection, testing & commissioning of EOT crane shall be done as per the
Technical Specifications, conditions given below and also in accordance with
latest editions of IS: 4137, IS: 807 & relevant codes and standards.
Supplier shall arrange "Third party inspection Agency " for deisgn
approvals, inspection during manufacture, load teasting, and certfying
the EOT craneas per QAP.
Arranging the third party inspection is in the scope of supplier for the entire
scope of work as given above and as per QAP enclosed. Bidder shall engage
TPIA - Third Party Inspection Agencies like M/s Mecon,(or) M/s M.N.Dhastur
only. The finalization of third party agency shall be done on mutual agreement
between ISRO and Bidder.
Usage of EOT crane
Department reserves right to select EOT crane of either option-1 or option-2
based on the offers submitted by bidders.
Main hoist drive system shall be designed to provide assurance
that a failure of single component of hoist mechanism (Motor, Gearbox,
brake, coupling, wire rope) would not result in loss of load and uncontrolled
movement of the lifted load. This can be accomplished by the application
of a single or dual hoist drive unit in two optional ways described below.
1.10
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:3
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
3.2Usage period & desired
life of crane
This heavy duty EOT crane will be put to use for 365
Days’ intermittent duty (Class II duty as per IS4137)
with CT, LT and Hoist movements. EOT Crane shall
be designed for minimum life of 30years.
4
4.1
4.2
5
Operating
Environment of Crane
/ Weather conditions
Operating environment is Indoor, near to sea (i.e.,
saline atmosphere), with ambient temperature of
50ºC and with relative humidity of 95%. Weather
conditions are tropical. Bidder shall consider above
while design of EOT crane, electricals, painting of
crane & related parts.
6
6.1 Type of CraneDouble girder, Flameproof, Indoor, Heavey duty EOT
Crane
6.2 Class & duty Class-II duty as per IS : 4137 and IS 807.
6.3EOT Crane capacity (in
ton)
250t (Main Hoist)
32t (Auxiliary Hoist)
6.4 Span 23.00 meters
6.5
6.5.1 Main Hoist (meters) Above FFL - 26m , Below FFL - 10m, Total : 36m
6.5.2 Auxilary Hoist (meters) Above FFL - 29m , Below FFL - 15m, Total : 44m
6.6
6.6.1
Main Hoist with dual
load path (two motors &
two gearboxes) Option-
1
2.0 m/min in main speed, and 0.2 m/min in creep
speed
2.0 m/min in main speed and 0.2 m/min in creep
speed with two motor in operation.
1.0 m/min in main speed and 0.1 m/min in creep
speed with one motor in operation.
6.6.3 Auxilary Hoist 2.5 m/min in main speed, 0.25 m/min in creep speed.
6.6.2
The EOT crane shall be equipped with flame proof electrical systems suitable
for operating in hazardous area classified as Zone 1, Gas group IIA/IIB, T4 as
per relevant IS 5572 / IEC standards.
Main Hoist with Single
Load path (Two motors
with planetary gearbox)
Option-2
Lift Height
MAIN PARAMETERS OF EOT CRANE
Hazardous area conditions
Operation Speeds ( meters/minute)
VVVF panels shall be provided in a separate room at the ground level and
cabling must be done to the EOT crane which is at a height of ~30m. The
VVVF panels shall be suitable for normal atmospheric conditions.
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:4
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
6.6.4 Cross travel 6.0 m/min in main speed, 0.6 m/min in creep speed.
6.6.5 Long travel 6.0 m/min in main speed, 0.6 m/min in creep speed.
6.7
Side clearance
(Distance from centre of
gantry rail to nearest
obstruction)
400mm (minimum) on both sides.
6.8
Head room available
(Vertical distance from
top of gantry rail to
lowest overhead
obstruction)
6.5 meters (maximum) (Refer clearance diagram).
6.9Distance from floor to
top of gantry rail~ 28.50 meters
6.10 Bay length in meters ~ 61.50 meters
6.11DSL Side Main Hook : 3.0m
Aux. Hook : 4.0m
6.12
NDSL side :
Main Hook : 3.5m
Aux. Hook : 2.5m
6.13CT DSL side : not more than 5 m
Non DSL side : not more than 5m
6.13 LT wheel base shall not be less than 1/5th of span.
shall be as minimum as possible for having optimum
LT hook approaches for better utilization of crane &
building.
Max. Width of crane not > 10.0m.
6.15
6.15.1
Main hoist drive system shall be designed to provide assurance
that a failure of a single component in hoist mechanism would not result
in loss of load and uncontrolled movement of the lifted load. This can be
accomplished by the application of a single drive or dual hoist drive
units. The wire rope drum, hook, hooknut, and load block structure are
exempted from this requirement. Supplier shall accomplish above failure
proof design feature in two optional ways described below. Bidder shall quote
seperate cost for each option (configuration) sperately. Department
reserves right to select any one configuration and place order.
Width of Crane
Main Hoist Drive
Hook Approaches
(Refer Clearance
diagram) (supplier shall
optimise these values)
6.14
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:5
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
6.15.3A
6.15.3
Bidder shall quote separate cost for Emergency Caliper disc brake in the Price
bid for this option.
6.15.2
Department reserves right to select EOT crane of either option-1 or option-2
based on the offers submitted by bidders.
Option - 2 : Single Hoist Drive, with one planetary gearbox, two motors,
and Emergency Caliper brake on Rope drum (Single drive load Path): The
single-hoist drive shall have one planetary gearbox with two drive
motors, two brakes per motor on each input shaft of gearbox (total : 4 brakes)
and one emergency caliper disc brake located at the rope drum. The rope
drum disc brake is to act as a fail-safe brake which acts in the event of
coupling/ geartrain failure and hold the load by monitoring overspeed of the
drum. The planetary gearbox shall be sized for total full load drive torque of
motors with appropriate service factors as per class-4 of IS4137. Both motors
shall be driven through two VVVF drives with syncronization with proper control
& interlocks. There shall be two independent wire ropes, each shall be capable
of holding the rated load. Refer Schematic arrangement given in Fig .2
Motors shall be rated such that, when both motors running, main hoist speed
is 2 m/min and when one motor running hoist speed is 1 m/min.
Option -1 : Dual Hoist Drive with two gearboxes, two motors and single
drum (Twin drive Load Path) : The dual-hoist drive shall have a single
rope drum, two pallel shaft helical gear trains (on each side of drum), two
drive motors (each gearbox driven by one motor) and at least two brakes
located on input side of each gearbox (total: 4 brakes) and related couplings.
This shall ensure two independendant load paths for main hoist drive and each
of two independant load paths shall be capable of driving & holding the full
rated load. Each gear train shall be sized for the total full-load drive
torque of the motor with appropriate service factor as per class-4 duty of
IS4137. Both motors shall be driven through two VVVF drives with
syncronization with proper control & interlocks. There shall be two independent
wire ropes, each shall be capable of holding the rated load. Refer Schematic
arrangement given in Fig .1. Supplier can suggest & design alternate
configuration which meet above requirement with optimum hook
approaches.
Motors and gearboxes shall be rated such that each set of motor and Gearbox
will take full rated torque at rated speed i.e., 2m/min
Main hoist gearbox & rope drum shall be designed considering application and
torque of emergency caliper disc brake.
In case of any problem & failure in one load path, easy & safe switch over to
second/redundant load path shall be done smoothly without free fall and heavy
jerks. Proper arrangement shall be made for safe & reliable mechanical
decoupling of defective drive system.
Proper Electrical and drive interlocks shall be provided betweein motors and
brakes such that drive system is safe gaurded without damage, incase of
failure in one load path and to overloading of other load path.
Main hoist gearbox shall be designed for class -4 duty as per IS 4137.
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:6
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
6.15.4
6.16
6.16.1
6.16.2
6.17
6.17.2
6.17.3
6.17.4Number of wheels for
LT drive
16 Nos & Drive wheels : 25% of total wheels i.e.
4nos.
6.17.5Diameter of wheels for
LT driveNot less than 710 mm.
6.18
6.18.1
6.18.2
6.18.3
6.18.4Number of wheels for
CT drive8 Nos., Drive wheels : 50% or 25% of total wheels
6.18.5Diameter of wheels for
CT driveNot less than 710 mm.
6.19Maintenance of CT
drives
Maintenance platform shall be provided for CT drives
covered with chequered plate.
6.20Type of bearings for
LT/CT wheelsAnti-friction, Double row Spherical Roller Bearings
6.21Type of mounting of
LT/CT wheels"L" type brackets
Two service brakes (Imported, flameproof brakes ) must be provided on either
side of input shaft of gearbox.
Wherever applicable the driving pinions shall not interfere with the removal of
wheels.
CT drive shall be provided with sufficient no. of drive systems. Helical parallel
shaft gearboxes, motors, and thruster brakes shall be used.
6.17.1
Drive size shall be selected such that Crane can be moved by two motors
drives with one VFD.
Auxiliary Hoist Drive ( conventional hoist system)
CT Drive
All the drive components shall be easily accessible and shall be designed with
interchangeable systems. (If twin drive is selected for CT)
Wherever applicable the driving pinions shall not interfere with the removal of
wheels.
Service brakes shall be located on Input shaft of gearbox. 2nos. of Imported
flameproof brakes shall be provided per motor.
Single motor with one Horizontal, foot mounted, paralle shaft Helical gearbox
of standard make mentioned in this specification.
LT drive shall be provided with four no. of drive systems at four corners of
crane. Horizontal foot mounted helical gearboxes, motors, and thruster brakes
shall be used.
All four corner drive components shall be easily accessible and shall be
designed with inter changeable components.
LT Drive
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:7
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
6.22Total Weight of EOT
Crane (tons) Bidder to Specify
6.23 Weight of trolley (tons) Bidder to Specify
6.24Weight of Bridge
Girders (tons) Bidder to Specify
6.25Weight of End Carriage
(tons) Bidder to Specify
6.26Weight of Electricals/
Panels (tons) Bidder to Specify
6.27 LT wheel load (tons) Bidder to specify
6.28 CT wheel load (tons) Bidder to specify
6.29Size of Cross Travel
Bridge Girder RailCrane rails not less than CR-120 as per IS 3443
6.30
Size of Crane gantry
rails (for Long Travel) -
Scope of Crane Bidder
Crane rails not less than CR-120 as per IS 3443
TECHNICAL SPECIFICATIONS OF 250t/32t FLAMEPROOF EOT CRANE
SECTION – II
MECHANICAL DESIGN AND DETAILS
SDSC SHAR
SPP
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SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:8
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
7
The design of components shall be done on the basis
of ultimate tensile strength, the value of stress factor
used shall be the product of the basic stress factor
and the duty factor for the appropriate mechanism
class as mentioned in IS:4137.
The design of all mechanical components shall be
done as per IS:4137 & as per this technical
specifications and also on the basis of minimum
ultimate tensile strength with factor of safety of not
less than 5.
7.1.1
7.1.2
7.1.3
7.1.4
7.1.5
7.2 Hoist hook type
Main Hoist : Ramshorn type hook with swiveling anti-
friction thrust bearing and safety latch as per IS:5243.
Aux. Hoist : Single Point hook with swiveling anti-
friction thrust bearing and safety latch as per IS 3815
& relevant standards.
7.2.1
7.3 Number of falls for HoistMain Hoist : ~ 24.
Aux. Hoist : ~ 8
7.4
7.4.1
7.4.2
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.
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.
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.
Rope Drum shall be of welded / fabricated type of IS:2062 steel with stress
relieved. Rope drum shall be designed as specified in IS:4137 in general.
Allowable stress in drum shall be 1/5th of UTS.
Rope drum diameter shall be minimum 40 times the diameter of wire rope.
ROPE DRUM
Factor of Safety
The hooks shall be free to swivel on antifriction roller thrust bearing of
adequate capacity and so constructed as to exclude dirt and also shall
be provided with a means for lubrication.
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.
MECHANICAL DESIGN AND ELEMENTS' DETAILS
7.1
The stresses in all components of hoist mechanism and gearboxes should not
exceed 60% of yield point of the material for the component under break
down conditions of motor i.e. pull out torque of motor.
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:9
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
7.4.3
7.4.4
7.4.5
7.4.6
7.4.7
7.4.8
7.5
7.5.1
7.5.2
7.5.3
7.5.4
7.5.5
7.5.6
7.5.7
Drum grooves shall be helical and machined with smooth surface finish.Drum
grooves shall be dimensioned as per IS4137.
Reeving system shall be divided into two separate load paths so that either
path will support the rated load and maintain vertical alignment in the event of
rope breakage or failure in one rope system.
In the event of failure of a drum shaft or bearing, the drum must
be retained on the trolley without falling.
MAIN HOIST WIRE ROPE - Double rope reeving system
In the event of a hook over travel, where the lower block contacts the
crane trolley structure, the ropes shall not be cut or crushed.
i). Sensing and automatic signaling of excessive rope load/displacement to
either side shall be provided.
ii). Provision, tooling and procedure shall be provided for adjustment of
wireropes to take equal load.
iii). The vertical displacement of the load, following a rope failure, shall be
minimized.
Upper block assembly and lower load block assembly shall be designed
such that the sheaves will be contained & maintain vertical balance of load
in the event of failure of single wire rope.
During hoisting & lowering hook block shall not oscillate/ rotate without load or
with load.
Length of the drum shall be sufficient to accommodate the rope in one layer of
the rope requisite for the specified lift and in addition rope drum shall be
provided with not fewer than three dead turns at each anchored end and at
least one spare groove at the other end when hook is at full height of lift
condition. Grooves shall be finished smooth and shall be rounded at edges &
corners.
Dual rope reeving system shall be designed such that the bottom load block &
hook shall follow a true vertical path ( true vertical lift) during hoisting and
during with No load & Full load conditions.
Fleet angle of wire rope from drum to sheave shall not be more than 2.5 deg
and drawings & calculations shall be provided in this regard.
Rope dead ends shall be clamped with minimum three clamping wedges
with two numbers of bolts on each clamp. The bolts shall be at the centre of
clamp and shall be wire locked.
Rope drum (for Main Hoist) in Option-2 shall have provision for accommodating
Emergency caliper disc brakes application on the rope drum flanges.
The design of the rope reeving system shall be such that a single
rope failure will not result in the loss of the lifted load. A load
balance sytem shall be provided on each rope system.
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:10
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
7.5.8
7.5.9
7.5.10
7.5.11
7.6
7.6.1
7.6.2
7.6.3
7.6.4
7.6.5
7.6.6
7.6.7
7.6.8
7.6.9
7.6.10
No joints shall be used for wire ropes under this specification.
The equalizer sheave /Equalizer Bar shall be mounted above the trolley floor
and shall be easily accessible for maintenance from the floor of the trolley.
Equalizer Bar / sheave shall be made in such a manner that it can
turn or swivel to align itself with the pull of the ropes.
ROPE SHEAVES
Equalizer sheave diameter (at the bottom of groove) shall be minimum 18 to
20 times the diameter of wirerope for Aux Hoist.
All sheaves shall be mounted on special roller type sheave bearings.Grease
lubricated sheave bearings should be provided with individual grease
lubrication fittings and shall be easily accessible for maintenance.
Sheave grooves shall be machined smooth and support wire rope uniformly at
least 136° angle of contact over its circumference.
Equalizer sheave /Bar shall be arranged such that reeving equalization
shall not be restricted under normal operating conditions. Adequate free
movement to compensate for operational block swing and/or normal rope
stretch shall be provided.
All Sheaves shall have guards, which fit closed to the flange having a clearance
not more than 1/3rd rope diameter between sheave and inside of guard, to
prevent the wire rope from leaving the sheave grooves.
All the upper block sheaves shall be mounted above the trolley platform for
ease of maintenance and inspection.
Design of sheaves in general shall be as per IS:4137-1985.
All sheaves shall be of forged steel only.
The wireropes shall be of M/s USHA MARTIN make, Non-rotating type, Hotdip
Galvanized, Powerform, 35x7 construction, core : IWRC, RH, Regular lay,
preformed, Minimum tensile strength / Grade : 1960MPa.
Minimum factor of safety on wire rope shall be 10 on Minimum Breaking
Strength (MBS) of rope with two ropes combined together. With single rope
the factor of safety shall be 5 on the MBS of rope.
Auxialary hoist wire rope shall be single path & conventional reeving system
with true vertical lift as per IS4137. Wire rope shall have factor of safety of 8
on Minimum Breaking Strength (MBS). The wirerope shall be of M/s USHA
MARTIN make, Non-rotating type, Hotdip Galvanized, 35x7 or 34x7
construction, core : IWRC, RH, Regular lay, preformed, Minimum tensile
strength/Grade : 1960MPa.
Sheave diameters (at the bottom of groove) shall be minimum 29 times rope
diameter. Sheave fleet angle shall not be more than 2.5 degrees.
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:11
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
7.7
A-1) Main Hoist (Twin
drive & Dual load path
Option-1)
Hoist drive shall be provided with two parallel shaft
helical gearboxes each driven by individual motors.
Standard make, Crane duty, Horizontal foot
mounted, Parallel shaft, Helical Gearboxes shall be
used in this option.
A-2) Main Hoist ( Single
load path/drive
Option -2)
Hoist drive shall be provided with a planetary gearbox
with driven by two motors. Standard make, crane
duty, Horizontal foot mounted Parallel shaft Helical
Planetary Gearbox shall be used in this option.
B) Aux. Hoist
Standard make, crane duty, Helical, parallel shaft,
horizontal foot mounted gearboxes, shall be used for
Aux. hoist motion.
Helical parallel shaft, Crane duty, gearboxes, shall
be used for CT & LT drives. LT drive shall be of
horizontal foot mounted gearboxes.
Travel drive gearbox ratings for bending strength and
pitting resistance shall be based on 2 times rating of
AC motor.
7.7.3 Make of Gearboxes
Heavy duty, and crane duty gearboxes of Elecon /
Shanti/ 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
requirement.
1) Gearboxes selection shall consider starting torque
of motor (i.e., 2 times the Full load torque) of selected
motors.
2) The gearing shall be designed for strength,
durability, and momentary high overloads which
includes the loads imposed during starting,
braking and failure of components.
3) Due consideration shall be given for braking torque
in selection of Gearboxes.
4) In case of emergency disc brake, (in option-2)
Gearbox shall be designed to withstand its
application & braking torque.
5) 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.
6) 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.
Gear Boxes for CT & LT
drives
Torque & Power rating
of Gearboxes / Pinions /
Gears / Shafts
Torque & Power rating
of Gearboxes / Pinions /
Gears / Shafts
7.7.1
GEARBOXES
7.7.4
7.7.2
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SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
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Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
7.7.5
7.7.6
7.7.7
7.7.8
7.7.9
7.7.10
7.7.11
7.7.12
7.7.13
7.7.14
7.7.15
7.7.16
7.7.17
7.7.18
7.7.19
7.7.20
7.7.21
7.7.22
Sufficient clearance need to be maintained between gear of one stage to pinion
of next stage of non meshing sets to avoid interference.
Radial clearance between the gear box inner surface and the outside diameter
of the gears shall be at least 1 ¼ times the depth of the largest gear tooth
inside gear box or 20 mm whichever is higher.
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.
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.
The casings of gearboxes shall be made from structural steel (IS:2062) or cast
steel.
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
All gear teeth shall be helical and with helix angle not less than 15°.
All gears shall be of forged alloy steel preferably case hardeneing steels.
Fabricated gearbox housings shall be made of minimum 10 mm thick steel
plate. All fabricated gearboxes shall be duly stress relieved.
Main hoist gearboxes for both options shall be designed & manufactured as
per class '4' duty of IS:4137.
Gearboxes with parallel shaft helical gearing shall be used for all motions.
All pinions shall be integral with shafts.
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.
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.
No oil leakage is allowed from gearboxes. Oil drip pans shall be provided
around the gearbox.
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 TPIA / Purchaser (SDSC SHAR) approvals
during design engineering phase.
Gearboxes shall have fill and drain connections, BREATHERS, lubricant
level indicator, and shall have good accessesibility for checking, maintenance
and oil filling.
For all gearboxes lubrication shall be esured even at creep speed of motor and
from the intial start of motion (i.e. main or creep).
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:13
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
7.7.23
7.7.24
7.8
7.81
7.8.2
7.8.3
7.9
Aux. Hoist : 1 motor and
2brakes.
7.9.3 Brake Rating Hoist.
Torque rating of each thruster brake shall be
minimum 2 times motor full load torque. Torque
adjusting provision shall be available in the Brakes.
Selected Brake shall have sufficient margin with
maximum catalogue torque rating.
7.9.4Braking distance/brake
path for hoist
Hoist components and brake shall be selected such
that the braking distance for lowering motion shall be
as IS4137 with one brake at full rated speed.
Necessary calculations shall be submitted in this
regard during design phase.
7.9.6 Brakes for CT & LT
Imported, flameproof Electro hydraulic thruster
brakes of above make, as per clause no 7.9.1, shall
be provided.
7.9.7
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.
Drive Shafts (LT & CT)
Brakes shall be mounted on the input pinion shaft of the gear boxes.
Shaft supports on plummer blocks of SKF / FAG / TIMKEN make only.
Imported Flameproof thruster brakes shall be used for all drives / motions in
EOT crane. Make of brakes shall be M/s Pincsh Bubenzer Bremsen- Germany,
M/s Galvi-Italy, M/s Wittonkramer-UK , M/s SIME-GKN Stromag-France.
Thrusters for all brakes shall be Explosion proof (Ex d), ATEX/ PTB Certified,
Make of thrusters : EMG, Germany or Brook crompton, UK. ATEX/ PTB/
Certificates shall be submitted for Approvals.
Open gears should not be used in any drive / motion. In case used for Main
Hoist Drive of Option-1, it shall be provided with firm metallic enclosure.
7.9.2
Brakes
Brake performance certificate, test certificate, and Exproof Certificate shall be
provided from original manufacturer of brakes.
Brake disc/ drum size and thermal rating shall be selected such that with the
duty cycle mentioned, the surface temperature shall not exceed "T4"
classification of hazardous area.
MAIN HOIST BRAKES
2 motors and 4brakes.
7.9.1
Two nos. of imported electro hydraulic flameproof
thruster brakes per motor with Manual release and
antiwear compenstor shall be provided (the second
brake is for redundancy).
Shafts shall be of 45C8 forged steel or alloy steel.
Realiable oil seal arrangement i.e., preferabley double stage oil sealing
arrangment shall be provided for shafts of gearboxes.
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:14
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
7.9.8Brake rating for CT and
LT motions
Braking torque shall be checked so that it is capable
of arresting the motion within a distance in meters
equal to 10% of speed when travelling with rated load
at rated speed, provided there is no skidding.
7.9.9Manual release for
Brakes
Brake 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.
7.9.9A
shall be made from forged/cast steel/ SG iron.
Drums shall be completely machined to smooth
surface and Statically & dynamically balanced.
Hardness of surface of finished drum shall be 38-43
Rc.
Width of the brake drum shall be 10mm more than the
width of the brake shoes.
7.11 Mounting of equipment
All the gearboxes, motors, brakes, bearing pedestals,
etc. shall be mounted on machined and levelled
surfaces.
7.12
7.12.1Couplings between
motors and gearbox
Flexible Full / half geared couplings. Make of
Couplings shall be of FENNER/ELECON/ Shanthi
Flexible Couplings
between gearbox and
rope drum for hoists
(For single load path/
Single drive)
Drum/ Barrel couplings of M/s Malmedie, Germany
shall be used for Main hoist an Aux hoist . Selection
criteria, service factor (as per ISO-M8 class), Torque
rating, drawing shall be submitted for approval.
Flexible Couplings
between gearbox and
rope drum for hoists
( For dual load path/
twin drive)
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
7.12.3
No oil leakage is allowed from thruster brakes. Oil drip pans shall be provided
under thrusters.
7.12.2
Brake drums
Couplings
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.,
7.10
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SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
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Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
7.12.4
7.14
7.14.1
7.14.2
7.14.3
Galvanized, high tensile fasteners of tensile quality
not less than 8.8 shall be used in crane parts, except
for Fit bolts of Girder. Make of all fasters shall be of
M/s TVS / M/s UNBRAKO
Maximum combined stresses induced in the
fasteners by normal operating loads (but not
including pretensioning loads) shall
not exceed 20% of the ultimate strength of
the fasteners.
7.16
7.16.1
7.16.2
7.16.3
7.16.4
7.16.5
7.16.6
Fasteners
Hoisting ropes shall be lubricated with lubricant approved by rope
manufacturer.
Adequate provisions/arrangements shall be made to prevent lubricants
falling from the crane.
Lubrication of Crane
Suitable provision shall be provided for lubrication of hook and sheave
bearings.
Trunion of wheel bogies shall be provided with suitable greasing points for both
the sides of the pins.
Wheel bearings shall be provided with suitable gearing points on both the sides
of wheel and shall be made approachable.
Track Wheels
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 shaf 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 Purchaser (SDSC SHAR).
All crane wheels shall be made from forged steel C55Mn75 and minimum
surface hardness shall be 350 BHN for a case depth of 10mm. The wheels
shall be capable of taking up misalignments in span as specified.
All crane wheels shall be of double flanged with straight tread, with 12° taper
flanges, and accurately machined. Drive wheels shall be precision machined
and matched in pairs with minimum deviaion.
General design & sizing of wheels shall be as per IS:4137.Crane wheels of
minimum 710mm dia for both cross travel and long travel shall be used.
Necessary sizing & contact stress calculations as per IS:4137 shall be
submitted.
Semi centralized lubrication system shall be provided for all mechanixms in
EOT crane with easy approach for all pedastal bearings, couplings, wheel
bearings, gearboxes etc.,
7.15
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:16
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
All keys where ever used should be of parallel keys
as per IS:2048 (Couplings / gear boxes / motor
shafts)
Material of keys shall be C45C8 or alloy steel.
Proper fits and tolerances shall be used between key
and key ways, such that key should not get loosened
in service life. Key end arrestors shall be provided.
Ball and roller antifriction bearings of approved make
SKF/ TIMKEN/ FAG/ INA only shall be used
throughout the drives except where specified
otherwise.Rated life of ball and roller bearings shall be not less
than total life (B10 or L10) in working hours not less
than 20,000 hrs .
Main hoist gearbox's bearings shall be selected based
on rated life given in class 4 duty of IS 4137.
Special consideration shall be given to
bearings which operate at low speeds. Certified
confirmation of the bearing's capacity at low
speeds must be obtained from the
manufacturer during design phase.
All bearings shall be provided with proper
lubrication or means of lubrication. Mounting fits,
tolerances and clearances shall be as recommended
by the bearing manufacturer.
Life of bearing shall be calculated in accordance with
bearing manufacturer’s recommendations.
7.18.1 Bearing Housings
All bearings housings shall be of STANDARD MAKE
(SKF/FAG/TIMKEN) and made of cast steel or
wrought steel or fabricated steel bolted to a rigid
portion of crane structure by at least 4 bolts. Housings
shall be split on the shaft centre line to permit removal
of the shafts. The underside of the base of each
bearing pedestal shall be machined and shall bear
upon a machined surface. Standard make Bearing
housings.
7.19
7.19.1
a)
b)
7.17 Keys & Keyways
Emergency disc brake shall be a device mounted on trolley and the disc brake
calipers should hold the main hoist rope drum flange, in case of any failure in
the hoist mechanical drive train between the high-speed shafting and the hoist
drum.
Bidder shall furnish cost of this brake along with accessories sperately in
the price Bid.
Emergency Caliper Disc Brakes of make : M/s SIME GKN Stromag, France
shall be provided on Main Hoist rope drum .
EXTRA SAFETY SYSTEMS TO BE PROVIDED IN MIAN HOIST MOTION
EOT CRANE (OPTION - 2)
Bearings 7.18
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Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
c)
d)
7.19.3
7.19.4
7.19.5
7.19.6
7.19.7
7.19.8
7.19.9
7.19.10
7.19.11
7.19.12
Emergency Disc shall allow safe lowering of the load without electrical power
in an emergency situation. Hand pump with required flow and pressure shall be
provided to open the calipers in case of lack of electric power with required
safety valves.
The emergency drum brake system shall provide an independent means for
reliably and safely stopping and holding the load following a failure in the main
hoist mechanical drive train. The make of the emergency disc brake unit shall
be of M/s SIME GKN Stromag, France.
Hydraulic power pack shall be provided with flame proof electricals with ATEX
certification from Authorised body. Power pack shall be ST210-20 or better of
M/s SIME GKN Stromag.
The holding distance (free fall of load) of emergency disc brake after the failure
shall be limited between 200 to 300mm.
Braking i.e. closing of calipers should be done in following modes:
Procedure & Plan from OEM for safe gaurding the load and safely lowering the
load (with above conditions), in case of kinematic chain failure, shall be
provided during design and detail engineering .
A mode shall be provided in the system for safe unloading of load, if powerpack
fails during handling.
Hydraulically operated & spring applied calipers shall be provided of make : M/s
SIME STROMAG, France of model not less than SH-18B suitable for Exproof
environment. Caliper brake shall have ATEX certification by authorised testing
labs/ Agency.
7.19.2
2) When Emergency push button is pressed by operator.
Emergency Drum Brake System shall have massive thermal capacity for
allowing the lowering of the design rated load continuously from maximum
hook height at rated speed, without exceeding the temperature limits of the
brakes/disc in T4 classification.
When power to the crane is shut off, Caliper brake system shall not release
energy from storage device and thus does not set emergency drum brake,
unless there is a failure as defined above. Thus release of energy from the
stored device to set the emergency disc brake shall be in the event of “failure”
only.
The Hydraulic power pack must be the source for the disc brake unit. The disc
brakes must be applied by spring force and released by hydraulic oil pressure
from power pack.
The Emergency disc brake system shall work with the support of hydraulic
power pack unit.
Emergency Disc Brake system shall be suitable for operating in hazardous/
Explosive environment Zone1, Gas Group IIA/IIB, T4.
The over speed condition of drum (due to mechanical failure) is sensed by an
over speed sensor/switch. This shall actuate the spring allied & hydraulically
released Caliper brakes.
1) When there is overspeed in load lowering, due to failure in kinematic chain
of Mian Hoist Drive.
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
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Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
7.19.13
7.19.14
7.19.15
7.19.16
7.19.17
7.20
7.20.1
7.21
Schematic arrangement of Emergency disc brake with model no. of M/s Sime
GKN Stromag, data sheets and hydraulic circuit shall be submitted along with
quotation.
Hoist Drum Rope mis-spooling monitoring on Main Hoist Motion :
Bidder shall quote separately for extra safety features that are to be provided in
crane i.e for emergency caliper disc brake for main hoist rope drum, and
wire rope spooling monitoring.
The wire rope spooling monitor is an electro-mechanical assembly that senses
improper or mis spooling of wirerope from drum grooves. Improper spooling is
sensed prior to wire rope damage. Since, wire rope damage and loss of the
load can result, if improper wire rope spooling is undetected, the wire rope
spooling monitor actuates the Failure Detection System (limit switches ) and
stops main hoisting motion.
Standard stainless steel tubing and fittings (SS 316) shall be used for hydraulic
lines of power pack. Make of tube fittings shall be of double compression ring
type of M/s Swagelok, M/s VOSS, M/s Parker only.
Safety interlocks with hoist motors/ drives shall be provided in the system, i.e.,
in case of emergency disc brake applied, main hoist motor shall be stopped
and shall not switch ON.
Power pack shall have access for easy maintenance and repair.
No oil leakage is permitted from the system. And also drip pans around the
hydraulic power pack shall be provided to avoid any oil spillage
TECHNICAL SPECIFICATIONS OF 250t/32t FLAMEPROOF EOT CRANE
SECTION – III
STRUCTURAL DESIGN AND DETAILS
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Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
8.0
8.1Design of structural
work of Crane
The crane should be rigid, robust and of sturdy
construction. The design of all structures shall be
Class II as per IS:807 and as per this technical
specifications.
8.2
8.3
8.4
8.5
8.6 Material of structurals
All the structural plates used in fabrication of Girders,
Trolleys and End carriages, machine bases shall be
of minimum 10 mm thick of IS 2062 Gr. B.
8.6.1Covering chequered
plates
Trolley and platforms shall be covered with
Chequered plates of minimum of 6mm thick.
Shall be of double Girder Box Type construction
having Maximum rigidity.
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.
Girders shall be cambered and amount equal to the
deflection caused by the dead load plus one half of
the live load and the trolley.
8.8 Deflection of Girders
Deflection shall not be more than 1/1000 of span in
mm with safe working load, with trolley stationed at
mid span and excluding deflection due to dead load.
8.9 Girder Joints
No splice joint is permitted. Girder is to be of single
piece only. Number of weldable butt joints along the
total length of the girder should not exceed two.
8.10Ratio of span to depth
of Girder
For Box Girders Span to Depth ratio shall not exceed
18.
8.11Local Buckling of top
flange
Local buckling of top flange and compression
members shall be considered and necessary
calculations shall be submitted for approval.
8.12 End Carriages
End carriage shall be fabricated as solid box section
made from rolled steel plates IS:2062, except for
essential openings which shall be reinforced.
STRUCTURAL DETAILS OF EOT CRANE
All the bolts, nuts, washers etc., shall be heavy duty galvanized and shall be
protected against corrosive environment.
Black bolts shall not be used in the main structures of the crane.
Unless otherwise specified, only bolted or welded joints shall be used.
For welded construction such as that of bridge girders and carriages, trolley
frames, rope drums, gearboxes etec., all steel plates shall confirm to IS:2062 or
its equivalent.
8.7 Girders
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Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
8.12.1
8.12.2
8.12.3
8.12.4 Rail Sweeps.
A rail sweep shall be provided in front of
each outside wheel. The rail sweep shall
project below the top of the bridge runway
rail.
8.13
8.14
8.15
8.16
8.17Structural bolted Joints/
Girder to End carriages
Fit Bolts ( as per IS:3640) with property class 5.6 and
reamed holes shall be used for all structural joints
between girder & end carriages, wheel L - bracket &
end carriages etc.,
8.18
8.18.1
8.18.2
8.18.3
8.19
8.20
8.21
8.22
The trolley frame shall be of rigid construction such that lifted loads do not
cause deflections that impair the proper operation of machinery.
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.
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.
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.
A rigid frame analysis shall be used to determine the proportions of the
loads resisted by the end ties and by the girders.
All electrical cables on trolley shall be so laid that they are not liable to be
damaged and can be easily inspected and maintained.
Lubrication of Bogie joint pins shall be from a centralized or semicentralized
lubrication points.
Safe access for maintenance and removal of all mechanical and electrical parts
must be ensured without any additional scaffolding.
Trolley
Details of Bogie joint of End carriages shall be provided along with quotation.
End ties shall be designed to accommodate up to 6mm difference in
elevation of the bridge rail between any wheels or pair of wheels without
exceeding allowable stresses.
End ties shall be designed to resist the loads due to crane
movement and the load combinations as per IS807 & IS4137.
All parts requiring replacement or inspection or lubrication shall be easily
accessible without the need for dismantling of other equipments or structures.
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.
The trolley frame shall be built up of rolled 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.
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Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
Full length chequered platform of width 750mm shall
be provided for both bridge girders in order to
access for LT drive and CT cable tack for
maintenance and with hand rails of height 1000mm.
The platforms shall be jointed to Girders with
fasteners.
Additional maintenance accesss platforms on four
inside corners of the girder shall be provided between
inside faces of girder for repair & maintenance inner
LT wheel bearings & mountings of End carriage.
These platforms must not hinder with the CT hook
approaches.
8.24.1Hand rails along girder
platform
Handrails of 1000mm height shall be provided along
the length of the girder near to platform.
8.24.2Hand rails for around
trolley
Handrails of 1000mm height shall be provided on all
the four sides of the trolley.
8.25Maintenance of CT
drives
Maintenance platform shall be provided for CT drives
and shall be covered with chequered plate.
8.26Top chequered plate of
trolley
Chequered plate of 6mm shall be used all over trolley
except for openings required for the ropes for bottom
block etc., to pass. All the mechanical and electrical
equipment shall be placed above trolley top only .
8.27 CT rail wear plateFull length wearing plate of minimim 10mm should be
provided under the trolley rails.
8.27.1 Rails
All bridge and trolley rails required to transmit
vertical down and horizontal loads due to
operation, and shall conform to the IS3443.
8.28 CT rail welding
CT Rails shall be made continuous by welding
standard lengths. Welding shall be done as per
standard procedure approved by Third Party
Inspection Agency and Purchaser.
8.29 CT & LT rail clamping
CT & LT Crane 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.
8.30Rail stoppers /Wheel
ramps
CT & LT Rails shall be prevented from creeping in
the longitudinal direction by welded rail stops and
Wheel ramps.
8.31 Jacking pads
Suitable jacking pads should be provided on end
carriages and trolley for jacking up the crane & trolley
for changing track wheels & bearings .
8.32 Safety Pads
Safety pads shall be provided under the end carriages
and crab to prevent the crane/ trolley from falling
more than 25mm in the event of breakage of a track
wheel/axle or bogie pin.
Platforms8.23
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Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
8.33
8.33.1
8.33.2
8.34
8.35Metric Component
Systems
All components including fasteners should be in
metric system only
8.36 Locking of All fasteners
Bolts in rotating parts shall be locked with spring
washers & lock nuts. All couplings & brake drums
shall be provided with "Fit" type bolts.
8.37NDT of Butt joints of
girders
All butt joints shall be 100% radiographed or
Ultrosonic tested for both compression and tension
joints.
Toe gaurds shall be provided for all openings, on
trolley and on bridge platforms with minimum height of
100mm.
8.39
Mounting of machinery
on machined bases on
trolley / LT
Parts of steel frames carrying machinery should be
provided with doubling plates (including stiffners) of
adequate thickness welded and machined to true
surface.
8.40
8.41
8.41.1
8.41.2
8.42Protection Gaurds for
rotating equipment
Guards: All the moving parts couplings, shaft should
be duly covered with guards as per safety norm.
Proper guard / cover / tray to prevent falling of bolts
from coupling etc should also be provided, wherever
required. The covers shall be strong enough to take
person weight ~ 100 kg.
8.43
Ladders
Approach ladder shall be of staircase type. Ladders shall be provided from
catwalk to end carriage and to LT platforms in all four corners.
Fasteners for pedestal blocks, motors, gear boxes etc., shall be easily
removable from the top of platform. Studs or body bound bolts shall not be
used as fasteners for mechanical items except for fixing covers.
End Buffers
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
5.0 m/s² at 50% of the rated travelling speed.
Welded snugs shall be fitted against against the feet of all pedestals,
gearboxes, brakes etc., except motors. Motors shall be provided with alignment
screws for side alignment.
Spring buffers are to be provided on four ends of the bridge and trolley.
Buffers shall be rigidly bolted in place preferably along the Centre line of crane
rail or trolley rail as the case may be, such that the bolts are not in direct shear.
Toe gaurds
Approach ladders to be provided for reaching the trolley at two locations along
the span of the girder.
8.38
TECHNICAL SPECIFICATIONS OF 250t/32t FLAMEPROOF EOT CRANE
SECTION – IV
ELECTRICAL DETAILS
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Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
9.0
All Electrical equipments shall be supplied for tropical
and humid climate (Temperature of 50°C & RH not
less than 95%) . De-rating of drive motors, power
cables etc., shall be done for ambient temperature of
50°C.
Flame proof electrical fittings and controls shall be
selected, assembled and tested as per relevant
Indian/ IEC standards like IS:5571, IS:2148, and
IS:5780. However for control circuit, intrinsic safe
modules of make : M/s. P&F shall be used.
9.2 Power supply condition
The power available at 415 Volts, 3phase, 4 wire, 50
Hz near by the Crane panel. The power and control
equipment selected shall be suitable for operation on
± 10% variation in the voltage and ± 3% variation in
supply frequency. Power source available to tap for
protective panel (where main power source is located
approximately 50m distance).
9.4Power Supply for
motors3 phase, 415 V, 50 Hz / A.C + 10%
9.5 Control voltage1 phase, 110 Volts AC, only for switchgears inside the
panel
9.6
For Push buttons,
Indication lamps, limit
switches in the field (top
of the crane) and all the
interlocks to the field
equipments:
24V, Intrinsic Safe Package Supply, Make : M/s P&F
9.7 DSL for LT & CT All cables for LT and CT are to be routed through
IGUS chain (plastic) with guided cable tray only.
9.8
9.8.1
9.8.2
9.8.3
9.8.4
9.8.5
9.8.6
9.8.7
Aux hoist panel – 1 No. (One)
Main Hoist panel - 2 Nos. (Two ) for individual motors.
The Electrical equipment shall conform to IS4137 and also to the latest Indian
electricity rules and regulations as regards safety requirements, earthing and
other essential provisions specified therein.
LT Panel - 1 No. (One)
Panels: (Non FLP), Make: M/s Rittal only. (Located in separate room at ground
level, suitable air conditioned units shall be part of the VFD panel).
CT panel - 1 No. (One)
Individual panels (nos.) to be provided as follows:
Protective panel – 1 No. (One)
9.1
Electrical equipment
environment
ELECTRICAL ELEMENTS DETAILS
Individual isolating switch (with SDF) to be provided for each panel.
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Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
9.8.8
9.8.9
9.8.10
9.8.11
9.8.12
9.8.13
9.9
9.10Mounting of panels and
resistance boxes
Panels are to be mounted on the floor with required
anchored Bolts and nuts.
9.11 Switchgears Make: SIEMENS only
AC4 Duty
The contactors shall be able to withstand their rated
current for one second without welding / fusing of the
contacts
Manually operable
To be provided for all panels except protective panel.
9.14 Fuses
Hoist, Aux hoist, CT and LT power supply to VVVF
drives to be routed through Semi conductor fast
acting Fuses of adequate rating only. Semi conductor
fuses shall have a indicator for fusing.
Make: M/s Siemens
Qty: 6 Nos.
Input voltage – 110V / 230 V AC
Output voltage – 24 V DC
Current rating – as per the circuit load
9.16
9.16.1
9.16.2
9.16.3
9.16.4
Insulating barriers shall be provided between adjacent terminals.
Labels shall be of anodised aluminium with white engraving on black
background / computerized labels.
The bottom most row of equipment mounted inside the panel excepting
terminal strip shall be at least 350mm above the panel bottom cover to facilitate
inspection and repairs.
Power terminal blocks shall be separated from each by means of replaceable
insulated spacers.
Terminal blocks and lables
9.12
9.15 SMPS
Terminal blocks shall be of 750 Volts grade of the stud type and shrouded.
Contactors
TPNSFU with Semi
conductor fuses9.13
Provisions shall be made for label inscriptions for the easy identification of
terminal blocks.
A minimum clearance of 250mm shall be provided between the terminal strip
and the panel bottom cover to facilitate cabling.
Rubber mats of 2mx1m shall be provided before the all panels such that
persons stand on rubber mats during maintenance.
Individual Power Contactors are to be provided for each motion for controlling.
All the Panels shall be provided with space heaters to avoid moisture
condensation.
Panel lighting shall be provided and it shall be CFL or LED lamps only.
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Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
9.16.5
9.16.6
9.17Motor protection circuit
breaker (MPCB)
To be provided for the motor which is not powered
viz. VVVF drive. (ie., Hydraulic power pack motor)
and all thruster brakes.
9.19
VVVF Drives
All the switchgear and termincal blocks to be covered with suitable electrical
protective cover.
ON/OFF/TRIP inscriptions shall be clearly marked over the individual panel
with clear marking of direction of the operation of handle apart from the
standard marking provided by the switchgear manufacturer.
Minimum clerance to be maintained as follows (IS 60947-1)
All the joints / tapping points of the terminal blocks / terminals shall be suitably
shrouded to prevent accidental contact.
Main Hoist – 2 Nos. ( Capacity of drive shall be suitable to motor kW selected
in Option -1 (Twin load path drive) and Option-2 (Single drive)
For Hoist motions, Control shall sense sufficient motor torque (or current)
before releasing holding brakes (i.e., torque proving).
The Control circuit shall be so designed as to ensure that brakes for all motions
are applied near about zero speed of rotation.
Make of VVVF drives : M/s. SIEMENS only.
CT – 1 No. or 2nos. Depending on drive motors.
LT – 2 Nos.
9.18
Drive shall be supplied with 20 % additional DI / DOs for future usage.
The rating of VVVF drive shall be one step higher than the calculated rating of
motor.
Aux Hoist – 1 No.
between phases - 25 mm
between phase and earth - 25 mm
All the live parts to be covered properly in order to avoid possibility of in advent
touching.
VVVF Drives shall have PROFINET Communication facility.
between neutral and earth - 19 mm
Safety in arrangements
Enamel Danger plates / stickers of size and descriptions as recommended in
the relevant IS, shall be provided on the Panel inscribed in Hindi and English
languages. The same is to be indicated in panel G.A dwgs after PO and before
proceeding for fabrication.
between phases and neutral - 25 mm
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Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
Suitable input and output chokes are to be provided
for controlling the harmonics from VVVF drive to
source for all VVVF drives.
THD should not exceed 5 % and individual Harmonics
should not exceed 3 %.
It needs to be demonstrated at site during erection
and commissioning.
9.21 DBUSuitable size and rating of DBU for all the above
drives.
Dynamic braking resistors of suitable capacity/rating
shall be provided to all VVVF drives. For Hoist
motions DBRs shall be sized for a minimum of
150% of motor full load torque and it shall not be
less than the torque limit setting of the VFD in the
hoisting direction.
Necessary forced cooling needs to be planned.
Controlling of the cooling fans needs to be linked with
control supply ON.
The DBR panels shall be designed such that during
maintenance activities the entire door has to be dis-
asssembled for enabling the better access to the
components inside the panel.
Each motion shall have its individual panel.
Each side of the LT platform 2 Nos. of 1 phase, 230
Volts AC FLP switch cum socket with plug top and 1
No. on the Crab.
1 Power socket outlet shall be provided on the top of
trolley platform.
2 Nos. of 230 V AC power sockets with ON / OFF
switch shall be provided inside for the all the panels
except protective panel.
Separate control is required for the following:
Under Slung Lights (In pendent)
Socket outlets on the Crane platforms (In protective
panel)
Control circuits (In pendent)
9.24.1Training on Siemens
Drives
Training shall be offered for our engineers by M/s
Siemens about operation, maintenance and trouble
shooting of VVVF drives during commissioning of
Crane.
9.24 Isolating Switches
9.22Dynamic braking
resistances
Input and output chokes
9.23
9.20
Power Sockets outlets
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Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
9.25
Hoist and Aux hoist motors shall be 8 pole with ~750
rpm speed.
Long Travel and cross travel motors shall be 8 poles
with ~ 750 rpm.
Bidder shall provide following details of motor like:
No. of motors / geared motors
Power of motor
Frame size
make
duty
no. of starts/hr
type and
No. of poles
amb.temp etc.
9.27
Details to be provided
related to motor
selection and
calculations
The Motors shall have preferably ZZ type bearings.
All the motors shall be housed with inbuilt thermistor and it is to be linked with
VVVF drive for necessary protection like switch OFF the motor in case of
increase in surface temperature more than T4 classification of hazardous area.
Hoist Motion - 2 Nos. (with required power/torque capacity suitable for Option -
1, Twin load path drive or Option-2, single load path drive )
In cases where sufficient clearance is not possible in front of terminal box for
facilitating maintenance / cable connections, terminal box shall be provided on
the top of the stator frame.
Aux Hoist Motor -1 No.
9.26 Speed rating of Motors
The Motors shall have both side extended shaft
Squirrel cage induction motors.
For accepting the input from VVVF drives, 60% CDF, min of with 300 starts per
hours, IP55, and Pull out torque of not less than 2.75 times of nominal value
and specifically designed for crane duty application .
Crane Motors with Inverter duty.
No of motors required
Cross travel - 2 Nos. (as per design)
Long travel - 4 Nos. (as per design)
Temperature classification - T4.
Flameproof (Zone 1, Gas group IIA/IIB, T4).
MOTORS
Hydraulic Power Pack Motor - 1 No. (For Option-2 of Main Hoist Drive)
Class of insulation - Class F
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Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
9.28Current drawn by
motors
Maximum Current drawn by all motors with full load
should not exceed 80% of the full load rated current.
9.29 Torque Rating of motorsMotor full load torque rating shall be min. 120% of
calculated rating with duty factors as per IS: 4137.
Imported Electro Hydraulic flame proof Thruster
Brakes for
Main Hoist motion - 2nos. Per motor
Aux. Hoist Motor - 2 nos.
CT Motors - each one no. per motor.
LT motors - each one no. per motor.
Rating, duration and frequency of operation shall be
mentioned in quotation.
Main Hoist motors - 2 Nos.(one no. per motor).
Aux Hoist Motor -1 No.
Flame proof speed switch/ sensor (1no.) for main
hoist rope drum shall be provided for detecting over
speed of drum and actuating emergency disc brakes.
Shall have FLP / Intrinsic safe hollow shaft
incremental encoder for better dynamic performance.
The same to be used to achieve vector control mode
of operation.
All Encoders shall be of Flameproof / Intrinsic safe in
nature.
Encoders' signal shall be of intrisic safe only.
Screened cable as per manufacturer
recommendations shall be used for all encoders.
9.32
9.31
Interlocking of both push button stations shall be provided such that operation
of EOT crane shall be possible from any one of the push button station only.
Two nos. of Push button stations shall be provided which are mounted on of
movable type trolleys, and should have connecting socket of required no. of
pins with control cable of flexible type of length 30m. Trolley wheels shall be of
adequate size of reputed make : M/s.Rexello
Push button stations mounted on trolley (Quantity - 2 nos.)
Crane pendent connections shall be available at 3 locations in the ground floor,
shall be in junction boxes at two different locations and should have socket to
tap the connections to movable type pendent as mentioned above. The no of
pins are to be decided as per the number of connections. (Refer building
drawing attached).
Encoders for motors
Pendent control cable securing provision shall be planned i.e cable drum is to
be provided with winding and re-winding the control cable and plug.
9.30 Brakes
Push Button Stations shall also provide with 3-way Selector Switch for
selecting the hoist motors.
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Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
Selector switches shall be of semi flush mounted
type.
Only the front plate and operating handle projecting.
Interlocking is to be carried out for selection of
command for all the motions.
Pendent level: Hard wired interlocks are to be
provided at push button station. For example when
Main Hoist UP motion push button is pressed Hoist
Creep / Hoist Down (Main and Creep) motions should
not be activated even if pressed and Vice versa.
Auxiliary contactor level: Hard wired interlocks are
to be provided such that when Aux.contactor operates
with respect to the motion selected, remaining Aux.
contactors with respect to other Aux. hoist motions
should not be operated.
In the VVVF Drive: It is to be programmed such a
way only one motion has to be selected for operation
at a time in the VVVF drive.
Selector switches
No. of push buttons and indication lamps shall be as per the Annexure -
2B
Crane ON indication Lamp – Powered through Intrinsic Safe circuit.
Cross Travel motion Right / Left - Main speed & Creep speed (with 5Hz)
Aux. Hoist motion UP / DOWN - Main speed & Creep speed
Main Hoist motion UP / DOWN - Main speed & Creep speed
PBS shall be provided with push buttons for controlling crane motions:
9.33
9.34 Interlocks
Pendent Shall be provided with Key way switch Lockable at OFF (for Control
ON command),
At least 30 % Spare Core shall be provided in PBS.
PBS shall also provide with 2-way Switch for Under Bridge Lights.
Emergency OFF (Lockable) ( One more emergency OFF shall be planned in
Bridge platform).
Long Travel motion Fwd / Rev - Main speed & Creep speed
All push buttons at Push button station are to be powered through Intrinsic safe
module only apart from other control elements like limit switch, over speed
switch, etc..,
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Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
1. Selection of Hoist motor / each load path.
2. Rotary limit switches i.e hoist and lower, Gravity
limit switch
3. Emergency Disc Brake opening limit switches
4. Over speed switch of rope drum (option-2)
5. Wire rope mis-spool limit operation
6. Auxilary Hoist operation
7. Emergency Disc brake Solenoid MCB ON condition
– need to be interlocked for Hoist contactor.
8. Pressure switch of Emergency Disc Brake shall be
interlocked with Main Hoist Motors.
9. Thruster Brakes' MPCB condition.
10.Provision shall be made for two extra interlocks
for future usage.
1. Rotary limit switches i.e. Aux hoist and lower
operation limit.
2. Gravity limit switch
3. Main Hoist operation
4. Thruster Brakes' MPCB condition.
5. Provision shall be made for two extra interlocks for
future usage.
1. Right and Left limit switches for respective motion
of the drive.
2. Brakes' MPCB condition.
3. Provision shall be made for two extra interlocks for
future usage.
1. Forward / Reverse limit switches for respective
motion of the drive
2. Brakes' MPCB condition.
3. Provision shall be made for two extra interlocks for
future usage.
Cross Travel VVVF
drive ON command is to
be interlocked with the
following.
9.38
9.35
9.36
Auxiliary Hoist VVVF
drive ON command is to
be interlocked with the
following.
9.37
Main Hoist VVVF drive
ON command is to be
interlocked with the
following.
Long Travel VVVF drive
ON command is to be
interlocked with the
following.
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:31
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
Indication lamps shall be provided for all 3 phases for
the protective panel.
Control ON / OFF (based on the pendent push button
control) indication lamps shall be provided on the
protective panel.
Indicating lamps shall be of Cluster LED type only,
provided with translucent lamp covers.
Lamps and lenses shall be easily replaceable from
the front.
Cluster LED module shall be suitable for direct
operation on 230 V, 50 Hz AC in general except the
indication lamps planned in push button station.
Indication lamps in push button station to be powered
viz. Intrinsic safe relays only.
All wiring for power, control, lighting etc., (which is not
running in the IGUS cable drag chain) shall be carried
out with 1.1.K.V grade XLPE Armored copper
conductor cables.
All wiring for power, control, lighting etc., (which is
running in the IGUS cable drag chain) shall be carried
out with 1.1.K.V grade flexible copper conductor
cables.
Minimum size 4 mm sq. in power circuit and 2.5 mm
sq in control circuit.
All wiring to be done neatly through perforated trays
from the protective panel / VVVF panel to the top
junction boxes fixed in suitable places.
Wiring shall be neatly bunched, adequately supported
and properly routed to allow easy access and
maintenance.
Wires shall be identified by numbered ferrules at each
end.
The ferrules shall be of the ring type and of non-
deteriorating material.
Cable tags to be provided for cable connections as
per circuit diagram.
Schematic Plug-in Pendant locations in side building
are given in Annexure-2A. The pendant control cables
are to be routed properly in suitable cable trays along
the building structure.
9.40Power and Control
Cables
Indication lamps9.39
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:32
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
9.41 Earthing
The crane rails, structures, motor/brake frames, metal
enclosures of all electrical equipment, conduit and
trays shall be effectively grounded with double
earthing and shall be connected to building earth
through gantry rails. The laying of Earth strip from
Gantry rail to Earth pit ( which is around 10m aways
from the crane bay) outside the building is in the
scope of party.
Labels of permanent nature to be specified.
All power and control cables, etc are to be tagged at
both the ends.
FLP junctions Boxes are to be planned for inter facing
the connections between field connections and panel
connections. Sufficient space to must be available for
the maintenance.
The probable locations of the JBs are
Crane LT Girder
Crane Platform
Crane Trolley / crab
Rotary Limit Switch – 1 No. To be linked with both the
hoist motors and linked to the control circuit according
to the operational requirement) (For hoist and lower
limit).
Gravity Limit Switch – 1 No.
Rotary Limit Switch – 1 No. (For hoist and lower limit)
Gravity Limit Switch – 1 No.
9.46Limit Switches for CT &
LTTwo Lever type - 2 Nos. for CT & 2 Nos. for LT
Over speed detection to be sensed by means of over
speed sensor switch of reliable make.
During over speed of drum (by ~20% of actual speed)
due to any reasons, the swich has to detect and
activate the emergency disc brake system and caliper
brakes shall be applied on ropedrum to stop the free
falling of the load.
9.42
9.45
9.43 Junction Boxes (FLP)
9.44
Drum Over speed
detector switch9.47
Identification of Circuit &
Cables
Limit Switches for Aux
Hoist
Limit Switches for Main
Hoist
SECTION – V
OTHER SPECIFICATIONS AND TERMS & CONDITIONS OF SUPPLY OF 250t/32t
FLAMEPROOF EOT CRANE
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:33
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
10
10.1 Surface Cleaning
The entire surface of fabricated materials, girders,
frames, platforms, trolley, end carriage, wheels etc.,
are to be sand / grit / abrasive blasted to white metal
finish (SA 2½ quality) and cleaned properly off rust,
grease & dirt.
10.2
Painting with Epoxy
Primer (Total thickness
of 80 microns)
Two coat of epoxy primer (Apcodur CP 680 of M/s
Asian Paints or equivalent) shall be applied to a Dry
Film Thickness (DFT) of 80 microns.
10.3
Painting Epoxy Paint
(Total thickness of 120
microns)
Two coats of epoxy paint of Golden Yellow color
(Apcodur CF 693 of M/s Asian Paints or equivalent)
shall be applied to a Dry Film Thickness (DFT) of 80
micron and 40 micron for first and second coats with
proper drying in between coats. Final touching shall
be done after erection & commissioning at site.
Painting quality shall ensure austhetic looking of
crane.
10.4Total paint thickness
including primer
Not less than 200 microns. This will be tested during
stage inpsections and final inspection at supplier
works.
10.5
10.6
11
11.1
11.2
INFORMATION/DOCUMENTS TO BE SUBMITTED ALONG WITH
QUOTATION (offer will be rejected unless these information / documents
are submitted)
PAINTING OF CRANE : Total painting thickness, DFT, shall be 200
microns. (DFT shall be measured at the time of final inspection)
Bid Qualification Criteria shall be submitted, along with specifications, in the
format specified in the instructions to tenderer.
11.3
Questionnarie, attached with BQ Criteria, shall be duly filled by Vendor and
shall be submitted along with quotation.
In addition if any intermediate cleaning required between successive coats of
paint are to be carried out as per the recommendation of paint manufacturers
and as per the instruction of the Purchaser (SDSC SHAR).
Interior of all gear box housings shall be sand blasted and painted with two
coats of oil resisting durable paint.
Technical & Major component DATA of EOT crane shall be provided as per
Annexure - 4.
Technical Specifications with Point-wise Specifications to all points as given in
this "Specification cum Compliance Statement" (given in this FORMAT).
Deviations, if any shall be mentioned clearly in a separate sheet. (See. II in
page 1).
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:34
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
11.5
11.6
11.7
12.1
12.2
12.3
12.4
12.5
12
As mentioned, Bidder shall quote seprately for two options of Main Hoist drive
system as per clause nos. 1.10 of this specifications.
11.4
GA drawing of Crane shall be provided for Both the options ( Twin load path
and Single load path) indicating clearances, hook appraoches and general
arrangment of main Hoist Drive.
Bidder shall submit following list of Three sets (03 sets) of drawings/
calculations / documents (in 03 -three sets) for approval before manufacture of
crane within 4 weeks after placement of purchase order. (12.5 to 12.40).
Note: It is the responsibility of the supplier to get the drawings/ documents
approved from TPIA/ Purchaser (SDSC SHAR).
At the same time, Supplier shall be responsible for proper submisssion of
following drawings & calculations along with technical specifications to Third
party Inspection Agency (TPIA) and obtain design Approvals from them.
DESIGN APPROVALS:
If the drawings and other particulars are returned by the Purchaser (SDSC
SHAR), because they are incomplete or faulty, the Bidder shall make the
necessary correction / modifications and resubmit the drawings and
calculations within a reasonable time, but in any case, should not exceed two
weeks from the date of receipt of purchaser’s / third party inspection agency's
comments.
General Arrangement (GA) drawing of crane to scale with dimensions, Bill of
materails, Boughtout items, makes, weight breakups and wheel loads.
The bidder shall quote separately for erection and commissioning of Crane.
DRAWINGS /DOCUMENTS (EACH 3 COPIES) TO BE SUBMITTED AFTER
PLACEMENT OF ORDER FOR APPROVALS.
[ Note : It is the responsibility of the supplier to get the drawings /
documents approved from Third Party Inspection Agency (TPIA) ]
GA drawing showing full details of crane, with dimensions, span, height of lift,
end clearances, head room, overhead clearance, hook approach limits,
weights, wheel loads, major components etc..
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.
Bidder shall quote separately for extra safety features that are to be provided in
crane i.e for emergency rope drum disc brake (Option-2) with model no.
and make.
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:35
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
12.6
12.7
12.8
12.9
12.10
12.11
12.12
12.13
12.14
12.15
12.16
12.17
12.18
12.19
12.20
12.21
12.22
12.23
12.24
12.25
12.26
12.27
12.28
12.29
Calculations for selection of wheels & wheel bearings.
All the componets of crane which are lifted for erection shall be design
checked for erection / lifting loads and necessary Calculations shall be
submitted.
GA drawings of Protective Panel and other panel and inside components
arrangements
Selection of keys, key ways & couplings
Calculation for selection of motors, brakes, drives, cables and switch gear with
manufacturer datasheets & Exproof certificates. All Motors' torque and speed
curves shall be submitted for approval.
Electrical circuit diagrams of EOT crane with individual drive circuits, control
circuit, and with interlocks' circuits.
Calculations for selection of wheel bogie connecting pins.
LT rail arrangement (on Ganrty Girders) drawing to scale with Bill of Materials
(BOM).
Quality Assurance Plan for total crane manufacture, erection & testing as
given in Annexure - 3.
Design & Constructional Drawings of Girder, end carriage, and trolley their
connections with bill of materials.
Sub-assembly drawings for rope drum assembly, wheel assemblies, hook
blocks etc.,
General Arrangement drwing of Dual wire rope reeving with dimensions and
rope equlizer assembly.
GA drawing, Hydraulic circuit, Electrical circuit, Calculations & selection of
Emergency disc brake system of M/s SIME STROMAG, France.
Selection of sheaves & sheave pin with calculations.
Calculations for drive shafts and plummer block bearings.
Calculations for selection of CT & LT rails.
GA drawings, details and selection criteria, design calculations for gear boxes
with manufaturer's data sheets
Selection of bearings for EOT Crane.
GA Assembly Drawing of Trolley with all components.
Calculation for bridge girder with deflection & camber, trolley frame, end
carriage, with weight breakup.
Delivery schedule of EOT crane in the form of Bar chart indicating different
stages.
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.,
GA Drawing of individual drive mechanisms for Main Hoist, Aux. Hoist, CT and
LT.GA drawing of both options of Main Hoist drive shall be submitted.
Bridge Girder CT rail arrangement drawing to scale with BOM.
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:36
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
12.30
12.31
12.32
12.33
12.34
12.35
12.36
12.37
12.38
12.39
12.40
13
13.1
13.2
13.3
13.4
13.5
13.6
13.7
13.8
13.9
13.10
13.11
Manufacturer installation & maintenance manuals, test certificates and
Warranty / Guarantee Cards for all Bought-Out-Items.
Lubrication schedule, diagram with details of lubrications.
Final test certificate of EOT crane from TPIA with inspection report
Trouble Shooting Chart for Main and all Sub-Systems.
4 sets of all as built Drawings of all systems of crane as mentioned above
aprroval drawings that have been finally approved by TPIA / Purchaser (SDSC
SHAR).
Total weight of trolley including electrical equipment.
Weight and name of individual heaviest mechanical components.
QAP/shop Inspection report document showing Third party design approvals,
manufacturer test certificates., all stage & final inspection reports, load test
reports as per QAP and TPIA report on final inspection at works & TPIA
clearance report.
Test certificates of all items like raw materials, hooks, wire ropes, motors etc
and for all crane parts certified by "Competent person of third party agency"
as per QAP & standards.
2 sets of Gearbox spare parts and service manuals shall be provided.
2nos. of Emergency disc brake spare parts and maintenance manuals shall be
provided.
4 sets of Crane operation & maintenance manuals
2 sets of spare parts manuals
Total weight of structural, mechanical and electrical components separately
Electrical ciruit, hydraulic circuit, and control circuit diagrams of Emergency
disc brake system.
List of Manuals / drawings/ documents/ certificates to be submitted at the
time of inspection of crane at supplier's works and also at the time of
commissioning at ISRO, SHAR
Lubrication arrangement of EOT crane with points indicated in drawing.
Bidder shall give the break-up weights of crane as mentioned below
during final design :
Weight of each bridge girder as assembled and ready for erection, with and
without mechanical and electrical components.
Total weight of crane including electrical equipment.
Weight of each end carriage as assembled and ready for erection.
Wire rope spooling monitoring G.A drawing and electrical circuit.
Weight of trolley structure ready for erection shall be provided.
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:37
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
13.12
14
14.1 Span over LT wheels + 4mm maximum
14.2 Diagonal on wheels ± 5mm maximum
14.3 Parallelism of Girders< 1/1000 of wheel gauge (measured at every 1m
interval)
14.4 Verticality of Girders < 2mm (measured at every 1m interval)
14.5Verticality of End
Carriages< 1mm (measured at every 1m interval)
14.6 Trolley wheel gauge ± 2mm (measured at every 1m interval)
14.7 LT wheel alignment ± 1mm (maximum)
14.8Difference in height
between trolley rails<1/1000 of wheel gauge maximum at 1m interval
14.9CT Rail alignment w.r.t
Girder centre±1 mm (measured at every 1m interval)
14.10Tilt of wheels ( both
horizontal & vertical)< D/ 1000mm where D = diameter Of wheels
14.11CT/LT wheel
displacement<2mm (measured at all wheels) Wheel alignment
14.12CT / LT wheel diameter
variationless than 0.1 mm in diameter of wheel
14.13Squareness of Girders
to End carriageswithin 1.60mm ( for wheel base of ~4000mm)
14.14 Hoisting speed +10% -5% of specified speed.
14.15 Lowering speed +20% -5% of specified speed
14.16 Travelling speed +10% -5% of specified speed.
Bidder shall ensure that the crane shall be manufactured as per the
tolerances specified below. Final inpection reports shall be submitted in
drawing format.
Final as built drawings of crane and machinery, Maintenance & spare part
Manuals, test certificates shall be supplied in soft form in the forms of DVDs
and Memory stick in the latest software format.
Tolerances on Crane dimensions and manufacturing :
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:38
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
15
15.1
DESIGN / DRAWINGS
APPROVALS &
CERTIFICATE from
TPIA before crane
manufacture.
Supplier shall obtain all design/ drawings approvals
from third party inspector (TPIA) before starting
crane's production. Crane & components shall be
manufactured & inspected as per the approved
drawings only. All inspection/test repots shall be
made with respect to approved drawing with ref. no.
15.2QAP & Third party
agency
Manufacturing stage INSPECTION and testing shall
be carried out as per QAP enclosed here with in
Annexure-3. 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 THRID PARTY and/or
ISRO. All the critical inspections and load testing
shall be done in the presence of Third Party and /or
ISRO.
15.3Raw materials
identification & stamping
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.
15.4Welding inspection &
Testing
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/or ISRO/SHAR for evaluation and shall form part
of the quality (QA) documentation submitted to
purchaser.
15.5Inspection major parts
and records
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.
15.6
Dimensional inspection
& alignment checking &
records
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.
15.7
15.8 Load testsNo load test, Full load tests and Deflection
measurement as per as per QAP and as per IS: 4137.
15.9 Load tests
Test at OVER-LOAD (125% SWL) capability Check
and Permanent Set Measurement as per QAP and as
per IS 4137.
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.
INSPECTION & TESTING DURING MANUFACTURE & SHOP TESTING OF
CRANE
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:39
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
15.10 Clearance for despatch
The equipment shall be despatched only after
satisfactory performance testing/ inspection at
supplier's works and on written clearance from ISRO
& TPIA.
15.11
15.12
16
16.1 At ISRO- SHAR worksPart of supplier's scope. Inspection and testing
during/after erection shall be as per QAP.
16.2Erection Plan &
Procedure
Before erection, supplier shall submit detailed
erection plan and procedure along with erection loads
on building & also on parts being lifted shall be
submitted for approval.
16.3 Erection Supervision
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.
16.4
Material (lifting
equipment, lifting
tackles, etc) required
during erection.
Part of supplier's scope. All lifting machines / tackles
used shall be tested & certified as per standards
before their usage for lifting crane.
16.5
16.6
16.7
Performance Proving &
Smooth running of EOT
crane
Proving out for the Crane’s Capacity and Smooth
Functioning of the Crane at Full load and Over load
shall be the responsibility of the supplier.
16.8Test/Clearance
certificates for crane
Part of supplier's scope. 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 fianl clearance & usage.
Initial filling of lubricants and spare parts required for commissioning at site
shall be provided by the supplier.
Testing the extra safety features in EOT crane.
Checking the Performance of Emergency disc brake system at supplier works.
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.
ERECTION & COMMISSIONING OF EOT CRANE
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:40
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
17
17.1GEAR BOXES and
Geared Motors
Elecon /Shanti /GREAVES(Premium transmission)
/DB-Radicon/Renold/Sumitomo/Flender.
17.2
Structural Steel
Materials Plates, rolled
sections
All the structural raw materials (plates, angles,
beams) shall be NEW and of reputed make of M/s
SAIL / M/s JINDAL/ M/s ESSAR/ M/s TATA STEEL /
VIZAG-RINL
17.3
Forged steel materials
wheels, shafts, keys,
gears
SAIL / JINDAL / TATA STEEL / ESSAR / VIZAG-
RINL / SUNFLAG STEEL / TIMKEN / Mahindra Ugine
Steel (MUSCO) / BHARTH FORGE
17.4 Wire Ropes M/s. Usha Martin only.
17.5 Bearings SKF / FAG / TIMKEN / INA
17.6Imported flameproof
Thruster Brakes
Pintsch BUBENZER-BREMSEN / SIBRE / WITTON
KRAMER / GALVI/ Sime GKN Stromag
17.8Emergency Rope drum
Disc BrakesSIME-GKN- Stromag, France only.
17.9 Hooks EEK / Hercules/IRIZAR/ Shilpa Udyog
FENNER / Elecon / Shanti
Drum/Barrel coupling - Malmedie, Germany
17.11 RailsSAIL / IISCO / JINDAL / ACCELOR / TATA STEEL /
ESSAR
17.12 Paints Asian Paints / Berger
17.13All Electrical Switch
gearM/s Siemens
17.14 Flame Proof Motors M/s. Siemens / Bharat Bijilee / Crompton Greaves
17.15 VVVF Drives M/s. Siemens only.
17.16 Pushbutton switches M/s Siemens
17.17 Limit switches M/s. Sterling controls / Speed-O-Control / Electromag.
17.18LT power & control
cables
M/s. Lapp / Universal / Nicco / Finolex / RPG /
Uniflex.
17.19 Panels M/s. Rittal
17.20 Terminal Blocks M/s. Elmex / M/s. Connectwell
17.21 EncodersM/s. Hubner / P&F (Flame Proof / Intrinsic safe)
Hollow shaft type Encoder can be planned.
17.22 Junction Boxes (FLP) M/s. FCEG / BALIGA
17.23Junction Boxes (Non-
FLP)M/s. Rittal
MAKE OF THE BOUGHT-OUT ITEMS
17.9 Couplings
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
17.24 Intrinsic Safe realys M/s P&F only
17.25
18
18.1
18.2
18.3
18.4
18.5
18.6
18.7
18.8
18.9
18.10
General TERMS & CONDITIONS during Supply and Installation :
Defects in the material like fractures, cracks, blow holes, laminations, pitting,
etc., are not allowed.
In the design of Crane, all indian standards, all safety regulations as applicable
under provision of factory Act, Indian Electricity rules etc. as prevailing in the
country / State of Andhra Pradesh (site of installation) shall be taken into
consideration.
Delivery Schedule:The crane shall be supplied with in 10 months from date
of Order and shall be erected & commissioned with in two months from date
of supply.
Other reputed and reliable makes of bought out items will be conisdered during
detail engineering with submission of technical details, references and
credentials. However about other makes final decision is of SDSC SHAR.
Only assembling of equipments shall be done at our site (SDSC SHAR).
Fabrication of crane parts shall fully completed at supplier works.
Dimensions of all parts used on crane shall conform to metric standards.
The supplier should satisfy himself about the site condition before hand to
avoid any difficulty during erection and commissioning of the crane.
Supplier shall submit complete erection plan with details of erection loads &
pattern of wheel loads that will act on building civil structure, erection
procedure, material handling procedure etc, during design and detail
engineering.
Arrangements shall be made by the supplier for the inspection and testing of
the crane during different stages of its manufacture starting form the raw
materials till the completion of the crane by the SDSC,SHAR and/or Third Party
Inspection Agency (TPIA) at the suppliers site as per the QAP schedule.
SDSC, SHAR / Third Party Inspection Agency (TPIA) shall have the right of
inspection and supervision of the manufacturing process adopted by the
Supplier for the manufacture of equipment at various stages through their
authorized representatives. In case the manufacturing process adopted is not
found suitable and commensurate with the desired quality of the equipment, the
Supplier will be advised to adopt the correct manufacturing process which will
be binding on the Supplier. SDSC, SHAR’s decision regarding the quality of
work and its acceptability shall be final and binding on the Supplier.
The transfer of title of Crane to the Purchaser (SDSC SHAR / ISRO) will take
place only after satisfactory erection, testing and commissioning of the crane by
the supplier and fully acceptance by the Purchaser (SDSC SHAR / ISRO).
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:42
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
18.11
18.12
18.13
18.14
18.15
19
19.1
19.2
19.3
19.4
19.5
19.6
Supply Prices shall be F.O.R. Sriharikota.
Free electricity and water will be provided by the Purchaser (SDSC SHAR) for
the erection, testing and commissioning of the crane at the site.
During the erection, testing and commissioning of the crane at site in
Sriharikota, the supplier has to make his own arrangements for boarding,
lodging, transportation of his men and materials. However, hostel
accommodation may be provided by the Purchaser (SDSC SHAR) on
chargeable basis, if available.
Liquidates Damages (LD) : Department will levy a penalty for delayed delivery
at the rate of 0.5% per week and part thereof subject to a maximum of 10% of
the value of unexecuted portion of the order.
Excise duty (ED) exemption Certificate will be issued by the Purchaser (SDSC
SHAR / ISRO) for the crane. Hence ED shall be NIL.
Transportation & Transit Insurance are fully in the scope of supplier, NO
transit insurance will be paid by department.
A toolbox containing all necessary tools as given in attached list which are
required for the maintenance of the crane should be supplied along with the
Crane. List of minimum tools required are given here shall be complied by
supplier. Any additional tools required can be indicated in quotation at extra
cost.
Before starting the site work (at SDSC SHAR), the contractor shall provide
insurance to all his personnel working at site in Sriharikota against accidents.
Till commissioning of EOT crane, the safe storing and handling of crane parts is
in the scope of supplier with insurance of materials. Insurance for the same will
not be paid by the Purchaser (SDSC SHAR) i.e, SDSC SHAR.
COMMERCIAL TERMS & CONDITIONS :
Bidder should quote separately for optional spares as considered necessary
for two years trouble free operation of crane as given in Annexure-5.
However, purchaser reserves right to place order for spares at the stage of
ordering.
Delivery : 12 months for total work. The crane shall supply the crane within
10 months from date of Order and shall be erected & commissioned with in 2
months from date of supply.
All Taxes (like sales tax, VAT, service tax etc.,) and duties applicable shall be
indicated clearly in quotation.
SDSC SHAR
SPP
250t / 32t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:43
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
19.7
19.8
19.9
19.10Advance along with
Order
Maximum 30% of supply value against Bank
gaurantee.
19.11Payment after crane
reciept at site
(90% - Minus value of 19.10.1) of Supply value
along with transportation charges, taxes & duties.
19.12
Balance Payment after
completion of erection &
commissioning &
acceptance.
10% of Supply value along with erection &
commissioning charges against submission of
Performance Bank Guarantee as per clause 19.9
19.13
Date : Signature & Office Seal of the bidder
Validity of Offer shall be minimum period of 4 (Four) months from the tender
due date.
Performance Bank guarantee (PBG) for 10% of total landed cost of the crane
(including taxes and duties) shall be provided by the Vendor for a period of 12
months from the date of commissioning and acceptance of the crane at
Purchaser (SDSC SHAR)’s site at Sriharikota.
Payment Terms in three stages. Bidder shall comply with.
Guarantee period shall be for a period of 12 calendar months, commencing
from the date of acceptance & taken over by the Purchaser (SDSC SHAR) at
our site. During this period any defect noticed on design, materials, poor
workmanship shall be replaced/rectified by the supplier at free of any cost.
44
List of Tools to be supplied along with the crane (Ref : 18.14)
S.No Description of Item Units Required Qty
1 Double end Spanners from 10-11 to 36-41 (set of 13nos.) Set 01
2 Ring Spanners from 10-11 to 36-41 (set of 13nos.) Set 01
3
Heavy duty socket spanner set with T-handle, Ratchet and Extension rod with ¾” drive or 1” drive from 20mm to 55mm. (1 set – 10 nos.)
Set 01
4 Torque wrench upto 55kg-m with ¾” drive or 1” drive.
No. 01
5
Screw driver set a) Flat - 300mm long b) Star – 300mm long
No No
01 01
6 Adjustable spanner of 12” or 300mm length No 01
7 Cutting plier ( Size ~10” length) No 01
8 Locking / Grip plier ( Size ~10” length) No 01
9 Circlip plier
a) External Circlip plier ( Size ~10”) b) Internal Circlip plier ( Size ~ 8”)
No No
02 02
45
CODES AND STANDARDS FOR 250t/32t FLAME PROOF EOT CRANE
The design, manufacture and testing of the crane shall conform to the latest editions of the following codes and standards wherever applicable:
IS:4137 Code of practice for Heavy duty electric overhead traveling cranes including special service machines for use in steel works
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
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 8623 : 1993 / IEC Pub 439-1 : 1985
Specification for Low-Voltage Switchgear and Controlgear Assemblies - Part 1 to Part 3
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
46
SECTION – VI
ANNEXURES
51
EOT CRANE CLEARANCE DIMENSIONS – 250t / 32t FLAMEPR OOF EOT Crane
(Top running, Double Girder, Flameproof EOT crane)
Refer Annexure – 1C (Fig) for details All Dimensions are in meters
Sl.No Facility Name
Rated SWL
In tons
Span (S) A B C D F G H P N M X Y
01 Casting – II MH– 250t AH – 32t
23.0 m 6.5m 1.0m 3.0m 2.5m 0.3m 0.4m 0.3m 28.50m ~ 8.0 m Not more
than 10.0m
~ 4.0m ~ 4.0m
Sl.No Facility Name
Rated SWL
In tons
Span (S)
Height of Lift (m)
Main Hoist Auxiliary Hoist
I J K L
01 Casting – II MH– 250t AH – 32t
23.0 m 26m 10m 29m 15m
Note :
1. The above dimensions are indicative only. EOT crane supplier shall work out the exact dimensions by keeping the view to minimize the end hook approaches and head room and shall provide the same in Cranes GA, drawing along with quotation.
2. EOT Crane span & lift are subjected minor changes which shall be accommodated by supplier during detail engineering.
53
Selector Switch
No. of
push
button
Indication
lamps
1 & 2
1
2
Main UP 1
Main DOWN 1
Creep UP 1
Creep DOWN 1
Main UP 1
Main DOWN 1
Creep UP 1
Creep DOWN 1
Main Right 1
Main Left 1
Creep Right 1
Creep Left 1
Main Forward 1
Main Reverse 1
Creep Forward 1
Creep Reverse 1
- 1 -
- 1 -
- 1 -
- 1
- 1 -
1 - -
- -
Emergency Stop with Lockable Key
UB lights
Control ON
Control OFF
Control ON Indication lamp
Push Button for Bell
Long Travel
Aux. Hoist - -
Cross Travel - -
Annexure - 2 B
-
Hoist - -
Crane Motion / Requirement
Selection of Main Hoist
Motor3-way Selector switch -
SCHEMATIC OF PUSH BUTTON OPERATING STATION FOR OPTION 1 & 2
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend 1 Third Party Inspection Agency 2 Vendor (Suppliers) 3 Sub Vendor / Item Supplier
(TPIA) Place: Date:
Signature of Crane Vendor with Designation
Annexure - 3
54
Sl. No
Components/ Operations
Characteristic to be checked
Category
Type / Method of
check
Extent of
check
Ref.
Document
Acceptance Norm
Format of record
Agency
Remarks
P
erfo
rme
d
W
itn
esse
d
V
eri
fie
d
A B C D E F G H I J K
i) H
Identification of Raw materials structural plates, forged steel material, Alloy steel etc.,
All raw materials shall be offered with test certificates for identification for Crane manufacture before start of fabrication. Stamping shall be done for verification at later date.
Component Specs./ IS 2062/ IS1570/ En steels
Stamping on parts & Identification record
1
-
_
All materials shall be Identified by Third
Party Agency . (HOLD)
1 STRUCTURAL WORKS : BRIDGE GIRDERS, END CARRIAGES, CRAB FRAME, DRIVE BASES & PLATFORMS ETC.
1.1
Materials - Plates/rolled sections
Chemical composition/ Mechanical Properties
Major T.C. Correlation (if not available then test)
One per heat
Approved drawings/ Specs./ IS 2062
Approved drawings / Tech. Specs./ IS 2062
Material T. C. / Supplier's Test Report
3,2
-
1
Reports / TC review by TPIA .
1.1.1 Lamination /Internal defects
Major Ultrasonic
Testing 100% ASTM A-435 ASTM A-435 Supplier IR
3,2
-
1
For a l l plates of thickness > 20mm, UT qualification ( volumetric test)
1.2 Welding Welding procedure & Welders qualification.
Critical Test piece visual
& physical test. One for each position
ASME Sec.IX ASME Sec.IX WPS/ PQR
format
2
-
1
1.2.1
Load Bearing Butt welds (both tensile and compression)
a) Welding quality & Surface defects
Critical Visual &
D.P. Test
100% IS:3658 &
AWS D14.1 IS:3658 & AWS D14.1
Supplier’s IR
2
-
1 Visual inspection & Use weld
gauges for measurement of weld size
b) Sub surface defects
Critical
Radiography
100 %
ASME Sec.VIII Div I
ASME Sec.VIII Div
I
Supplier’s IR
2
1
-
Review of radiography films by I.A.
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend 1 Third Party Inspection Agency 2 Vendor (Suppliers) 3 Sub Vendor / Item Supplier
(TPIA) Place: Date:
Signature of Crane Vendor with Designation
Annexure - 3
55
Sl. No
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
Wit
ne
ssed
Ve
rifi
ed
A B C D E F G H I J K
1.2.2 Other than load Bearing Butt welds & fillet welds
Surface defects & Size Major Visual & DPT 100% Visual check & DP test
10% random
IS:3658
IS:3658
Supplier’s IR
2
-
1
Use weld gauges for measurement of weld size
1.2.3
H
Bridge Girder & End Carriage inspection before closing the box
Visual, & Welding
Measurement Major Visual &
welding quality Visual 100% DPT- random of 10%
Component drawing AWS D14.1
Component drawing/ AWS D14.1
Supplier’s IR
2
1
-
Use weld gauges for measurement of weld size (HOLD)
1.2.4 Final Welding Inspection
Visual Inspection Major Inspection of
Welding quality 100% Specification/
AWS D14.1 AWS D14.1 Supplier’s IR
2
-
1 Visual final welding inspection by TPIA
1.2.5 Final Inspection of fabricated components Girders, End carriages, Trolley, LT drive frame, etc..,
Dimensional , Camber , straightness, level, Parallelism, verticality, etc.,
Major Measurement tolerances as per specifications
100% Tech. Specification/ Component drawing/IS 807
Tech. Specification/ Component drawing/IS 807
Supplier’s IR
2
-
1
Measured Dimensions shall be marked on component drawing. Review of reports at next stage by TPIA. (HOLD)
2.0 ROPE DRUM Fabricated/ Heavy duty Seamless pipe
Material composition/ Mechanical Properties UTS, YS, % elongation
Major T.C. Correlation (if not available then test)
One per heat
Spec/drawing/ ASTSM A106/ IS 2062
Spec/drawing/ ASTSM A106/ IS 2062
Material T. C. / Supplier’s Test Report
3,2
-
2, 1
Reports / TC / pressure test reports review by TPIA
2.1 ROPE DRUM joint Welding / Seamless pipe
Welding Joint quality & Weldment defects
Critical Visual/DP Test/RT/ UT
100% Component drawing
ASME Sec.VIII Div I
Supplier’s IR
3/2
2`
1 Measured Dimensions shall be marked on component drawing. Examination of RT films by TPIA.
Stress relieving Major Verification 100% Mfg’s std. Stress relieving chart
Supplier’s IR
3/2
2
1
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend 1 Third Party Inspection Agency 2 Vendor (Suppliers) 3 Sub Vendor / Item Supplier
(TPIA) Place: Date:
Signature of Crane Vendor with Designation
Annexure - 3
56
Sl. No
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
Wit
ne
ssed
Ve
rifi
ed
A B C D E F G H I J K
3.0
Gear box Housings Fabricated
Material composition/ Mechanical Properties UTS, YS, % elongation
Major T.C. Correlation (if not available then test)
One per heat
Spec/drawing/ IS 2062
Spec/drawing/ IS 2062
Material T. C. / Supplier’s Test Report
3,2
-
2, 1
Reports / TC to be
review by TPIA
3.1 Stress relieving Major Verification 100% Mfg's std. Stress relieving chart
Supplier's IR 2
-
1 SR chart will be reviewed by TPIA.
3.2 Surface defects & dimensional check
Major Visual/DP Test/ Measurement
DPT 10% random & 100%
visual
IS:3658/ Component drawing
IS:3658/AWS D14.1
Supplier's IR
2
-
1
Measured Dimensions shall be marked on component drawing
4.0 a) Platform b) LT Frame c) Hand Rails
d) chequered Plates
Dimensional Conformity/
Visual checking / Mfr’s TC
Minor Measurement 100% Critical dimension s / others at random
Component drawing/ Mfr’s TC/ Industrial standards
Component drawing/ Mfr’s TC/ Industrial standards
Supplier's IR
2
-
1
5 MECHANICAL COMPONENTS – GEAR BOXES
5.1 MH, AH , CT & LT Input shafts, Gears , Pinions, keys, spacers
Material composition/ Mechanical properties Hardness value / UT / MPT/ DPT of materials
Major Correlation with Mfr’s TC ( if not test materials)
100% Specification IS:1570 / BS 970 / IS:2048
Component drawing/ IS2048 Specification/ IS:1570 / BS 970
Mfr's TC/ Supplier's IR
3,2
-
1
1) UT volumetric test for wrought or forged materials as per ASTME 114 and A388.
2) DPT or MPT shall be performed as per ASTM A 275, E709
5.1.1 Machined components
for Gear boxes like input shafts, gears, pinions, keys, spacers etc.,
Dimensional conformity Hardness of gear teeth/ Bearing s/ Oil seals/ keys and key ways.
Major Measurement/ Visual examination for finishing
100% Component drawing/ IS4460/ AGMA/DIN IS:2048
Component drawing/ IS4460/ AGMA/DIN/ Heat treatment chart
Supplier's IR
2
-
1
Key ways shall be inspected by TPIA before assembly of gearboxes. Measured Dimensions shall be marked on component drawings.
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend 1 Third Party Inspection Agency 2 Vendor (Suppliers) 3 Sub Vendor / Item Supplier
(TPIA) Place: Date:
Signature of Crane Vendor with Designation
Annexure - 3
57
Sl. No
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
Wit
ne
ssed
Ve
rifi
ed
A B C D E F G H I J K
5.1.2
H Gear box Assembly Dimensional
conformity/ Inspection of machined surfaces like gearbox base, bearing mounts etc.,.
Major Measurement/ Visual check of Internal painting
100% Gearbox GA
drawing Gearbox GA Drawing.
Supplier's IR
2
-
1
Measured Dimensions shall be marked on Gearbox GA drawings with allowed dimensional variations. (HOLD)
5.1.3
Gear box assembly testing (No load run test for minimum of 4 hours )
Contact ratio of surfaces/ Backlash/
Noise level & Bearing temperature/ Breather/ Oil level gauge
Major Measurement & no load running
100% Gearbox GA drawing / IS4460/ AGMA / Specification
Gearbox GA drawing / IS4460/ Specification / Noise level of gear box ≤ 75dBA
Supplier's IR
2
1
-
No Load Test shall be witnessed by TPIA. Noise level of gearboxes shall be ≤ 75dBA. Temperature rise
shall be less than 4 0C
5.2 MECHANICAL COMPONENTS – LT AND CT DRIVE SHAFTS
5.2.1 Materials of LT & CT Shafts, and Keyways & Keys
Material composition/ Mechanical properties Hardness of material / UT / DPT
Major Correlation with Mfr’s TC ( if not test materials)
100% Approved drawing/ IS2048/ Specification IS:1570/BS970/
Approved drawing/ IS2048
Specification/ IS:1570 / BS 970
Mfr's TC/ Test reports/ Supplier's IR
3, 2
-
1
UT of wrought and forged materials as per ASTM
5.2.2 Machining of LT & CT Shafts, and Keyways & Keys ( Dimensional measurement)
Straightness & Dimensional conformity Checks & Inspection of Key way milling
Major Dimensional Measurement/ Visual examination
100% Approved drawing/ Specification IS:1570 / BS 970/IS2048
Approved drawing/ IS2048 Specification/ IS:1570 / BS 970 /IS 2048
Supplier's IR
2
-
1
Keys & keyways shall be inspected by TPIA before assembly.
5.3 COUPLINGS a) Materials b) Torque capacity c) Key ways
Coupling s Size/ Material composition/ Mechanical properties / Hardness value / UT / DPT
Major Correlation with Mfr’s TC
100% Approved drawing/ Specification IS:1570 / BS 970
Approved drawing/ IS2048 Specification/ IS:1570 / BS 970
Mfr's TC/ Supplier's IR
3, 2
-
1
Keys & keyways shall be inspected by TPIA before assembly. UT of wrought and forged materials as per ASTM
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend 1 Third Party Inspection Agency 2 Vendor (Suppliers) 3 Sub Vendor / Item Supplier
(TPIA) Place: Date:
Signature of Crane Vendor with Designation
Annexure - 3
58
Sl. No
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
Wit
ne
ssed
Ve
rifi
ed
A B C D E F G H I J K
5.4 Plummer blocks & bases
PB & bearing sizes/ Material composition/ Mechanical properties
Major Correlation with
Mfr’s TC 100% Approved
drawing/ Specification
Approved drawing/ Specification/
Mfr's TC/ Supplier's IR
2
-
1
Review of Test certificates by TPIA and issue Compliance certificate.
Measured Dimensions shall be marked on Component drawings with allowed dimensional variations.
5.5 LT & CT Wheels
5.5.1
a) Material Forged steel C55Mn75
Material composition/ Mechanical properties Hardness of material /
Major Correlation with
Mfr’s TC 100% Approved
drawing / Tech. Specification IS:1570/BS970
Approved drawing / Tech. Specification IS:1570/BS970
Mfr's TC/ Test reports/ Supplier's IR
3, 2
-
1
Review of Test certificates by TPIA and issue Compliance certificate.
UT of forged blanks Major UT checking 100% ASTM A-388 ASM A-388 Mfr's TC Supplier's IR
3, 2
-
1 Review of Test certificates by TPIA and
issue Compliance certificate.
5.5.2 b) Wheels after machining with Keys & key ways
Dimensional Conformity for Bore, wheel tread, taper of flange / Hardness/depth
Major Measurement 100% Approved Component drawing
Approved Component drawing
Supplier's IR
2
-
1
Measured Dimensions shall be marked on each Component drawings with allowed dimensional variations.
5.6 WHEEL AXLES with key ways & keys
Material composition/ Mechanical properties Dimensional inspection
UT & DPT /MPT
Major Correlation with Mfr’s TC / Measurement
100% Approved drawing / Tech. Specification IS:1570/BS970
Approved drawing / Tech. Specification IS:1570/BS970
Mfr's TC/ Test reports/ Supplier's IR
3, 2
-
1
Measured Dimensions shall be marked on each Component drawings with allowed dimensional variations.
5.7 Pulleys with Roller Bearings
5.7.1 a) Material (Forged Steel ) Material composition/ Mechanical properties Hardness of material / UT & DPT / MPT
Major Correlation with
Mfr’s TC 100% Approved
drawing / Tech. Specification IS:1570/BS970
Approved drawing / Tech. Specification IS:1570/BS970
Mfr's TC/ Test reports/ Supplier's IR
3, 2
-
1
Review of Test certificates by TPIA and issue Compliance certificate.
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend 1 Third Party Inspection Agency 2 Vendor (Suppliers) 3 Sub Vendor / Item Supplier
(TPIA) Place: Date:
Signature of Crane Vendor with Designation
Annexure - 3
59
Sl. No
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
Wit
ne
ssed
Ve
rifi
ed
A B C D E F G H I J K
5.7.2 b) Visual Inspection
c) Dimensional Inspection Overall visual inspection / All dimensions as per drawing like bore, width, groove, etc.,/hardness of
Major Measurement with vernier / Micrometer
100% Component drawing / Specification
Component drawing / Specification Noise level of gear box < 80db
Mfr's TC
3
-
1,2
Measured Dimensions shall be marked on each Component drawings with allowed dimensional variations.
5.8 Snatch block Cross head
Material composition/ Mechanical properties Dimensional inspection, 100% UT & MPT
Major Correlation with Mfr’s TC / Measurement
100% Approved drawing / Tech. Specification IS:1570/BS970
Approved drawing / Tech. Specification IS:1570/BS970
Mfr's TC/ Test reports/ Supplier's IR
3, 2
-
1
Measured Dimensions shall be marked on each Component drawings with allowed dimensional variations.
5.9 Snatch block assembly Dimensional Conformity Major Measurement 100% Approved Assembly dwg .
Assembly Drawing
Supplier's IR 2
-
1 Review of reports by TPIA
5.10
Hook
Material composition/ Mechanical properties/ and 100% UT& DPT / MPT
Major Correlation with TC.
100% Component drawing / IS1875
Component drawing /IS 1875
Mfr's TC 3
-
2, 1
Proof load test from Govt. approved test house.
Proof Load Test Major Testing 100% IS3815 IS3815 Mfr's TC
3
-
2, 1
Stress relieving Major Verification 100% Component drawing/ IS3815
Component drawing /IS3815
Vendor TC 3
-
2,1
5.11
Brake Drums with key and Key ways
Material composition/ Mechanical properties
Major Correlation with Mfr’s TC /
100% Approved comp. drawing / Tech. Specification IS:1570/IS1030
Approved comp. drawing / Tech. Specification IS:1570/IS1030
Mfr's TC/ Test reports/ Supplier's IR
3, 2
-
1
Measured Dimensions shall be marked on each Component drawings with allowed dimensional variations.
5.12
Dimensions/ Dynamic balancing/ Key way and key inspection.
Major Balancing test/ Measurement with
100% Component drawing / Specification
Component drawing / Specification
Mfr's TC
2
-
1
1. Dynamic balance report shall be reviewed by TPIA.
2. Measured Dimensions shall be marked on each Component drawings with allowed dimensional variations.
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend 1 Third Party Inspection Agency 2 Vendor (Suppliers) 3 Sub Vendor / Item Supplier
(TPIA) Place: Date:
Signature of Crane Vendor with Designation
Annexure - 3
60
Sl. No
Components/ Operations
Characteristic to be checked
Category
Type /
Method of check
Extent
of check
Ref. Document
Acceptance Norm
Format of record
Agency
Remarks
Pe
rfo
rme
d
Wit
ne
ssed
Ver
ifie
d
A B C D E F G H I J K
6 BOUGHT-OUT & Other items
6.1
Wire Rope
Dimensional, Genuine of make, Lay, core and stands, Tensile grade
Major Mfr's TC 100% Component drawing/ BOOM
Component drawing / BOOM
Mfr's TC 3,2
-
1
Review of Mfr's TC by TPIA. Visual examination of wire rope for any defects by 2 & 1.
Breaking Load test Major Mfr's TC 100% IS2266 IS2266 Mfr's TC 3 - 1
6.2 Bearings Bearing No./ Genuine Major Mfr's TC/
Invoice 100% Approved make
and type SKF/FAG/TIMKEN Mfg TC/
Supplier IR
2
-
1
6.3 Machined Fit Bolts & Nuts
Material composition/ Mechanical properties / Measure dimensions
Major Correlation with Mfr’s TC / Measurement
100% Approved comp. drawing / Tech. Specification /IS
Approved comp. drawing / Tech. Specification IS:1570/IS1030
Mfr's TC/ Test reports/ Supplier's IR
3, 2
-
1
Measured Dimensions shall be marked on each Component drawings with allowed dimensional variations.
6.4 FASTENERS (Bolts, nuts, washers, lock nuts)
Type / Genuine make conformity Major Mfr's TC/
Invoice 100% Approved make
and type TVS/UNBRAKO Mfg TC/
Supplier IR
2
-
1
7 ELECTRICAL EQUIPMENT
7.1 Electrical Control Panels ( VVVF drive panels)
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
7.2 Motor Visual/ Name Plate Major Name Plate 100% IS 325/ Spec IS 325/spec Mfr's TC
2
-
1
7.2.1 Routine / No load test Major Elec. test 100% IS 325 IS 325 Mfr's TC
3
-
2, 1 Review of TC & Flameproof certificates by TPIA
7.2.2 Flameproof test cert. Major Gap measure 100% IS2148/ CMRI IS2148/ CMRI Type test cert.
3
-
2,1
make conformity
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend 1 Third Party Inspection Agency 2 Vendor (Suppliers) 3 Sub Vendor / Item Supplier
(TPIA) Place: Date:
Signature of Crane Vendor with Designation
Annexure - 3
61
Sl. No
Components/ Operations
Characteristic to be checked
Category
Type /
Method of check
Extent
of check
Ref. Document
Acceptance Norm
Format of record
Agency
Remarks
Per
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Wit
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A B C D E F G H I J K
7.3 Brakes and
Thrusters,
Brake Coil
Visual/ Name plate/ Make Torque & Thrust / Material TC verify / Test certificate/ Ex proof certificate
Accessibility of parts.
Major Name plate details, make Verification of TC
Verification of Ex-proof TC
100% Approved Drawing/ Make/ BOM/Spec
Approved Drawing/ Make/ BOM/Spec/ ATEX- PTB/ IS2148 -CMRI
Mfr's TC/ Type test cert for Flameproof / Supplier IR
3
-
1
Review of TC & Ex-proof certificates by
TPIA
7.4 Resistance box Megger test, Resistance value
Major Electrical test 100% BOM/ drawing / Specifications.
BOM/ drawing / Specifications.
Mfr's TC 3
-
1 Review by TPIA.
7.5 Master controller / Limit switches / Switch Gear
Sequence, Number of cams, Idle operational test
Major Visual 100% BOM/ drawing / Specifications.
BOM/ drawing / Specifications.
Mfr's TC
3
-
1
Review of TC by I.A.
7.6 Cables Routine test Major Test One per BOM/spec. BOM/spec. Mfr's TC 3
-
1
Review of TC by I.A.
8 H ASSEMBLY OF CRANE (Before assembly of EOT crane all parts shall be inspected by TPIA/Purchaser. Supplier shall inform readiness of all parts) (HOLD)
8.1 Bridge Girder & End carriage assembly.
Overall Dimension s Structural Alignment & LT Wheel alignment. Span measurement Diagonal Checks
Major Measurement/ visual inspection
100% Approved General Arrangement drawing / Specifications
Approved General Arrangement drawing / Specifications
Supplier's IR
2
1
-
Measured Dimensions / alignment values shall be marked on GA
/component drawings with allowed dimensional variations.
8.2 Crab assembly with Main Hoist & CT machinery
Dimensional & CT Wheel alignment Couplings’ alignment
Major Measurement 100% Approved drawing / Specifications
Approved drawing / Specifications
Supplier's IR
2
1
-
Measured Dimensions / alignment values shall be marked on GA /component drawings with allowed dimensional variations.
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend 1 Third Party Inspection Agency 2 Vendor (Suppliers) 3 Sub Vendor / Item Supplier
(TPIA) Place: Date:
Signature of Crane Vendor with Designation
Annexure - 3
62
Sl. No
Components/ Operations
Characteristic to be checked
Category
Type /
Method of check
Extent
of check
Ref. Document
Acceptance Norm
Format of record
Agency
Remarks
Per
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Wit
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A B C D E F G H I J K
9 H LOAD TESTING AT WORKS (HOLD)
9.1 NO LOAD TEST
(MH ,AH , CT & LT mechanisms)
NO Load test/ Performance & Safety systems verification speed, Current etc.,
Major NO Load test/ Measurement of parameters
100% Approved dwg / IS807/ IS 3177 /Specification
Approved dwg / IS807/ IS 3177 /Specification
Supplier's IR & Load test Format
2
1
-
Measure Gear Box Noise. (Noise Level should be <75dBA).
9.2 FULL LOAD (SWL) TEST AT WORKS FOR HOIST & CT MOTIONS
9.2.1 DEFLECTION TEST
With Safe Working Load Deflection Major Measurement
as per approved procedure.
100% Specifications/ IS807/ IS 3177
Specifications/ IS807/ IS 3177
Supplier's IR & Load test Format
2
1
-
Deflection < Span/1000 . Record procedure of test & measurement with sketch.
9.2.2 Main Hoist and Auxiliary Hoist With Safe Working
Load
Performance, duty cycle, Speeds, Current, , Safety systems etc.,
Major Full Load test/ Measurement of parameters
100% Approved dwg / IS807/ IS 3177 /Specification
Approved dwg / IS807/ IS 3177 /Specification
Load test report /Supplier's IR
2
1
-
Measure Gear Box Noise. (Noise Level should be <80dBA) .
9.2.3 CT Mechanism With Safe Working Load
Performance, duty cycle, Speeds, Current, , Safety systems etc.,
Major Full Load test/ Measurement of parameters
100% Approved dwg / IS807/ IS 3177 /Specification
Approved dwg / IS807/ IS 3177 /Specification
Load test report /Supplier's IR
2
1
-
Measure Gear Box Noise. (Noise Level should be <80dBA) .
9.2.4
OVER LOAD (125% SWL) TEST (MH, AH & CT)
Static test/ Capability of all motions/ Permanent set
Major Capability of CT
&Hoist motion/ Measurement
100% Approved dwg / IS807/ IS 3177 /Specification
Approved dwg / IS807/ IS 3177 /Specification
Supplier's IR & Load test report
2
1
-
Record procedure followed for test & measurement with sketch. After testing check for any damage, cracks/paint flaking in load bearing members.
10 PAINTING
10.1 Sand/ Grit Blasting & Surface Cleaning
Surface Cleanliness/
texture visual inspection Major Visual Random Specification /
SSPC SA2 1/2 Specification / SSPC SA2 1/2
Supplier's IR 2
-
1
10.2
Primer Coat Painting DFT Thickness/ visual inspection
Major Measurement in µm / Visual
Random Specification / DFT ≥75µm
Specification / DFT ≥75 µm
Supplier's IR 2
-
1 Paint thickness shall be measured
with paint thickness gauge/ elcometer.
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend 1 Third Party Inspection Agency 2 Vendor (Suppliers) 3 Sub Vendor / Item Supplier
(TPIA) Place: Date:
Signature of Crane Vendor with Designation
Annexure - 3
63
Sl. No
Components/ Operations
Characteristic to be checked
Category
Type /
Method of check
Extent
of check
Ref. Document
Acceptance Norm
Format of record
Agency
Remarks
Per
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Wit
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A B C D E F G H I J K
10.3 Epoxy paint Painting (Two coats of 80 µm & 40 µm)
DFT Thickness/ visual inspection
Major Measurement/ Visual
Random Specification / DFT ≥195 µm
Specification / DFT ≥195 µm
Supplier's IR 2
-
1
Paint thickness shall be measured with paint thickness gauge/ elcometer . Final DFT measured in presence of TPIA.
11 ERECTION AT SITE
11.1 GANTRY GIRDER RAIL ALIGNMENT
Gantry rail Span, Level, straightness, rail Joints and Rail clamp distance.
Major Measurement of parameters
100% Approved drawing / IS 807
Specification / IS3177
Approved drawing / IS 807
Specification / IS3177
Supplier's IR
2
-
1
Tolerances: Rail span : ±5mm; Slope of rail : 1/1000 at 2m interval; Height diff : ±10mm between LH & RH rails; Rail Gap :2mm; Straightness of rails: ±5mm
12 LOAD TESTING AFTER ERECTION AT SITE.
12.1 NO LOAD TEST
(MH ,AH , CT & LT mechanisms)
NO Load test/ Performance & Safety systems verification speed, Current etc.,
Major NO Load test/ Measurement of parameters
100% Approved dwg / IS807/ IS 3177 /Specification
Approved dwg / IS807/ IS 3177 /Specification
Supplier's IR & Load test Format
2
1
-
Measure Gear Box Noise. (Noise Level should be <75dBA).
12.2 DEFLECTION TEST
With Safe Working Load Deflection Major Measurement
as per approved procedure.
100% Specifications/ IS807/ IS 3177
Specifications/ IS807/ IS 3177
Supplier's IR & Load test Format
2
1
-
Deflection < Span/1000 . Record procedure of test & measurement with sketch.
12.3 Main Hoist and Auxiliary Hoist With Safe Working Load
Performance, duty cycle, Speeds, Current, , Safety systems etc.,
Major Full Load test/ Measurement of parameters
100% Approved dwg / IS807/ IS 3177 /Specification
Approved dwg / IS807/ IS 3177 /Specification
Load test report /Supplier's IR
2
1
-
Measure Gear Box Noise. (Noise Level should be <80dBA) .
12.4 CT Mechanism With Safe Working Load
Performance, duty cycle, Speeds, Current, , Safety systems etc.,
Major Full Load test/ Measurement of parameters
100% Approved dwg / IS807/ IS 3177 /Specification
Approved dwg / IS807/ IS 3177 /Specification
Load test report /Supplier's IR
2
1
-
Measure Gear Box Noise. (Noise Level should be <80dBA) .
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend 1 Third Party Inspection Agency 2 Vendor (Suppliers) 3 Sub Vendor / Item Supplier
(TPIA) Place: Date:
Signature of Crane Vendor with Designation
Annexure - 3
64
Sl. No
Components/ Operations
Characteristic to be checked
Category
Type /
Method of check
Extent
of check
Ref. Document
Acceptance Norm
Format of record
Agency
Remarks
Per
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Wit
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A B C D E F G H I J K
12.5 LT Mechanism With Safe Working Load
Performance, duty cycle, Speeds, Current, , Safety systems etc.,
Major Full Load test/ Measurement of parameters
100% Approved dwg / IS807/ IS 3177 /Specification
Approved dwg / IS807/ IS 3177 /Specification
Load test report /Supplier's IR
2
1
-
Measure Gear Box Noise. (Noise Level should be <80dBA) .
12.6 Brake Path Test/ Brakes Effectiveness testing for all motions
Each Brake holding Brake path / Delay between two brakes
Major Measurement of path & Brake currents
100% Specifications/ Brake path ≤17mm for Hoist
Specifications/ Brake path ≤17mm for Hoist
Load test report /Supplier's IR
2
1
-
12.7
OVER LOAD (125% SWL) TEST (MH, AH , CT and LT motions)
Static test/ Capability of all motions/ Permanent set
Major Capability of CT
&Hoist motion/ Measurement
100% Approved dwg / IS807/ IS 3177 /Specification
Approved dwg / IS807/ IS 3177 /Specification
Supplier's IR & Load test report
2
1
-
Record procedure followed for test & measurement with sketch. After testing check for any damage, cracks/paint flaking in load bearing members.
13.
Final Painting & touch up
Aesthetic look of crane/ DFT measurement
Major
Thickness measurement
Random
Tech . Specifications.
Tech . Specifications.
Supplier's IR
2
1
-
Final DFT measured in presence of TPIA.
14
Safety features like limit switches, overload relays, buffers, stoppers etc.,
Performance, interlocks
Minor
Performance
100%
Tech . Specifications./ IS3177
Tech . Specifications./ IS3177
Supplier’s IR
2
1
-
15
Emergency disc brake unit.
Performance checking, Interlock checking, Leak checking, Checking of manual lowering of load in case of failure in the system.
Major
Testing at no load condition and full load condition.
100%
Tech Specifications
Tech Specifications and Supplier recommendations
Supplier`s IR / SHAR report
2
1
-
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend 1 Third Party Inspection Agency 2 Vendor (Suppliers) 3 Sub Vendor / Item Supplier
(TPIA) Place: Date:
Signature of Crane Vendor with Designation
Annexure - 3
65
Sl. No
Components/ Operations
Characteristic to be checked
Category
Type /
Method of check
Extent
of check
Ref. Document
Acceptance Norm
Format of record
Agency
Remarks
Pe
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Wit
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A B C D E F G H I J K
16 Spool limit switch
Performance
Major
No Load test
100%
As per Specifications
As per Specifications Load test
report /Supplier's IR
2
1
-
17 Decoupling of main hoist output shaft coupling to rope drum of option – 1
Ensuring the decoupling of drive system
Major Ensuring the removal and fixing of drive system
100% As per specifications
As per specifications Load test
report /Supplier's IR
2
1
-
66
DETAILS OF EOT CRANE’S MAJOR COMPONENTS CONSIDERED BY BIDDER (TO BE DULY FILLED AND SUBMITTED ALONG WITH QUOTATION)
EOT CRANE – SWL: ________________ , SPAN: ______m, Lift: ________m
Sl.No Specifications Specification quoted by Bidder
1.
EOT crane SWL : (in metric tons)
Span : (in meters)
Height of lift: a) Main Hoist : Above FFL / Below FFL (m) b) Auxiliary Hoist : Above FFL / Below FFL (m)
2. Duty class Class-II of IS 4137
3. Flame proof (FP)
4. Bay length / Travel of crane
5. Under slung HVMV lights - 4nos (400 Watts)
6. No. of rope falls: a) Main Hoist b) Auxiliary Hoist
Details to be furnished for both the options For Option 1 For Option 2
7. Main Hoist: a) Motor KW b) RPM of motor : ~ 750 c) IP55 / Flame proof d) No. of motors.
8. Main Hoist MOTOR Encoder for VVVF drive feedback
a) Make b) Type / Model
9. Main Hoisting coupling between motor and gearbox a) Type b) Size c) Torque rating @ r.p.m
10. Main Hoisting Brakes shall be Flame proof Electro hydraulic thruster brakes of imported make a) Model / Make b) Size c) Torque rating d) No. of brakes
11. Main Hoisting Brake drum a) Type b) Size c) No. of brake drums
12. Main Hoisting Gearbox a) Model / Make b) Size/Reduction ratio c) Torque rating of Gearbox d) No. of reductions
67
13. Main Hoisting Rope drum a) Pitch Diameter of drum b ) Length of the drum (approx)
14. Main Hoist coupling between rope drum and gearbox a) Type b) Size c) Make d ) Torque Rating
15. Emergency Disc brake details (For Option – 2) a) Model of brake calipers b) No. of calipers. c) Hydraulic power pack model d) Make of tube fittings
16. Over speed switch (for option – 2) a) Type b) Make & Model
Details to be furnished for both the Hoists
For Main Hoist
For Aux Hoist
17. Hoist wire rope (Galvanized) a) Diameter b) Construction c) Grade Breaking strength
18. Sheaves & pulleys a) Size / diameter b) Material: Forged steel
19. Fleet angle for hoist wire rope shall be less than 2.5 deg.
20. Hoist limit switches a) Rotary limit switch : Make & Model b) Gravity limit switch : Make & Model c) Enclosure type (IP55/ISC)
21. Type of hook a) Ramshorn hook b) Single point “C” hook
22. Bearing size in bottom hook block and hook
23. Auxiliary Hoist: a) Motor KW b) RPM of motor : ~ 750 c) IP55 / Flame proof
24. Auxiliary Hoist MOTOR Encoder for VVVF drive feedback
a) Make b) Type / Model
25. Auxiliary Hoisting coupling between motor and gear box
a) Type b) Size c) Torque rating @ r.p.m
68
26. Auxiliary Hoisting Brake drum a) Type b) Size c) Rating d) No. of brake drums
27. Auxiliary Hoisting Brakes (Imported flame proof Electro-hydraulic thruster brakes) a) Model / Make b) Size c ) Torque Rating d ) No. of brakes
28. Auxiliary Hoisting Gearbox a) Make & Model b) Size / Reduction ratio c) Torque rating of Gearbox d) No. of reductions
29. Auxiliary Hoisting Rope drum a) Pitch Diameter of drum b) Length of the drum (~approx.)
30. Auxiliary Hoist coupling between rope drum and gearbox a) Type b) Size c ) Make d ) Torque Rating
31. Trolley a) Wheel base b) Wheel span
32. CT wheel a) No. of wheels. b) Diameter of wheel. c) Rail Size. d) Wheel bearing size
33. Trolley drive a) Central /Corner drive b) No. of driven wheels c) KW of motor d) No. of motors e) RPM of motor
34. Trolley drive coupling between Motor & gearbox a) Model /Type / Make b) Rating and RPM
35. Trolley drive brake (Imported Flame proof thruster brakes) a) Model / Make b) Size c) Rating d) No. of brakes
36. Trolley drive coupling a) Make / Model b) Torque Rating c) Rating and RPM
69
37. Trolley drive gearbox a) Type of gearbox Vertical / Horizontal b) Make c) Size/reduction ratio d) Torque rating e) No. of reductions
38. Trolley drive floating shaft a) Diameter b) No. of plummer block supports c) Make of shaft plummer blocks
39. Trolley drive couplings between Wheel & gearbox output a) Model & Make b) Rating
40. Trolley limit switches a) Type b) Qty c) Make
41. Bridge: a) Main girder size (Section: Height x Width) b) End carriage size c) No. of LT wheels d) Wheel base e) Wheel span
42. LT wheel a ) No. of wheels b ) Diameter of wheel c ) Rail Size d ) Wheel bearing size
43. Rail Clamps : a) Double bolt type b) Make : GANTREX c ) Model of rail clamps
44. Bridge drive a) No. of corner drives (4 nos.) b) No. of driven wheels c) KW of motor d) RPM of motor e ) No. of motors
45. Bridge drive gear box a) Type of gearbox - Horizontal b) Make c) Size/ reduction ratio d) Torque rating e) No. of reductions
46. Bridge drive coupling between motor & gear box a) Make & Model b ) Torque Rating
47. Bridge drive brake (Imported flame proof brakes) a) Model & Make b) Size c) Torque Rating
d) No. of brakes (each 1No. per motor)
70
48. Bridge drive coupling a) Make & Model b) Torque rating
49. Bridge drive shaft a) Diameter b) Distance between bearing supports c) Plummer block make
50. Bridge drive coupling between wheel & gearbox output a) Make and Model b) Torque rating
51. Bridge limit switches a) Make & Model b) Qty
52. Overall end carriage length
53. Overall Width of Crane
54. Torque rating of all motors 20% more than the calculated torque as per specifications.
55. The pull out torque of all motors shall be 2.75 times nominal torque.
56. VVVF Drive rating
55.1 Main Hoist (KW/ Current)
55.2 Aux. Hoist (KW/ Current)
55.3 CT (KW/ Current)
55.4 LT (KW/ Current)
57. Contractor ratings
58. Control voltage
59. Intrinsic safe circuit for push button station
60. Intrinsic safe Circuit for limit switches
61. IGUS Cable drag Chain for both bridge travel and trolley travel
62. Earthing as specified in tender document.
63. VVVF control positioning in separate identified room at ground level.
64. Laying of control cables from VVVF control room to the panels mounted on the crane.
65. Confirm that Basic price of crane quoted in price bid for Option – 1 i.e Main Hoist with Twin load path along with GA drawing.
66. Confirm that Basic price of crane quoted in price bid for Option – 2 i.e Single drive load path for Main Hoist along with GA drawing.
67. Confirm that Spare parts for two years trouble free operation is furnished with quantity and price (quoted separately)
71
S.No Item Description Unit Qty
I Electrical
1 Main Hoist - CUVC card No 1
2 Contact Kits for each power contactor above 63A Set 2
3 Auxiliary contactors No. 5
4 Semi conductor fuse (for each type) Nos. 3
5Lever type limit Switch (Two way lever / One way lever as
provided in the EOT crane)No. 1
6 Indication lamps Red, Yellow, Blue (Each) Nos. 2
7 Push buttons Nos. 6
8 Emergency push button with lock and key Nos. 2
9 Encoder for main hoist No. 1
10 Encoder for Auxiliary hoist No. 1
11 Intrinsic safety relay No 4
12 Brake MPCB w.r.t each rating (Each) No. 1
II Mechanical
13 Main hoist gearbox input shaft oil seals. Nos. 4
14 Aux. hoist gearbox input shaft oil seals. Nos. 4
15 CT gearbox input shaft oil seals Nos. 4
16 LT gearbox input shaft oil seals Nos. 4
17 Sealing rings for geared coupling (each type - 1no.) Set 2
18 Main hoist thruster brake springs Nos. 2
19 Aux. Hoist thruster brake springs Nos. 2
20 Main Hoist thruster brake shoes (1Set = 2 Nos.) Set 2
21 Aux. Hoist thruster brake shoes (1Set = 2 Nos.) Set 1
22 LT rail clamps Sets 10
23 CT rail clamps Sets 10
Annexure - 5
LIST OF SPARES PARTS TO BE SUPPLIED