ANNEXURE FOR DESIGN,SUPPLY,INSTALLATION AND COMMISSIONING,TESTING OF PLC BASED AUTOMATION FACILITY TO HARD ANODISATION WITH ZINC PHOSPHATING PROCESS

WITH TANKS ON TURNKEY BASIS

BIDDERS RESPONSE BIDDERS REMARKS COMPLIED / NOT COMPLIED

SCOPE OF SUPPLY
SL.NO. 1 DESCRIPTION MS Epoxy coated motorized Gate type Transporter with Drives : Qty : 1 set Details of Gate type transporter is as follows: 1.Drives with motors for up/down movement & reverse and forward movement. 2.Frame work made from MS epoxy coated grade with lifting capacity of 250 kgs. 3.Vertical up/down frame work made out of SS 304L grade the transporter for up/down movement. 4.Transverse end carriage made out of MS epoxy coated shall house the main driving & driven wheels and the cross traverse gearbox cum motor. 5.Set of traverse guide wheels shall made out of PE duly fitted with closed bearings for smooth movement and guidance. 6.Set of up/down wheels shall made out of PE duly fitted with closed bearings for smooth up/down movement. 7.The entire transporter control is through flat cables duly running all along the full length of line. 8.The entire transporter operation is controlled by the PLC using chemical resistant inductive proximity switches, limit switches etc. 9.Safety features like upper limit, lower limit, end limits, operator safety, emergency pull card system, emergency stops, collision free, end software and hardware limit switches etc shall be provided. 10. Proximity switches, electrical & mechanical limit switches shall be Omron/Schnieder electric/Siemens. 11.New flat cable and its sliding accessories supply and fixing for transport system from control panel. Flat cable make: Lapp/Helu cable for cyclic load applications 12.Providing of two loading stations at front side, one unloading station at the rear side.
Note: If there are any deviations from the tendered specifications please mention in remarks column. 1

ANNEXURE FOR DESIGN,SUPPLY,INSTALLATION AND COMMISSIONING,TESTING OF PLC BASED AUTOMATION FACILITY TO HARD ANODISATION WITH ZINC PHOSPHATING PROCESS WITH TANKS ON TURNKEY BASIS

BIDDERS RESPONSE BIDDERS REMARKS COMPLIED / NOT COMPLIED 13.Up/down movement shall be achieved by a slip free Nylon belts. 14.Play should not be there in the transporter sliding mechanism 15.Transporter feed rate shall be specified in the offer. 16.Pneumatic clamping for Flight bar during transporter movement. 17.Proper routing of the cable in the PVC box to be done for the entire running of the cable with necessary angular supporting 18.Provision of new short blasted MS railing for the movement of transporter for one side .the existing railing to be reconditioned (if necessary). 19.New V-saddle railing throughout cad/zn line for both the sides with proper MS supports with epoxy coating to meet the dynamic loads of automatic transporter movement from one place to other. 20.One loading station front side and one unloading station at rear side to be provided. 2 Program Control Cabinet : Qty 1 set Details of program control cabinet is as follows: 1.Centralized controlled cabinet shall be Rittal/Hoffman make duly powder coated to industrial standard (leak proof). 2.All electrical for transporter control, heating, cooling control, filtration system, controls will be Telemechanique. 3.OMRON/SIEMENS/HONEYWEL/ALEN BRADLEY PLC (* for quoted PLC support must be there from OEM) 4.Panel switches shall be Telemechanique.

Note: If there are any deviations from the tendered specifications please mention in remarks column. 2

ANNEXURE FOR DESIGN,SUPPLY,INSTALLATION AND COMMISSIONING,TESTING OF PLC BASED AUTOMATION FACILITY TO HARD ANODISATION WITH ZINC PHOSPHATING PROCESS WITH TANKS ON TURNKEY BASIS

BIDDERS RESPONSE BIDDERS REMARKS COMPLIED / NOT COMPLIED 5.Outgoing feeder for rectifiers (2 nos) (hard anod-2) and other electrical (6 nos) (2-for degreses,2-for passivations 2-for hot swill and 2 for phospating). 6.Heating and cooling control will be OMRON/Eurotherm temperature controllers mounted on the panel with calibrated thermocouples for temperature sensing. 7.Complete panel wiring, transporter flat cables and field wiring shall be polyurethane Lap/Finolex makes cables. 8.All the wiring shall be housed in cable ducts running along the length of cable line duly painted and earthed using copper flats. 9.Polycarbonate junction boxes shall be provided. 10.All the field wiring from junction boxes to the individual equipment shall be done using PVC sheeted multi core cables. 11.Auto rectifier control. 12.Provision of buzzer during alarms and messages, transporter movement with light indication. 13.All the electrical items viz relays, contactors, terminal blocks, fuses etc., must be of standard make. 14.The supplied PLC must have provision for extending the automation to other lines by adding necessary PLC hardware in future. 15.Color Front Panel view size: 9 for recipes running 16.Rectifier current and voltage display units for each rectifier Rectifiers controlling is either from the control panel/PC

Note: If there are any deviations from the tendered specifications please mention in remarks column. 3

ANNEXURE FOR DESIGN,SUPPLY,INSTALLATION AND COMMISSIONING,TESTING OF PLC BASED AUTOMATION FACILITY TO HARD ANODISATION WITH ZINC PHOSPHATING PROCESS WITH TANKS ON TURNKEY BASIS

BIDDERS RESPONSE BIDDERS REMARKS COMPLIED / NOT COMPLIED 3 PLANT MANAGEMENT SYSTEM: 1 Set Details of plant management system is as follows: It shall have: User friendly screens for easy access to the plating line parameters, all the real time data like temperature, rectifiers current, chemical maintenance, immersion times, loading unloading parameters, machine operation report, shift reports and on inline maintenance manuals shall be provided in the system. The plant management system shall be loaded in latest industrial PC interfaced with PLC. Saved programs calling facility for selected component and automatically setting up the preset currents required for the plating through the rectifier i.e. controlling the rectifier through industrial PC, necessary alarms and messages, hooter for alarms, messages, end of cycle. Laser printer shall be provided. PMS shall have auto, semiautomatic, manual mode operation of total line and its hardware , recipe screens, temperature monitoring & control screen, rectifier screen, troubleshooting and maintenance screens, MIMIC diagram of electroplating line showing real time transportation operation, tanks loading details, alarms & events, reports. The supplied software must have provision for extending the automation to other lines by adding necessary PLC logic in future. 4 HEATERS, CONTROLLERS, SENSOR: 1 set Heater controls shall be Omron/Eurotherm temperature controllers, RTD sensors. SS heaters for degreasing & hot rinse tanks : 8 nos, passivations & phospatings tanks shall have titanium : 8 nos, Party may indicate the wattage of heaters for four tanks. Wiring using cables from panel to the heaters etc. lump sum

Note: If there are any deviations from the tendered specifications please mention in remarks column. 4

ANNEXURE FOR DESIGN,SUPPLY,INSTALLATION AND COMMISSIONING,TESTING OF PLC BASED AUTOMATION FACILITY TO HARD ANODISATION WITH ZINC PHOSPHATING PROCESS WITH TANKS ON TURNKEY BASIS

BIDDERS RESPONSE BIDDERS REMARKS COMPLIED / NOT COMPLIED 5 Automatic Solid state SCR controlled RECTIFIERS : 2 nos SCR Includes. A).Air cooled rectifiers complete with main MCB, power on indication, digital DC voltmeter, digital DC ammeter, finely controlled set current potentiometer, single phasing and over current protection, fully solid state rectifier Rectifier shall be Associated powercon equipments India/equivalent Rectifier shall be supplied as a standalone unit with controls mounted on Front panel of primary controller. a) 0-100Volts, 0-500 Amps : 2nos( Ramp up current) B). Rectifier power cabling from rectifiers to tanks - lump sum 6 1. Copper V saddle with 100% conductivity: a) qty: 06 nos , 04 for fixing and 2 as spares with necessary PP pads/mountings. 2. 7 8 Transporter and flight bar loads shall be on V Saddle railing.

For all non plating stages, V saddle PP: a) qty: 44 for use 4 as a spares

i) Flight bars: qty: a) nos for present usage ii) SS316L flat bar guarding on top of each tank (2 places) for all tanks to avoid accidental slipping of flight bar/components during operation.

2 75 mm DC cable: Appx 400 mts

Note: If there are any deviations from the tendered specifications please mention in remarks column. 5

ANNEXURE FOR DESIGN,SUPPLY,INSTALLATION AND COMMISSIONING,TESTING OF PLC BASED AUTOMATION FACILITY TO HARD ANODISATION WITH ZINC PHOSPHATING PROCESS WITH TANKS ON TURNKEY BASIS

BIDDERS RESPONSE BIDDERS REMARKS COMPLIED / NOT COMPLIED 10 Supply of 2 years normal running spares: Rectifier fuses 3 sets, Heaters 3 sets, Temperature controllers- 3 nos, Relays 3nos, Nylon belts 1 set, PP wheels 1 set, Limit switches 2 nos, Proximity switches 3 nos, stand by CPU with all loaded software- 1 no, Maintenance and data transfer device1no.make:DELL/HP. 11 12 13 14 Split ACs, capacity: 1.5 TR make: Blue star/Voltas qty: 1 no. Two coats of epoxy painting on walk way ( MS Grating) and structure : 30sq.m Plating tanks : 22 nos including air dryer (please refer ANNEXURE-I) Air cooled Chiller: 02 nos. to maintain the bath temperature up to + 14 deg C for each 1000 ltrs Capacity, Make: Werner Finley/Reynold. Chiller consists of: Refrigeration unit, SS water storage tank of 1000 lits, water circulation pump for circulating water to cooling coil of Anodisation bath make: Grundfoss, digital temperature controller. Note: These chillers will be used for cooling the bath of another Anodisation line. 15 Extension of supporting & main railing system for gate type transporter.22.5 meters Supply and fixing of lip suction hoods and connecting to existing man scrubber duct qty: 22 nos(2 nos/tank) and carrying necessary FRP repair work.

16

Note: If there are any deviations from the tendered specifications please mention in remarks column. 6

ANNEXURE FOR DESIGN,SUPPLY,INSTALLATION AND COMMISSIONING,TESTING OF PLC BASED AUTOMATION FACILITY TO HARD ANODISATION WITH ZINC PHOSPHATING PROCESS WITH TANKS ON TURNKEY BASIS

BIDDERS RESPONSE BIDDERS REMARKS COMPLIED / NOT COMPLIED 17 Supply & fixing of pneumatic line Aprox.running length: 80 mtr to all cold rinse tanks from main line for air agitation. This agitation shall through an electrically operated solenoid valves. These valves shall switched on through PLC when flight bar going to dip in cold rinse tanks. Supply of Titanium (Gr-2 ) Fixers/baskets/Jigs for phosphating process qty: 20 nos. the Drgs are reference only. After P.O components will be issued for making jig/fixture/basket. Please refer Annexure - 2 & 3. Existing Air GI pipe line is available below the MS grating walkway. For 8 tanks UPVS(working pressure: 10 bar) piping supply and fixing with shut off UPVC ball valve for air supply to tanks for agitation. The pipes to be run inside the tanks for agitation. Appx length of UPVC=100 mtrs. Supply includes UPVC pipes, L bends, ball valves Existing DM water line is available below the MS grating walkway. For 7 tanks UPVS(working pressure: 6 bar) piping supply and fixing with shut off UPVC ball valve for DM water supply to tanks. Appx length of UPVC=60 mtrs. Supply includes UPVC pipes, L bends, couplings, ball valves, proper clamping of pipes to tanks. For 21 tanks drain there peace heavy duty ball valves are to supplied and fitted. Connecting of outlet of ball valve to be given to existing effluent treatment drain line by means of UPVC pipe w.p: 10 bar, No of ball valves: 21 nos, pipe length: 30 mtrs, L bends, couplings etc

18

19

20

21

Note: If there are any deviations from the tendered specifications please mention in remarks column. 7

ANNEXURE FOR DESIGN,SUPPLY,INSTALLATION AND COMMISSIONING,TESTING OF PLC BASED AUTOMATION FACILITY TO HARD ANODISATION WITH ZINC PHOSPHATING PROCESS WITH TANKS ON TURNKEY BASIS

BIDDERS RESPONSE BIDDERS REMARKS COMPLIED / NOT COMPLIED At present 60 TR (voltas) & 40 TR(blue star) water cooled chillers are available for cooling of baths to -12 deg C. These chillers will cool ethylene glycol bath capacity: . Grundfoss make reciculating pumps are available for circulating the chilled ethylene glycol to baths. The same chillers are to be used for cooling the proposed Anodisation baths. Accordingly interconnecting piping has to be supplied and to be connected proposed to Anodisation baths. No of Tansk: 2 nos. Apx length of chiller pipe along with insulation, casing, flanges, and necessary hardware is 25 mtrs. The chillers mentioned at point: 20, are to be switched on and off using the supplied control cabinet. 2 chillers on and off push buttons to be provided. Ethylene glycol bath temperature is to displayed on control panel, on & off of ethylene glycol circulations pumps from the control panel. Switching on/off of cooling tower motors from control panel. Chillers and Motors switch on indication etc., are to be provided in the supplied control panel. For maintenance emergency push button interlocking to be provided to chillers & cooling towers.

22

23

24

SCOPE OF WORK
a. Dismantling of existing cantilever type transporter, supporting system , railing, disconnecting of existing heater control panels b. Dismantling of railing and supporting system, electrical wiring, and exhaust lip sections. c. Shifting of existing phospating plating tanks to out of EP. d. Installation and commissioning of new anodisation line with zinc process, Gate type transporter, Control cabinet, PC, installation of PMS system, interfacing of supplied rectifiers to automation system. Interfacing of all the supplied items. e. Installation of angular supporting structure of all the tanks as well as railings.

f. Installation of pneumatic line has to be provided from main line of compressor including pipes in cold rinse tanks.
Note: If there are any deviations from the tendered specifications please mention in remarks column. 8

ANNEXURE FOR DESIGN,SUPPLY,INSTALLATION AND COMMISSIONING,TESTING OF PLC BASED AUTOMATION FACILITY TO HARD ANODISATION WITH ZINC PHOSPHATING PROCESS WITH TANKS ON TURNKEY BASIS

BIDDERS RESPONSE BIDDERS REMARKS COMPLIED / NOT COMPLIED g. 2 Coats of epoxy coating of total anodisation plus zinc phospating line. h. BDL will provide power cable up to the main control panel supplied by the party and remaining all the cabling which are required for the automation work and interfacing of all the supplied hardware shall be in the partys scope. i. The total work has to be completed on turnkey basis as per direction of engineer in charge, the party has to supply/carried out at least 5 jobs of similar type anywhere in India and necessary document shall be submitted along with quotation. j. Layout drawing with PLC, transporter drawing, screens details, reports details, shall be submitted along with quotation. k. PDI shall be offered.

NOTE: PARTY HAS TO VISIT THE SITE (BDL,BHANUR) BEFORE QUOTE.

Note: If there are any deviations from the tendered specifications please mention in remarks column. 9