ANNEXURE TO TENDER NO.

DPS/MRPU/IGCAR/ENG/4539/PT-1064

TECHNICAL SPECIFICATION FOR DESIGN, MANUFACTURE, TRANSPORTATION, SUPPLY, ERECTION, TESTING AND COMMISSIONING OF 5T EOT CRANE AT FRTG/CG, IGCAR, KALPAKKAM.

INDEX
Sl.No. Description of file Page No. Section A (Tendering and Contract Conditions) 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 Scope of Work Location of Site Delivery Information to be Included with the Quotation Price Submission of Tender Submission of Drawings Approval of Drawings Purchasers Drawings Quotation Deviations from Original Tender Submittals Packing and Transportation Transport Limitations and Facilities Source of Equipment Operation and Maintenance Manual Sub-Contractors Quality Surveillance and Testing 01 01 01 01 01 01 01 02 02 02 02 03 03 03 03 04 04 04

Section B [Part I] ( Technical Specifications EOT Crane) 1.0 2.0 3.0 4.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 Scope of work Dimensional and major specifications of EOT crane Structural fatigue Design requirements Structural Bridge Girder End Carriage Traveling Trolley / Crab Drum Support Welding Access Hand Railings, Stairs and Ladders Walkways Repair Cages Guards Crane Gantry Stops Wheels Stoppers Hardware 06 06 06 07 07 08 09 09 09 10 10 10 10 11 11 11

Sl.No. 6.0 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 7.0 7.1 7.2 7.3 7.4 7.5 7.6 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0

Description of file Design requirements Mechanical Brakes Wheels and Rails Hook Hoist Rope Hoisting Drum Sheaves Gear Boxes and Shafts Flexible Coupling Electrical Requirements Push Button Pendant Box Limit Switches Down Shop Leads Electrical System Motors and other electrical equipment Grounding Inspection Platform Lubrication Spares & Tools Painting Workmanship, Materials etc Marking Safety Features & Controls Standards & Codes Applicable Inspection & testing Tolerances Drawings & Manuals Guarantee Preferred Makes of Equipment List of spares for 2 years of smooth operation maintenance List of tools and tackles

Page No. 11 11 11 11 12 12 12 12 13 13 13 13 14 14 14 15 15 15 15 15 16 16 16 16 17 18 19 19 20 20 20

Section C (Erection Specifications) 1.0 2.0 3.0 4.0 5.0 6.0 Scope Inspection of Site Superintendence and Labor Notices Sub-Contractors Co-ordination of Work 22 22 22 22 22 22

Sl.No. 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0

Description of file Layout and Measurements Sanitation Site Handling & Storage Equipment and Materials for Erection Access Roads and Temporary Building Accommodation and other Facilities Power Supply for Crane Erection Testing at Site after Commissioning Contractors Responsibilities for Installation

Page No. 22 23 23 23 23 23 23 23 24

Section D (Format for submission of Tender) 1.0 2.0 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4.0 5.0 6.0 6.1 Documents Validity Technical Particulars General Bridge Trolley Main Hoist/ Auxiliary Hoist Electrical Mechanical Shop Testing Facilities Erection of Crane at Site References and Proof of Ability Submission of Drawings/ Documents Price Price Schedule 25 25 25 25 25 26 26 26 27 27 27 27 27 28 28 29

Section E (Schedule of quantity & rates) Annexure I : Quality Assurance Plan Annexure II : Pre-engineering building details Annexure III : Crane reach diagram

SECTION-A Tendering and Contract Conditions 1.0 Scope of Work: The work covered by this specification consists of designing, manufacturing, inspection, shop testing, packing, transportation, installation and testing at site, placing in successful operation & guarantee of 5T EOT crane as per IS: 3177 & IS: 807 for High temperature electrorefiner (HTER) facility at FRTG/CG, IGCAR, Kalpakkam. 2.0 Location of Site The HTER site is located to north-west of CTD, IGCAR, Kalpakkam, about 80 Km away from Chennai in Tamilnadu. 2.1 Site Weather Conditions Weather condition at site is generally hot and humid. The air has traces of salt & sand as carry over. The ambient temperature varies from 17.5 0C to 43.6 0C. Relative humidity is 15% - 100%. Most of the rainfall is generally from Oct Dec. 3.0 Delivery The bidders attention is drawn to the fact that the tender is not likely to be considered unless the bidder can satisfy the purchaser that he can meet the delivery dates specified in the document. Bidders must be prepared to carry out the work with in time prescribed in the tender document. The equipment shall be delivered at site within 6 months of receipt of the purchase order. 4.0 Information to be Included with the Quotation The bidder shall submit all supporting information, technical data and specifications as required in the various clauses of Section D - Format for submission of tender, to permit the engineer to have a detailed comparison and evaluation of tenders without the need of request for further information from the bidders. 5.0 Price The tender shall be for the equipment manufactured in India and the price payable in Indian Rupees. All the bidders shall furnish their prices as per details given in Section E of this tender document, failing which the bid will not be considered further. Prices shall be fixed and valid till the supply of equipment is completed in all respects. 6.0 Submission of Tender Four (4) copies of tender properly with four (4) copies of all supporting information shall be submitted to, The Regional Director, MRPU, VI th FLOOR, SHASTRI BHAVAN, 26 HADDOWS ROAD, CHENNAI- 600 006. 7.0 7.1 Submission of Drawings The contractor shall forward four (4) sets of firm time schedule regarding procurement of material, manufacture, assembly, inspection, testing, delivery, Quality Assurance

plan in the shop floor, etc. within two (2) weeks from the date of placing the order by the purchaser. 7.2 Within four (4) weeks from the date of placing the purchase order by the purchaser, the contractor shall submit detailed drawings as follows: A general arrangement drawing (4 copies) indicating overall dimensions of the EOT crane, span, clearances, approaches, lift, orientation of various crane components, ratings of the motors, brakes, wheel loads, makes of all major bought out components DSL arrangement etc. Soon after placement of the purchase order, the supplier shall also furnish drawings indicating details of rail fixing arrangement of long traverse. A typical sketch indicating details of rail fixing is enclosed in Annexure II. The foundation bolts shall not be used for fixing the rail clamps. The following electrical drawings shall be submitted for approval. Equipment make and ratings shall be marked. a. Power wiring and grounding diagram. b. Control wiring diagram. c. DSL wiring scheme. d. Equipment layout, cable routing. 7.3 The supplier shall provide drawings not herein specified, but which may be necessary for a thorough understanding of the construction, operation and maintenance of the equipment. The supplier shall submit design calculations as well as analytical reports in support of the crane design to meet the specification and seismic requirements specified in the document. Approval of Drawings The above drawings and schedules when approved by the purchaser shall form a part of this tender. After the said drawings have been approved, the supplier shall furnish four additional sets of all final drawings including subsequent revisions approved by the purchaser. Any shop work done prior to the approval of drawing will be at the contractors risk and cost. The time consumed by the contractor in securing approval of drawings shall not be added to the time allowed for completion of contract. A period of up to 8 weeks should be anticipated for this item of procedure in the schedule. Approval of the contractors drawing by the purchaser shall not relieve the contractor from the responsibility for any error or omission therein or from any obligation or liability under the contract. Purchasers Drawings The work shall be carried out in accordance with the specifications and with drawings prepared by the contractor and approved by the purchaser. 10.0 Quotation Bidder shall quote for equipment strictly in accordance with the specifications, as per the Performa Schedule of quantity and rate in Section E and the quality assurance plan as in Annexure-1. The quotation should contain a price list of recommended spare parts separately

7.4

8.0 8.1

8.2

8.3

9.0

for two years trouble-free operation. The list should consist of wire rope, brake-liners, contactors, fuses etc. 11.0 Deviations from Original Tender Bidder is free to suggest modifications, if any, to improve the performance of the crane. However, such deviations if approved by the purchaser shall form part of the original tender. 12.0 Submittals 1. Submittals with quotations: The following documents shall be submitted along with the technical offer. General Arrangement Drawings and the schematic for electrical layout. Quality Assurance plan List of clients along with contact person name, address etc. List of deviations if any. Technical catalogue of bought out items if any. 2. Submittals after Purchase Order: The following documents shall be submitted within four weeks after purchase order placed by the purchaser and accepted upon by the supplier, for approval by the concerned Engineer-in-charge. The detailed General arrangement drawing of the crane containing all basic dimensions and vital particulars of the crane. These drawings should indicate the main specification, number and location of joints provided on the girder plates, CT rails etc. Structural calculation for girder, and carriage etc. and drawings of main load carrying members. General arrangement drawing of the trolley. Motor power and brake selection calculation. Wheel load & rail selection calculation. Hook selection and cross piece design calculation. Motor and gearbox selection calculation for creep speeds. Design calculation for selection of gears, brakes, wire rope, rope drum, sheaves etc. Individual drive assembly drawings for the hoist cross travel and long travel. Wheel skidding calculation. Gearbox assembly drawings with material of gear, pinion, module, bearing used etc if asked by purchaser. Arrangement drawing showing details of trolley power collection system Location and mounting arrangement of control panels, resistance boxes, rectifier units etc on the bridge. Drawings for control and schematic wiring shall be of A3 size. Packing and Transportation Bidder shall note that packing shall be in accordance with the instructions outlined. Each package shall be limited to the sizes and weights that are permissible under the existing rail and road limitations. Equipment shall be well packed, protected (against rain etc.) and insured against damage or breakage during shipment and delivery. Insurance if desired, shall be on the account of supplier.

13.0 13.1

13.2

13.3

Each package shall be properly labeled to indicate the type and quantity of material it contains, the purchase order no., its dimensions and weight and other necessary data to identify the equipment related to contract. Transport Limitations and Facilities It shall be the responsibility of the contractor to see that the equipment is delivered to site in packages of sizes and weights that are permissible under the existing rail and road limitations. The crane girder is a oversize consignment for a span of 18750 mm.

14.0

15.0

Source of Equipment Bidders are informed that the purchaser will provide no foreign exchange and the quote shall be in Indian Rupees only.

16.0

Operation and Maintenance Manual The contractor shall furnish to the purchaser after supply but before final acceptance, 4(four) copies of operation and maintenance manual in a suitable form for each equipment at no additional cost. The manuals shall contain operation and maintenance instructions as follows: i. Purchasers Purchase Order Number ii. Contractors equipment serial number iii. General information iv. Principal technical data v. Description of components with parts lists and sectional drawings vi. Operating instructions a. General b. Special operating instructions such as starting instructions, signals, etc. c. Operating limits d. Safety precautions vii. Maintenance a. General b. Lubrication (recommended lubricants & frequency) c. Inspection (with frequency) d. Dismantling the equipment e. Repair instructions f. Setting of critical clearances & adjustment viii. Recommended spare parts ix. Reference drawings including electrical control and power wiring diagrams

17.0

Sub-Contractors The contractor may sub-contract part of the work with approval of the the purchaser. The purchaser shall approve the sub contractor. The list of sub contractors should be declared at the time of tender, and subcontractor shall also be evaluated during tender evaluation. The contractor shall be responsible to the purchaser for all the work of the sub-contractors, if approved by the purchaser to sub-contract the work.

18.0 18.1

Quality Surveillance and Testing The supplier shall submit the Quality Assurance Plan (QAP) for the approval of the purchaser, and the final QAP shall be mutually agreed upon by the supplier and the purchaser. The purchaser or his authorized representative will carry out Quality Surveillance and Testing relevant to all aspects of the contract, for which purpose the supplier shall:

a) Allow access as per the QAP agreed upon, during the manufacture, testing and erection to: The premises in which the work is being carried out. The drawing and/or tooling involved. Gauges/instruments/testing equipment, etc. required for inspecting the work.

b) Produce an inspection plan to the purchasers satisfaction and notify him when the check- points on the plan are imminent to enable the purchasers representative to be present if it is so desired, as per the QAP agreed upon. It shall be noted that the primary responsibility of detailed Quality Surveillance rests with the contractor. c) All bought out items like motors shall be tested in the presence of Department representatives at respective manufacturers works, as per the QAP agreed upon. 18.2 Parts found unsatisfactory as to workmanship or material or design shall be removed by the contractor and replaced in a satisfactory manner acceptable to the purchaser or his authorized representative. Any modification of inspection procedure or acceptance of the work by the purchasers representative does not relieve the contractor from the responsibility of supplying the material in accordance with the requirements of the tender document. Inspection and tests shall be carried out as per requirements of the specifications governing the tender document. All material shall conform to the standards specified in the tender document. Proof in the form of certified test reports or mill certificates that the required tests have been carried out and their co-relation with the actual material offered will have to be proved by the manufacturer. If these are not available, then the contractor shall perform the tests at his own expenses. The following test certificates shall be provided: Wire rope break load test Hook proof load test Material test certificate for main girder (chemical analysis & physical test). Certificate of radiographic examination of LT girder welded joints as per IS 807 (20% of the tension butt joints shall be checked, test reports & radiographs to be produced at the time of inspection). Manufacturers test certificates for bought out items like brakes, reduction gearboxes, etc. The following tests shall be conducted prior to dispatch: Type and routine tests of all drive motors in presence of purchaser. Speed test, load cum overload test and deflection test. 18.5 Delivery must not take place until the purchaser has been notified and written shipping release of material is obtained.

18.3 18.4

SECTION B (Part I) Technical Specifications - EOT Crane 1.0 Scope of Work The work covered by this specification consists of designing, manufacturing, inspection, shop testing, packing, transportation, installation and testing at site, placing in successful operation & guarantee of following capacity EOT crane as per IS: 807 & IS: 3177 and other relevent applicable latest BIS Standards and amendments thereof with all necessary accessories & tools required for maintenance for HTER, FRTG/CG, IGCAR, Kalpakkam. 5 ton capacity EOT crane 2.0 Dimensional and major specifications of EOT crane Classification Crane to conform in general to Gantry type Material of construction No. of starts M 5 (Medium duty indoor) IS: 3177-1999 & IS: 807-2006 Steel Structure (Pre-engineered Building) As per IS: 2062 150 per hour Technical details 5 ton (Class: M5) Double girder box type 18750 ** 14000 mm 2500 mm (Rail height & working clearance included) 350 mm both side (crane shall be limited to 300mm from the centre of the rail) 1200mm Not more than 2250mm on each side 40000 mm LT 15/1.5 mpm CT 10/1 mpm Hoist speed 5/0.5 mpm 90 lbs/yd Shrouded copper conductor Not to exceed 1/ 900 of span. As per the standard As per IS 807 Twin drive motors Push Button Pendent type

Lifting capacity Type of crane Span in mm Maximum height of lift Over head clearance of crane Side clearance

Hook approach (on both sides) on CT Hook approach ends on LT Length of Bay Maximum desirable speed / Creep speed Type of LT track Down Shop Leads Maximum deflection of crane girder Camber Type of LT drive Type of control

(** Tentative, will be Confirmed During GA Drawing Approval)

3.0

Structural fatigue Crane loading will produce cyclic stress and induce fatigue failure in the metal; it shall be designed suitably after fatigue analysis taking in to account the effect of cyclic loading from construction and operating period as per the crane design standards.

4.0

Design requirements - Structural The Crane shall be a complete unit with bridge girder, end carriage for long travel, Crab (travelling trolley) for cross travel with rope drums, wire ropes, sheaves, drive units, brakes, rails and fixtures, rail clamps, end stoppers, buffers, conductors, all electrical equipment and control etc., to make the equipment complete in all respect. For main load carrying members only shop welded and site welded connections shall be used. In case turned and fitted bolts are used, all the holes shall be reamed with the matching parts at the shop before dispatch. For side alignment of motors, strong adjustable screws with lock nuts shall be provided. All butt welded joints of load bearing members in the tension zone shall be 100% tested radio graphically. In addition 20 % of remaining butt welded joints shall be tested radio graphically. Plates, bars, angles and where practicable other rolled sections used in the load bearing members of structures shall not be less than 8 mm thick. Steel tubes, if sealed at the ends shall not be less than 4.9 thick and if unsealed, not less than 8mm thick. Splice shall be designed to resist all the forces and moments to which it is subjected to plus 50% thereof. However, in no case the strength developed by the splice shall be less than 50% of the effective strength of the material spliced. Splices shall be proportional and arranged so that the gravity axis of the splice is in line with the gravity axis of the member joined so as to avoid the eccentricity of loading. Chequered plates for platforms shall not be considered to share loads with the loads carrying members. Every platform shall be provided with double tiered hand railings having a minimum height of 1 m and toe boards, unless parts of the crane structure provide safety. The platform shall be of sufficient width for carrying out normal maintenance work smoothly. Minimum thickness of chequered plates for platforms shall be 6 mm over plain for the crane. Hand rails shall be of minimum 42 mm OD steel pipe.

5.1

Bridge Girder

5.1.1 Plate girders, boxed construction, all welded and radio-graphically tested as per specifications (20% of longitudinal joints to be radio-graphed randomly) & made of M.S and tested quality as per IS 2062. The girder fabrication shall be checked by radiography and ultrasonic inspection as appropriate, to ensure the absence of lamellar tearing in the base metal and the surrounding weld metal. All weld joints whose failure could result in the drop of critical load should be examined using any of the approved NDT methods. The girders shall be provided with suitable lifting lugs for ease of erection at site. 5.1.2 The girder shall be provided with maintenance platform made out of MS chequered plate with rubber mat covering at Drive side of the crane. Girders shall be suitably cambered. The bridges shall not deflect more than 1/900 of span with safe working load on the trolley, with trolley stationed at mid span and excluding deflection due to

dead load. There shall be no permanent set when the crane is loaded with 1.25 times the safe working load. Box girders shall be so constructed as eliminate accumulation of water or oil inside them. Where specified, welded box girders shall be provided with breathing holes to allow for expansion or contraction of air due to temperature changes. For outdoor cranes, special care shall be taken to eliminate crevices or openings where water may accumulate and cause corrosion. The bridge girders shall be connected to the end carriages by gusset plates. The bridges girders shall be attached to the end carriages by riveted or welded connection if the end carriages are built up in two pieces or by turned fitted bolts in case of one piece end carriage. The main girders shall extend over the whole width of the end carriage and the extension shall have sufficient section to take the maximum reaction and moment. Number of welded joints in a web or flange plates of the girder shall be restricted to 2 numbers for girders up to 24 m span. Match marks shall be provided on each girder to facilitate erection and squaring of the bridge. Load testing purpose one hook shall be provided at the centre of the end carriage Both the girders shall carry track rails, wheel stoppers for the CT trolley to run. Access walkways with neat hand railings are required along the full span length of drive side bridge girder. Gaps between hand railings shall be so designed as to prevent accidental fall of persons through them. 5.2 5.2.1 End Carriage End Carriage shall be of rigid box-section design. Tolerances in the crane girder connection shall guarantee high inherent rigidity and optimum travel characteristics with minimum wear. It is connected with bridge girder at the two ends. The girders with gusset plates shall be set on the end carriages and joined with fit bolts in reamed holes. All bolts and nuts used in the structural components shall be of high tensile steel quality and shall be used with proper washers. Anti derailment lugs shall be provided on the LT frame. Travel wheel arrangement shall be precise and exactly matching to the crane span dimension. End Carriage design shall be such that it facilitates easy removal of the wheels for maintenance. Suitable jacking pads shall be provided for maintenance and easy removal of crane wheels. The wheels shall be double flanged and shall be machined on their treads to match the runway rail section. Wheel base and structural frame of the end carriage shall be designed and connected with bridge girder in such a way that the crane remains square and skewness is prevented. The ratio between wheel base and crane span shall be as stipulated in IS 807. Twin drive is to be used for LT motion. The motors should be tripped based on differential speed in case of skew movement between the wheels. Hard rubber buffers shall be provided on both sides of each end carriage. Preferred material of the buffer is DPZ cellular plastic, the energy absorbed by which increases with the increase in the speed of impact due to polytrophic compression of the gases in the cellular structure. The end carriage shall be amply strong to resist all stresses likely to be imposed on them under severe service conditions, including collision with other cranes or stop. The end carriages shall be of sufficient width and their length shall be such that no other part of the crane is damaged in collision. Unless otherwise specified the wheel base shall not be less than 1/5th of the span. On the end carriages with more than two wheels, the wheel base shall be taken as the distance between the centres of the outside wheels.

5.2.2

5.2.3

5.2.4 5.2.5

The end carriages shall be fitted with substantial safety devices to prevent the crane from falling more than 25 mm in the event of breakage of a track wheel, bogie or axle. These safety devices shall not interfere with the removal of wheels. Suitable jacking pads in a height of 350 mm from rail level shall be provided on each end carriage jacking up the crane with changing track wheels. Jacking pads shall not in any case interfere with the replacement of track wheels, but located as near to the wheels as possible. 5.3 5.3.1 Traveling Trolley /Crab Trolley frames shall be fabricated from steel plates. The structural framework carrying mechanical and electrical equipment shall be fitted with stiffening plates of adequate thickness. The trolley shall be provided with chequered plate platform with openings for ropes, sheaves etc. Hand railing shall be provided all around the platform. Suitable jacking pads shall be provided for maintenance and easy removal of wheels. Hard rubber buffers shall be provided on both side of Trolley (4 corners). Trolley frame shall be fabricated in one assembled unit within the scope of transport limitations. Drum bearings and supports for upper sheaves shall be so located that the load on each of the trolley wheels shall be as nearly equal as possible. The trolley shall be fitted with substantial safety devices to prevent the trolley from falling by more than 25 mm in the event of breakage of a track wheel, bogie or an axle. These safety devices shall not interfere with the removal of wheels. The trolley frame should be so built up that a required clear head room is available over the top of trolley platform from the bottom of roof beam. Drum Support Proper support of the rope drums is necessary to ensure that they would be prevented from falling or disengaging from their braking and control system. The load-hoisting drum on the trolley should be provided with structural and mechanical safety devices to limit the drop of the drum and thereby prevent it from disengaging from its holding brake system if the drum shaft or bearings were to fail or fracture. Welding Welding procedure and performance qualification shall be carried out as per IS 816/ ASME section-IX (latest). No welding shall be undertaken unless welding procedure (including heat treatment, if any) is approved by the Department and duly qualified. All welders shall be qualified as per ASME codes in the presence of department personnel and only such qualified welders shall be allowed for carrying out this job. 5.5.1 E 7018 electrode manufactured by a reputed company shall be used for arc welding. 5.5.2 All lateral welding of main plates of box girders shall be butt welded. The butt welds shall be 5tested by radiography and test report shall be submitted to the Department for approval. Minimum 20% of the longitudinal joints shall be tested by random selection. In addition, each welding pass shall be subject to liquid penetrant examination and the reports shall be submitted. The root welding of the plates shall be done in presence of the quality assurance personal assigned by the purchaser or as per the QAP. 5.5.3 All welds shall be free from defects like blow holes, lack of penetration, slag inclusion etc. The contractor shall be responsible for the quality of work performed by his welding group. 5.5.4 The welding procedure shall include relief to minimise residual stresses in accordance with good practice for crane manufacturing. 5.5

5.3.2 5.3.3 5.3.4

5.4

5.6

Access Hand Railings, Stairs and Ladders Suitable access shall be provided from the main girders to the crab. Inspection walkways shall be provided at the end of the bridge for the maintenance of hoist, control panels etc. Safety hand railings preferably of tubular construction shall be provided around all accesses on bridge footwalks, crane gantry footwalks, end carriages, staircases, landing in cabin, trolley etc. Railings shall not be less than 1000mm high with an intermediate railing at height of 500mm. Ladders shall be provided at the following locations: a) Crane walkway to crane gantry b) Crane walkway to wheel inspection platform where provided c) Crane walkway to power collector inspection platform d) Trolley floor to crane walkway Besides these, ladders shall be provided wherever else found necessary. All edges or openings shall be provided with toe guards. Toe angles or bent plates wherever required shall be 100mm high minimum. Walkways Access walkway of minimum 550 mm clear inside width with hand railings on both sides of bridge girder for the full span length for inspection and maintenance of the crane shall be provided. Walkways shall be of chequered plate or non-slip steel surface of minimum 6 mm thick. Walkways shall be of rigid construction and designed to sustain a distributed live load of not less than 3 KN/m2. Walkway platform shall be complete with hand railings, posts and toe plate all around. The hand railings shall consist of 32 mm NB pipe in two (2) tiers. Top pipe shall be at about 450 mm height from the walkway platform level. Posts shall be spaced at 1.5 m maximum centres. Toe plate shall be 6 mm thick and shall project 100 mm above the walkway platfor;m. Ladders shall be provided to reach the walkway platform from the operating floor. Ladder shall be at least 450 mm clear width with 20 mm diameter rungs spaced at a pitch of 300 mm and shall be equipped with safety cages when the ladder is more than three (3) M high. One ladder for access from the crane girder walkway to long travel walkway on each side of crane span shall be provided

5.7

5.8

Repair Cages Repair cage shall be provided on the inside of the end carriage for attending to the current collectors. The cage shall be of structural steel and shall be made substantially rigid by gusset plates and braces, welded. Guards All gears and chain drives shall be completely encased. All moving parts, which may constitute a hazard, shall be guarded. Guard shall be provided on the bottom blocks of the hooks where the wire rope enters the bottom block to prevent trapping of hand.

5.9 5.9.1 5.9.2

10

5.10

Crane Gantry Gantry will be made of steel structure and the building is a pre-engineered building. An IBeam or suitable structure shall be provided by the purchaser for mounting of the LT rails. The crane supplier shall quote for suitable full-length base plate (16 mm thick minimum), nuts, LT crane rail, fish plates, clamps, washers, shims, stoppers and all hardwares. Stops Wheels Stoppers Bridge and trolley stops shall be provided with ramp type mechanical stops on the LT and CT rails to prevent the bridge and trolley from running off. Stops shall be curved to encase the rail wheels. Hardware All screws, bolts and nuts shall be made of high tensile steel. All bolts likely to loosen due to vibrations must have lock-wires/ locknuts. Design requirements - Mechanical Brakes The hoist shall be provided with two independent full capacity brakes. One set of brake shall be DCEM shoe type, while other one shall be hydraulically operated thruster brake. The brakes shall be of fail safe design and shall be operated automatically when the driving motor stops. Out of the two brakes, one shall be provided on the gearbox input shaft and other on the motor side. For cross travel and long travel, electromagnetic shoe brakes shall be provided on the highspeed side of the gearbox. It shall be located on the input shaft or extension of the input shaft of the gear reducer. Hoisting brakes shall be designed to hold 1.5 times full load torque while cross travel and long travel brakes shall be designed to hold full load torque. All the brakes shall have weatherproof enclosure. Brake lining shall not be subject to more than 80% of rated lining temperature. Coupling halves shall not be used as brake drums. Integrated electronic modules may be used for fast-acting of brakes. The provision for brake over ride shall be available for manual release of brakes in a safe manner for lowering of load in case of black out. Wheels and Rails Bridge and trolley track wheels shall be of C55 Mn75 steel with cylindrical straight tread. The steel shall not contain more than 0.06% of either Sulphur or Phosphorus. The minimum hardness of the wheel rim shall be above 300 BHN. The wheels shall be mounted in such a manner as to facilitate easy removal and placement. All track wheels and trolley wheels shall be machined to suit the contour of the rail. Anti-derailment arrangement shall be provided at CT & LT wheels. Preferred material used for wheel blocks is Spheroidal Graphite GGG 70 cast Iron for its high inherent dampening. The design shall be simple and maintenance free to reduce downtime. Rail section used shall conform to IS 3443. ISCR 90 rail shall be used for the crane. The level and parallelism of the rails will be checked by optical instrument after the erection. Hardness of the rail shall be marginally lower than wheel hardness. Hook Hooks shall be solid forged heat treated alloy or carbon steel point hook with rugged construction. Lifting hook shall be plain shank type conforming to IS 15560 and shall be provided with ball or roller thrust bearing, mounted on heavy cross head trunion to provide 3600 swivel supported on guarded sheave casing. Safety latch is to be provided to avoid

5.11

5.12

6.0 6.1 6.1.1

6.1.2

6.1.3

6.2 6.2.1

6.2.2 6.2.3 6.2.4

6.3 6.3.1

11

6.3.2

slippage of slings. The proof load Test certificate shall be provided as per IS 3815. The surface of the hook shall be subjected to ultrasonic examination also for detection of crack as per IS 15560. Hoist Rope Hoisting rope shall comply with IS 2266 and shall be extra flexible, improved plough steel rope with lubricated hemp core. The rope shall be fastened to the drum with an attachment having strength equal to that of rope. Adequate redundancy shall be provided in fastening arrangement. Rope shall be of sufficient length so that two full laps remain on the drum at the lowest position of the hook. Reverse bends and cross bends are to be avoided. Minimum four fall arrangement shall be provided. The braking load for hoist rope shall not be less than six times the calculated load on the rope at the drum (based on the summation of rated load on hook, weight of the bottom block and weight of the rope). Manufacturers test certificate shall be provided. In the absence of linkable test certificate they will be subjected to test at a reputed laboratory. Hoisting Drum The construction of rope drum shall be as per IS 3177. Drum shall be designed such that there is no overlapping of wire rope. The drum shall be of seamless. Drums shall have grooves of a proper shape and size for the rope used. Grooving shall be of proper length to handle entire rope required to make the specified lift plus the three dead laps at each anchor point, without overlapping. Sheaves Material for sheaves shall be as per IS 3177. The sheave bearings shall have adequate lubrication. Sheaves shall be fully guarded so that rope cannot come out. Load block shall be preferably closed type permitting generous lubrication of wire rope. A flange shall be provided at hook opening to prevent dripping of oil/ grease. All sheaves shall have guards which fit close to the flange having a clearance not more than 1/3rd rope diameter between the guards and the sheaves. Gear Boxes and Shafts All gears and pinions shall be accurately generated by hobbing to shape and finish acceptable to the Department. Gears shall be manufactured from rolled or forged steel solid blank. Helical spur gear shall be used for silent operation. All gears shall be totally enclosed type in enclosures which must be dust proof and firmly sealed to prevent oil leakages. Suitable oil indicators shall be incorporated. No open gears shall be used anywhere. All gear boxes shall allow easy opening for inspection, oil changing and maintenance. Gearboxes shall be run with oil for about 12 hours prior to fitting the same in the crane. Oil and burrs falling out of the above run shall be drained and flushed out before fitting on the crane with fresh oil. The oil used shall be crane duty gear oil with high viscosity. Gears and shafts shall be subjected to ultrasonic examination. Shafting shall be turned from solid rolled or forged steel bars. Small shafts may be of cold rolled steel. Epicyclic gearbox shall be used for obtaining the micro-speed in the crane. Fasteners, keys, coupling etc shall be with 25 % additional safety margin. All the parts like gear, shaft, and gearbox etc. should be tested ultrasonically. Electrical Requirements
12

6.4 6.4.1 6.4.2

6.4.3

6.5 6.5.1 6.5.2 6.5.3

6.6 6.6.1 6.6.2

6.7 6.7.1

6.7.2

6.7.3

6.7.4 6.7.5 6.7.6 6.7.7 7.0

All the electrical system and equipment shall be provided as per IS: 3177. The crane is to be designed for operation with input power from 415 V, 50 Hz, and effectively grounded 3-phase supply. a. All controls of the crane shall be from the operators cabin. It shall have a height not less than 2000 mm. The cabin shall be placed / fixed to the main crane bridge so that the operator shall have unrestricted view of the load and as far as possible a clear view of the surroundings. b. The hoist, crab, bridge controls shall be suitable for reversing heavy-duty service. The controls may consist of magnetic contactors, protective relays, etc. in enclosures (IP54) mounted in an easily accessible position. 7.1 7.1.1 Push Button Pendant Box All controls of the crane shall be operated from push button pendant station mounted on the trailing girder of the bridge. Pendant station shall be provided with separate tracks and be capable of movement along the girder independent of the crab position. The pendant shall be supported by chrome plated chain in such a way that load does not come directly on the cable. The pendant shall have Mushroom type Emergency Stop button, lockable key and Power On indicator lamp. Selectable horn/ buzzer shall be provided on the pendant to enable operator to alert nearby persons when crane is working. It has a two speed provision for Hoisting, Long travel and Cross Travel. It is important that the markings for various movements of crane on push button pendant box and also in crane are not confusing during operation. Contractor shall submit the design of box and scheme of marking for approval of the Department before manufacture. Provision of local operation from control panel shall be available after disabling the pendant during maintenance. Limit Switches Preventing over hoisting (Gravity Limit Switch) Preventing over lowering (Rotary Limit Switch) The crab for both the ends of the cross traverse The bridge for both the ends of the long travel b. Necessary tripping levers shall be provided for fitting at both the ends of the gantry for long travel and cross travel. c. All limit switches shall be of self-resetting type and easily accessible for maintenance purposes. c. Hoist limit switches - One in power circuit - One in control circuit 7.3 Down Shop Leads 7.3.1 Supplier shall quote for supply and erection of shrouded copper conductor type DSL for the specified bay length, brackets, insulators, etc, Suitable MS plates and DSL brackets shall be fixed by the bidder at about 1000 mm intervals. A drawing showing DSL arrangement shall be submitted for approval. Suitable guard shall be fitted on the crane bridge to prevent accidental contact with DSL. 3 phase indication lamp shall be provided at the DSL.

7.1.2

7.1.3 7.1.4

7.1.5 7.2

a. Limit switches shall be provided for:

13

7.4

Electrical System

7.4.1 Electrical system of the crane shall meet the electrical requirements of IS: 3177-1999 under section-3 on Motors, Electric braking, Crane control, Protective equipment, Isolator, Limit switches, Cables, Conductors, Auxiliary Conductors, Current calculators, Earthing and Electrical equipment loaded on the bridge.
7.4.2 Further protection shall be provided in the crane protection control panel:

i) ii) iii) iv) v) vi)

Triple pole main isolator with HRC fuses. Triple pole main contactor panel with no volt coil. All contactors and overload relays shall be suitable for the crane duty like high switching frequency hoisting and inching application. Thermal Overload trips in all phases of each motor. Voltage sensing type single phasing preventor for all motors. External lamp to indicate that the main power is ON and a 24 volts portable inspection hand lamp with sufficient length of T.C. PVC insulated and PVC sheathed cable and LV transformer.

vii) Grounding: Proper double earthing for crane motors, control panels and both LT rails shall be provided as per the IS 3043. viii) Control voltage shall be 110 V AC derived from main supply by introducing a control transformer. ix) x) xi) Control circuit of each motor shall be provided with independent fuses. Triple pole isolator with HRC-fuse unit shall be provided in the bridge in addition to the panel incoming switch fuse unit. Phase failure cum under voltage relays shall be provided in each motor in addition to the normal relays.

xii) Control cables shall be 1100V, 90C rating with standard annealed tinned copper conductor having high conductivity, FRLS PVC insulation, extruded PVC inner sheathed, armored and extruded FRLS PVC sheathed cable. xiii) Power wiring shall be 1100V, 90C rating with standard copper / aluminum conductor, XLPE insulated, FRLS PVC inner sheathed, steel wire armored and over all FRLS PVC outer sheathed cables. 7.5 Motors and other electrical equipment a. All the equipment shall be designed for operation in tropical humid atmosphere with ambient temperature of 500C. b. The electrical equipment to be supplied shall be suitable for an electric supply of 415 V, 3- phase 50 Hz as per latest IS. c. All the main motors shall be 3 phase induction motor TEFC crane duty type either of Siemens/Bharat Bijlee/SEW/Demag make only (IP-54). Rating shall be of 30 minutes duration. d. Motors shall be designed for class F insulation with CDF value of 40 % minimum. They shall be suitable for plugging and jogging application. e. All the motors to be fitted with ball or roller bearings.

14

f.

Termination ends of wire/cables shall be with crimped tinned copper lugs for easy connection and disconnection. Letter/Number ferrule shall be provided as per the approved drawings.

g. Grounding connections shall be of copper conductors of adequate capacity and conform to IS: 3043. Cable glands and rail joints shall also be earthed. h. Power wiring shall be 1100 V, 90C rating with standard copper / aluminum conductor, XLPE insulated, FRLS PVC inner sheathed, steel wire armored and over all FRLS PVC outer sheathed cables. i. j. Stud type terminal with nut and washers shall be used for terminal box. The buzzer shall be provided on crane with push button to signal, while crane is on the move.

k. Hoists shall be provided with dead weight type limit switch as second stage protection and it shall be in power circuit. 7.6 Grounding. Crane structure, motor frames and metal cases of all the electrical equipment including metal conduits shall be effectively grounded. Both LT rails of crane shall be grounded separately by suitably size copper conductors. Inspection Platform The platform on the crane bridge, shall be not less than 760 mm in width and with suitable hand rails of height 1000 mm (min) for easy access to various items, viz., gear box, shaft, rope drums, electrical panels, etc., fixed on the crane structures. For attending to LT wheels on nondrive side, two short platforms shall be provided. 9.0 Lubrication The crane shall be provided with a lubrication arrangement, i.e. it should be easier for the operator to lubricate the various parts from a few grouped lubricating points. The supplier shall supply first charge of lubricant. All the lubricating points shall be easily accessible and clearly marked for easy identification. 10.0 Spares, Tools & Tackles 10.1 The Manufacturer shall supply at least one portable jack of adequate capacity for changing bridge and cross track wheels. For this purpose suitable lugs or pads shall be provided on end carriages at convenient locations to form jacking points. The supplier shall provide tools and tackles for normal maintenance and inspection. A list of these items with their cost must be furnished separately. A list along with their individual prices for spare parts sufficient for at least two years of normal maintenance shall be submitted along with the offer. Generally, the spares should include all items as listed in Sl no.21.0 & 22.0. Painting The structural parts shall be painted with two coats of high-grade red oxide primer after sand blasting. The final painting shall be done at site after the erection of the crane with the two coats of approved color paint (Deep orange to Code 506 of Asian Paints or equivalent). 12.0 12.1 Workmanship, Materials etc. Materials, processes and workmanship which are not specifically designated herein and which are necessary for the fulfillment of this specification shall be of good quality
15

8.0

10.2 10.3

11.0

and in accordance with the good practice pertinent to the manufacture of overhead cranes and hoists. 12.2 12.3 12.4 All materials shall be new. The material and workmanship throughout shall be of the highest quality that may be considered usual and suitable for such types of machinery and equipment. All castings shall be free from objectionable flaws and imperfection, machined true to a standard acceptable to the purchaser and shall be ultrasonic tested. All castings shall be spot faced for bolting. All structural steel works shall be accurately fabricated, true to line and free from warp or twist. No patching, plugging, shimming or other such means of overcoming defects, discrepancies shall be resorted to without permission of the purchaser. Marking The following information shall be permanently attached to the crane in the form of a metal nameplate or in some equivalent form: a) b) c) d) e) f) 14.0 Manufacturer's Name, trademark or other symbol of identification. Plant equipment number. Rated voltage, HP of motors, number of phases, frequency, etc. Wiring diagrams and instruction sheets shall be supplied with the equipment in form of proper stickers or labels to the interior of the cabinet or enclosure. Maximum Critical Load (MCL) for main hoist and auxiliary hoist. Design Rated Load (DRL) for main hoist and auxiliary hoist shall be painted boldly on both the girders and hooks.

12.5 12.6 13.0

Safety Features & Controls Other than the special safety features, instrumentation and controls shall be provided as per standard industrial practice. The crane shall be provided with mechanical and electrical safety devices like end stoppers for both long and cross travel motions, limit switches etc., to shut off power to motors when the hook, trolley or bridge reaches the end of travels. In addition to this, over-speed and over-power controls shall also be provided. Over load protection shall be provided for all motors. All isolating switches shall be capable of being locked in OFF position. An emergency STOP push button shall be provided in the control station to stop all motions.

15.0

Standards & Codes Applicable The design, Manufacture and testing of the crane shall strictly conform to the codes and standards with latest revision wherever applicable. a) IS: 3177 -1999- Code of practice for design of over-head traveling cranes and gantry cranes other than steelwork cranes. b) IS: 807 -2006 -Code of practice for design, manufacture, erection and testing of cranes and hoists. c) IS: 816 -1969 -Code of practice for the metal arc welding for general construction in mild steel.

16

d) IS: 823 -1964 -Code of procedure for the metal arc welding for general construction in mild steel. e) IS: 1323 -1982 -Code of practice for oxy-acetylene welding for structural MS. f) IS: 325 -1978 -3 phase induction motors. Also refer NEMA g) IS: 4029,1231,2253,4691,4722,4728,12065 -Guides for 3 Phase Induction motors. h) IS: 7098 XLPE insulated PVC sheathed cables. i) j) l) IS: 13947 part 2 Circuit breakers. IS: 13947 part 3 Switches, disconnectors, and fuses. IS: 13947 part 5 Control circuit devices.

k) IS: 13947 part 4 Contractors. m) IS: 3043 -1987 -Code of practice for grounding. n) IS: 2208 -Specifications for HRC cartridge fuse links up to 650 V. o) IS: 3443 -Specifications for crane rail section. p) IS: 3815 -1969 -Crane hooks with shanks for general engineering purposes. q) IS: 2365 -1963 -Steel works, suspension ropes for lifts and hoists. r) Acceptance norms for EOT cranes -Interplant standard -steel industry IPSS: 2 02-002-83. s) AISE (STD no. 6) - General items for O/H cranes for components like drum, Reeving system, blocks, controls, electrical, mechanical & structural components. t) ASME- Testing, materials and mechanical components. u) ASTM- Testing and selection of materials. v) AWS- Fabrication requirements and standards for crane structure and weldments. w) SAE- For wire rope shafting, lubrications, fasteners, material selection, and load stability. x) WRC (Welding Research Council)- Control of Steel construction to avoid brittle fracture. (Note: Incase of bidders quote for their crane confirming to other equivalent like DIN/ISO and/or more stringent standards, the same shall be mentioned in the quote and the purchasers decision on acceptance of the quote is final). 16.0 Inspection & testing a. Quality Assurance Program should be established to include all recommendations of various standards for design, fabrication, installation, testing of crane handling system. The cranes shall be tested at manufacturer's works strictly as per IS & NUREG specifications and this tender specifications in presence of purchaser's representative. The tenderer shall furnish a detailed inspection plan for approval.
17

b. The geometrical accuracies of span, perpendicularity/ alignment of LT/CT wheels, diagonals etc. & the fabrication of structural components shall be strictly within the tolerances specified in the standards. The LT girders will be inspected before closing of 'U' box at the first stage. Similarly, purchaser will inspect the LT/CT wheel parallelism and verticality at suitable stages. c. The manufacturer shall furnish all test certificates for inspection as listed in the Technical Specification for various materials, workmanship and bought out components. d. The supplier shall arrange at their works, following tests as per IS to assess the performance of the crane at appropriate time: Deflection test at full load. It shall not be more than L/900. Full load test for hoist, cross/long traverse. Long traverse shall at least be shown in idle running Speed test of hoist, CT and LT. Performance test of all other components, like brakes, motors, gearboxes, bearings, shafts, couplings, etc. shall be clearly carried out during the testing. Insulation test of all electrical components. Cold proof test should be done for all structural members (Made of low alloy steel) and it should be followed by a nondestructive examination of critical areas for cracks. Test for material toughness is also required to avoid brittle-fracture tendencies. Type and routine tests of all drive motors. Test to qualify seismic criteria. Test for evaluation of structural fatigue.

e. The geometrical rail alignment for straightness and level shall be strictly within the tolerances as per BS 466:1985 f. All deficiencies/defects noticed at the time of inspection shall be promptly made up and rectified to the complete satisfaction of the inspecting engineer.

g. The crane shall be given clearance for shipping only thereafter. The contractor shall furnish all internal inspection records for perusal during stage /final inspection. h. All these tests together with overload test, insulation test shall be done again after erection of the crane at site. i. The equipment will be given full acceptance only after completion of erection, testing and commissioning as above. 17.0 Tolerances The cranes shall be manufactured within the tolerance specified below: a) b) c) Span over LT wheels Diagonal on wheels Trolley track gauge : + 6 mm up to 40 meters : + 7.5mm above 40 m. : + 5 mm : + 3 mm
18

d) e) f)

g) 18.0

Long travel wheel alignment (horizontal and vertical) Tilt of wheels or balancer axle Difference in height (H) between trolley rails in relation to the trolley track gauge (S) shall be with the following tolerances: Wheel load

: + 0.5 mm : + 0.25 mm : 4 mm - Up to 2,500 : 6 mm - 2,500 to 4,500 : 8 mm - Above 4,500

: + 3% of the calculated value

Drawings & Manuals The crane manufacturer shall submit following documents at time of delivery of crane: (4 hard copies and one soft copy of each document) a. Drawings General arrangement of the crane components with main Technical Specification Hoist gearbox assembly Bottom block assembly CT gear box assembly LT gear box assembly Track wheel assembly Wheel clearance diagram Wheel load diagram Electrical schematic connection diagram Complete crane wiring diagram Grounding diagram b. Manuals Erection, operating and instruction manuals (4 Copies) Spare parts list Recommendation for lubrication and lubricants Schedules for inspection and checking.

19.0 19.1

Guarantee The firm shall guarantee to replace or repair the faulty material or component free of cost during guarantee period of twelve months after the final acceptance certificate is issued. Conformity to design and to details set forth in the contractor's proposal and subsequently embodied in the written contract and in the working drawings approved by the purchaser, unless deviations are specifically authorized in writing by the purchaser. The firm shall guarantee the quality of all the materials and components entering into the completed work.

19.2

19.3

19

19.4 19.5 19.6 19.7

The firm shall guarantee suitability of all material selected for their respective duties and requirements. The firm shall guarantee the strength and suitability of all parts to withstand successfully the most exacting demands of test and service. The firm shall guarantee the successful performance of the equipment in accordance with the requirements of these tender documents. The firm shall guarantee the delivery, installation, commissioning and site testing of the equipment. Preferred Makes of Equipment Motor Brakes (DCEM) Brakes (EHT) Wire rope Hooks Couplings Gear & Bearbox Cables DSL TPN switches Fuses (HRC type) Bearings Contactors Relay (with negative Phase sequence protection feature) Timers Push Button Resistance Box GEC / Bharat Bijlee / Siemens / ABB / SEW/ Demag BCH / Stromkraft / Electromag / Speed-OControl/Demag Electromag / Magco Control / Crane Control/ BCH/Demag Usha martin / Bombay wire rope EE Karachiwalla / Karan Engineering Crane manufacturers own make Crane manufacturers own make Finolex / Universal / Polycab / Nico / Kamadenu / Lapp Safe track GE Power / Siemens make GEC / BCH / Siemens make Original SKF / FAG make L & T / Siemens / BCH Siemens / L & T / BCH

20.0

Siemens / L & T / BCH Siemens / L & T / Telemechanique / RAS Control Electromag / Speed-O-Control / Magco Control / Technical System / Crane Control

21.0

List of Spares for 2 years of smooth operation maintenance Sl No. 1 Item Description Brake lining with necessary rivets/screws/fixtures for each type of DCEM and HT brake Overload relay of each type Limit switches of each type HRC fuses links of each type Cup seals of each type of Thrustor Brake Indicating lamp of each type Qty Required 1 set

2 3 4 5 6

1 set 1 set 1 set 1 set 2 sets

20

7 8 9 10 11 12

Fixed & Moving contacts of each type of contactors Bearings for the motors Bearings for the Gear Box Oil seals for the Gear Box Wire Rope Fuses

1 set 1 set for each type of motor 1 Set 1 set 1 length One in each type of fuse used

22.0

List of Tools and Tackles Sl No. 1 2 3 4 5 6 7 8 9 10 Item Description Complete set of spanner Complete set of Screw Driver Complete set of Pliers (Insulated) Complete set of adjustable wrench Grease Gun Allen Keys Line Tester Hand Lamp Tool box Portable jack Qty Required 1 set 1 set 1 set 1 set 2 set 1 set 1 no. 1 no. 1 no. 1 no.

21

SECTION - C Erection Specifications 1.0 Scope The contractor shall erect equipment under this specification at the locations shown in the attached drawing. 2.0 Inspection of Site The contractor or his representative shall be deemed to have inspected and examined the site and surroundings before submitting his tender, and shall obtain the necessary information about risks, security procedure, contingencies and other circumstances which may influence or affect his tender. 3.0 Superintendence and Labor The contractor shall provide supervision of erection, which shall include without limitation employment of a competent erection supervisor who shall be constantly at site and shall give his whole time to the supervision of the erection of works and whose duties shall include the supervision of unloading, assembly, installation, repair and replacement of any damaged components or any operating adjustments. The contractor shall employ sufficient number of competent assistants to the erection supervisor to provide supervision in round the clock shifts, if necessary, to complete the work within the time specified. The contractor shall employ only such persons as are careful, skilled and experienced in their respective trades. A qualified safety supervisor shall be employed during the crane erection. The contractor shall ensure that the workers employed make use of safety gadgets like helmets, safety belts, etc. while working at heights. 4.0 Notices Any notice, order, direction or other communication to be given to the contractor under any provision of the contract shall without limitation be conclusively deemed to have been received by the contractor, if delivered, or mailed to the contractor at the address mentioned in the contract or to the contractors last known place of business or residence, or to his erection supervisor or foreman. 5.0 Sub-Contractors The contractor shall not sub-let the whole of the erection work. The contractor shall not sublet any part of the erection work, without the written consent of the purchaser. The contractor shall be responsible to the purchaser for all the work of subcontractors. All sub-contractors shall be bound to the contractor by the terms of the drawings and specifications and shall assume towards the contractor all obligations and responsibilities that the contractor assumes towards the purchaser. 6.0 Co-ordination of Work The contractor shall plan his operations so as to avoid interference with the operation of the purchaser, the civil contractor, or of other contractor or sub-contractors at the site. The contractor shall organize his work to suit the timings shown on the construction schedule or revision thereto, issued by the purchaser. 7.0 Layout and Measurements

22

The purchaser will layout basic building lines and establish datum but such layout shall not relieve the contractor of his responsibility for performance of work. The contractor shall provide necessary equipment for checking out layout and alignments and shall carry out and check all precision and detailed layout including setting and alignment of machinery. 8.0 Sanitation The contractor may use free of charge, the purchasers first aid facilities (First aid room and attendant) in the work area. The contractor at his own expense shall arrange all other medical and sanitary facilities. 9.0 Site Handling & Storage Site handling, storage of materials and equipment shall be incorporated in the works. The contractor shall unload and store the items at the site, at locations designated by the purchaser, until such times as required all materials and equipment to be incorporated in the works. The contractor shall be responsible for loading and transportation of the equipment/crane from the place of storage to the point of installation. 10.0 Equipment and Materials for Erection The contractor shall take into account the weight of components, height to which they are to be lifted and shall arrange for all necessary mobile crane, scaffolding, lifting tools, tackles, winches, welding set, gas cutting set, etc. required for erection and commissioning. The contractor is also be responsible for transportation of all erection equipment and materials to the site. 11.0 12.0 Access Roads and Temporary Building The contractor shall have the reasonable use of existing roads at the site. Accommodation and other Facilities The contractors lump sum erection prices shall include all traveling, transportation and accommodation costs of all his site forces including supervisory personnel. 13.0 Power Supply for Crane Erection 415 Volts, 3 phase and neutral, 50 Hz power supply will be given at one point by the department near the premises where the EOT crane has to be erected, free of cost. The contractor will provide suitable switch board/switches for receiving the power supply and to extend the same to equipment properly with 2 Nos. of earth pipe/pit and adequate interconnections. One switchboard with ELCB for portable appliance power supply shall be provided. The contractor, if required, shall carry out extension of power supply, in a safe and proper manner with the approval of the departmental engineers. The contractor shall follow all electrical safety rules and regulations in force at the time of erection. 14.0 14.1 Testing at Site after Commissioning Static and Dynamic Load Tests The EOT cranes shall be tested as per IS specifications at site after satisfactory erection. Testing will be carried out with 25% load in the first run followed by three runs with MCL (SWL). The crane should be static load tested at 125% MCL. The tests should include all positions generating maximum strain in the bridge and trolley structures and other positions as recommended by the designer and manufacturer.

23

After successful completion of the 125% static test and adjustments required as a result of the test, the crane handling system should be given full performance tests with 100% of the MCL for all speeds and motions for which the system is designed. This should include verifying all limiting and safety control devices. The features provided for manual lowering of load and manual movement of the bridge and trolley during emergency should be tested with the MCL. All the parameters like motor current, deflection of EOT crane girders, operation of the brakes etc. will be checked & shall be within the permissible limits. A detailed report and tabulation will be prepared and submitted to the departmental engineers for acceptance. Any deviation with the design intent will be rectified to the satisfaction of the department. The department will supply test loads and testing cradle free of cost. 15.0 Contractors Responsibilities for Installation The contractor shall: 1. Ship the equipment from the factory as fully assembled, as transportation conditions will allow. 2. Be responsible for any damage and costs resulting from badly and incorrectly installed equipment. 3. Co-operate with other contractors during the contract period and on the site in all matters of common interest in regard to the equipment being supplied under the respective contracts and ensure that all works are completed.

24

SECTION -D Format for Submission of Tender 1.0 Documents The tenderer is deemed to have examined all the parts of the tendering documents listed below and to have been fully informed as to the nature of work and the conditions related to its performance: Section A Section B Section D 2.0 Validity The offer shall be kept valid for a period of 90 days from the date fixed for opening of price bid of the offer. 3.0 3.1 Technical Particulars The tenderers should fig up all details as per the format for each crane. General tonnes tonnes tonnes tonnes mm Crane (For main hoist) 3.1.2 Estimated total weight of crane 3.1.3 Weight of the heaviest single piece (approximately) 3.1.4 Maximum deflection of the crane under full workload mm 3.1.5 Maximum wheel load on the crane rail excluding impact 3.1.6 Distance between wheel centers on end carriages 3.1.7 Impact factor adopted for design of bridge and trolley 3.2 Bridge 3.2.1 Material of construction 3.2.2 Type, construction of main girders 3.2.3 Diameter of wheel on end carriage & No. of wheels 3.2.4 Material of construction of wheels 3.2.5 Type & make of bearing used 3.2.6 Type of axle 3.2.7 Size and type of LT rail offered 3.2.8 Number and type of motor for bridge travel 3.2.9 Make of motor, HP, speed, class of insulation and rating 3.2.10 Make, type and rating of brakes mm 3.1.1 Safe Working Load (SWL) rating for EOT Tendering and Contract Conditions Major Technical Specification (Part I)

Section C Erection Specification

Format for Submission of Tender The format shall be filled up in detail. Incomplete offers will be rejected

25

3.2.11 Type of walkways and width including service platforms (900mm x 900mm) on either side 3.2.12 Operating speed 3.3 Trolley 3.3.1 No. of trolley wheels and diameter 3.3.2 Materials of construction of trolley frame and wheels 3.3.3 Type of axle 3.3.4 Type and make of bearings Used 3.3.5 Type of motor 3.3.6 Make of motor, HP, speed, class of insulation and rating 3.3.7 Make, type and rating of brakes 3.3.8 Type of trolley conductors 3.3.9 Operating speed 3.4 3.4.1 Specification Make of Motor Motor rating(hp/kW) Motor speed(rpm) Class of insulation Current(Amps) Voltage(Volt) Rating Enclosure Frame Frequency Efficiency Duty 3.4.2 Type of speed control provided, make & technical details. 3.4.3 Type of rope drum, pitch diameter length and material used 3.4.4 Number of falls 3.4.5 Type of hook and make 3.4.6 Whether of fully swiveling type with thrust ball bearing 3.4.7 Make, type and rating of brakes 3.4.8 Operating speed 3.5 Electrical
26

Main Hoist/ Auxiliary Hoist Main Hoist

3.5.1 Make and type of motors offered 3.5.2 Make and type of limit switches 3.5.3 Type and make of contractors, push buttons, overload and under voltage relays, etc 3.5.4 Type of control operation available at cabin (Off, On, Hoist Up/down, etc) 3.5.5 Deviation from main specifications, if any 3.6 Mechanical 3.6.1 Type and make of all gearboxes 3.6.2 Type and make of flexible coupling used in various drives 3.6.3 Make of bearings offered 3.6.4 Include general arrangement drawing with the quotation 3.6.5 Whether inspection facilities are available at works for radiographic examination, DPT, ultrasonic test of welded joints of girder and other critical components as required in the technical specification 3.6.6 Do you agree for carrying out all nondestructive tests of critical components as per specification 3.6.7 List of deviations, if any, with reasons 3.6.8 List of bought out Items 3.7 Shop Testing Facilities a. Deflection test for girders b. Full load/speed test for hoist and cross traverse c. Speed test for long traverse 3.8 4.0 Erection of Crane at Site References and Proof of Ability The bidder should furnish following details of EOT cranes of similar capacities supplied and commissioned during the last three years. a. b. c. d. 5.0 1. Clients name and full address (postal, email, contact name etc.) Capacity, type and quantity Committed and achieved periods of delivery, erection and commissioning Copies of performance report, if any Do you agree to furnish complete design calculations for selection of motors, brakes and main structural on placement of order along with general arrangement drawings for approval? Do you agree to submit seismic design calculations & test procedure for verification and approval? 3.8.1 Whether by sub-contracting or by having erection team 3.7.1 Whether following tests can be conducted at the works before shipment of crane:

Submission of Drawings/Documents

2.

27

3.

Do you agree to submit design calculations and test procedure for structural fatigue criteria, for verification and approval?

6.0

Price The price quoted shall be for delivery at CTD, FRTG, Indira Gandhi Center for Atomic Research, Kalpakkam, Tamilnadu. The offer shall be complete with all types of duties, taxes and other levies applicable at current rates. No foreign exchange / import license will be provided for this crane by the purchaser. The offer for erection shall be made seperately.

6.1

Price Schedule The bidder shall quote firm prices for crane and each item seperately. Prices for supply and erection of DSL, gantry rails, etc. should clearly reflect cost per unit length of bay or total cost.

28

SECTION E SCHEDULE OF QUANTITY & RATES Design, Manufacture, Supply, installation, testing & commissioning of the following as per detailed technical specification specified in Section-B (Part I). (Only main items of the tender have been brought out specifically in the schedule. However, all accessories required to complete the automation system is deemed to have been included in the offer) SL. No. 1.0 Description Qty Unit Rate (R) Amount (R)

5 ton cap EOT crane No.

a. Design, manufacture, testing at factory & 01 supply of 5 ton cap. double girder EOT crane as per technical specification in Section A Part I b. Supply of full length base/sole plates, 01 gantry rails (for 40 m bay length), clamps, fish plates, bolts, nuts, end stoppers, shims, etc. complete for fixing on Steel gantry for the specified bay length c. Supply of insulated down shop leads 01 brackets, insulators, etc. for the specified bay length. d. Erection of gantry rails, alignment, leveling 01 of base plates, etc. for the specified bay length. e. Erection of DSL for the specified bay 01 length f. Erection, testing (shop and site) and 01 commissioning of the crane. g. Supply of recommended spare parts. 01 (Attach separate list showing cost Item wise) 2.0 3.0 4.0 Supply of tools and tackles (Attach separate list showing cost Item wise) Transportation, delivery and unloading at site Duties, taxes, levies etc. as applicable Total cost 01 01

Set

Set

Set

Set Set Set

Set Set

29

Annexure 1 Quality Assurance Plan

Items / Classificati Components/ on Operation RAW MATERIAL Steel Plates Major Format of Record T.C

Sr. No (A) (a)

Type of Check

Quantum Reference Acceptance of Check Documents Norms IS 20622006

Agency P 1 W V 2 2

Remarks

(b)

Shafts

Major

(c )

Wheel (Forged)

Major

(d)

Sheaves

Major

(e)

Brake Drum (Seamless pipe) Gearing / Pinion (blnks)

Major

(f)

Major

Co-relation with 100% IS 2062Mfrs. TC if TC is not 2006 available then sample testing for chemical & mechanical analysis. Co-relation with Sampling Mfrs. TC if TC is not as per IS available then 2500 sample testing for chemical, mechanical analysis and UT testing 1 C55Mn 75 Co-relation with IS:1570 (Part II) -1979 Mfrs. TC minimum hardness 300 BHN Co-relation with Sampling IS-1030Mfrs.TC as per IS 1999 2500 Co-relation with sampling IS-1030Mfrs. TC as per IS 1989 2500 Co-relation with sampling IS-2707Mfrs.TC as per IS 1989 GR1 UT test 2500

EN-B BS970:1983

T.C

C55Mn 75 IS:1570 (Part II) 1979 IS-10301989 IS-10301989 IS-27071989 GR1

T.C

T.C

T.C

T.C

Sr. No [B] (a)

Items / Components/ Operation BOUGHT OUT ITEMS Hook & hook cross piece

Classificati on

Type of Check

Quantum Reference Acceptance of Check Documents Norms

Format of Record

Agency

Remarks

Major

(b) (c )

Wire Rope Motor

Major Major

Visual , UT, corelation with Proof Load test certificate from recognized test House Visual Operational & functional check Operational & functional check Operational & functional check

(d)

Brakes

Major

(e)

Limit Switch

Major

Plant / Design IS3815 1969, IS-57491970 1 IS 22661989 1 IS-325 -1978 Mfrs. Catalogue Sampling Mfrs. as per IS Catalogue 2500 Sampling Mfrs. as per IS Catalogue 2500 1 Mfrs. Catalogue

Plant / T.C Design IS3815 1969, IS-57491970 IS 2266- Mill T.C. 1989 IS-325 Routine 1978 Mfrs. test Catalogue Mfrs. T.C Catalogue Mfrs. Catalogue T.C

1 1

2 2

Final adjustment to be checked at site

(f)

Resistance Box

Major

Operational & functional check

Mfrs. Catalogue

T.C

[C] (a)

FABRICATED COMPONENTS Butt Weld

Major

Radiographic Test

(b) Final Inspection of Fabricated components (Girders, End Carriages Trolley)

Major

Dimensional & Visual Check

100% in ASME Sec tension IX zone, 20 % of remaining 100% As per drg

ASME Sec Radiogra 1 IX phic test

As per drg

I.R

To be checked at the time of Final Inspection

2

Sr. No

Items / Components/ Operation

Classificati on Major

Type of Check

Quantum Reference Acceptance of Check Documents Norms 1 Plant Design Plant Design

Format of Record T.C

Agency

Remarks

[D] CONTROL PANEL

Operational & functional check DIMENSIONAL

- 2.3

[E]

FINAL INSPECTION -AT WORKS

Major

Major

Major FINAL INSPECTION Major

Span. Diagonal & wheel base dimensions 100% OPERATIONAL (Without Load) Hoist Speed & Current measurement Operational checks for CT& Motion 100 % Load & overload testing 100 % 1. Speed & current measurement with load & without load for Hoist Cross Travel Long Travel Motion 2. All functional end operational 3. Deflection test at SWL (Safe Working Load) 1

Appd. G.A Appd. GA Drg. Drg. Relevant IS Relevant IS Appd. G.A Appd. GA Drg. Drg. Relevant IS Relevant IS

Test report Test report

2.

2.

IS 3177 1999

IS 3177 1999

Test report

2.

Appd. GA Appd. GA Commiss 1 Drg. Drg. ioning Relevant IS Relevant IS Report

2.

-AT SITE

Sr. No

Items / Components/ Operation

Classificati on

Type of Check 4. Over load Test (25%)

Quantum Reference Acceptance of Check Documents Norms

Format of Record

Agency

Remarks

Note: All test certificates shall be linkable to the item else the material to be identified and tested at approved laboratory. Incase of cranes manufactured and supplied meeting other standards like DIN/ISO/BS standards, equivalent stringent standards shall apply. LEGENDS: TC I.R. P W V Test Certificates Inspection Report Performed by Witnessed by Verified by Agency: 1. Main Supplier 2. Client / Purchaser

Note: After publishing the tender, if there is any change in specification, it will be published as corrigendum in the MRPU portal. Accessories, Breakup costs etc. if any, may be quoted online in the Price Bid Alternate Offer form.

Annexure - II

Annexure III
6