specifications cum compliance statement …...cable system as per the following specifications,...

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SL. NO. DESCRIPTION ISRO -SHAR SPECIFICATION VENDOR OFFER

Design, manufacture, testing, supply, erection,

commissioning and performance proving of 1Nos.

of Dual VVVF drive EOT CRANE [ 35t capacity

(flame proof)] Top running, double girder, along

SPECIFICATIONS CUM COMPLIANCE STATEMENT FOR SUPPLY OF EOT CRANES

Bidder shall completely fill the following format of technical specifications & supply conditions with the

mention of required details. If required Bidder can attach speperate sheets by giving point no. in 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. Mentioning "as per

enclosed specification" is not acceptable and Vendor shall submit all the specifications by filling in the

following FORMAT only.

Bidder shall submit complete information asked in the following specification (clause no.7.1 to 7.5).

The offer meeting all the requirements & conditions in all respects would only be considered for further

processing.

DNAME & ADDRESS OF

THE VENDOR :

Deviations with respect to specifications given below are not acceptable. However Bidder can submit /

suggest improvements, if any, seperately by indicating the caluse no. in this specifications.

1.1 SCOPE OF SUPPLY

(flame proof)] Top running, double girder, along

with LT bridge rails and Cable Drag chain power

cable system as per the following specifications,

conditions given below and also in accordance with

latest editions of IS: 3177, IS: 807 & relevant

codes and standards.

1.2

Third party inspection

is in the scope of

supplier

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. Supplier shall

engage third party inspection agencies like M/s

Mecons, M/s M.N.Dhastur, M/s Lloyds register, M/s

DNV . The finalization of third party agency shall be

done on mutual agreement between ISRO and

Vendor.

1.4 Application

These EOT cranes are used for handling of

dangerous / high value materials like rocket

motors, propellant containers, etc., for positioning

and assembly during process operations. In case

of any failure of crane, there will be loss to

property and life. Hence vendor shall design &

manufacture the crane with emphasis on quality,

35t x 18.65m Span EOT Crane : 01 no.

(flameproof)1.3

QUANTITY

REQUIRED

manufacture the crane with emphasis on quality,

reliability and safety and shall ensure smooth

operation of crane.

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1.5Usage period & desired

life of cranes

The crane will be put to use for 365 Days’

intermittent duty (Class II duty) with CT, LT and

Hoist movements. EOT Crane shall be designed

for minimum life of 30 years.

1.6

1.6.2 for 35t EOT Crane

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/IEC standards

1.7Operating Environment

of Cranes

Operating environment is indoor, near to sea (i.e.,

saline atmosphere), with ambient temperature

50ºC and with relative humidity 95% . Weather

conditions are tropical. Vendor shall consider above

while design of EOT crane enclosures & painting of

crane & related parts.

II .2

2.2.1 Type of CraneDouble girder top running, Flameproof, Dual VVVF

drive EOT Crane for Indoor use

Hazardous area conditions

MAIN PARAMETERS OF 35t EOT CRANE (FLAMEPROOF)

2.2.1 Type of Cranedrive EOT Crane for Indoor use

2.2.2 Class & duty

Structural Class-II duty (M5) duty as per IS807.

Mechanisms: Class-II (M5) as per IS 3177 of latest

edition

2.2.3 EOT Crane capacity 35 tons (35000 kgs)

2.2.4 Span 18.65 meters approximately

2.2.5Lift Height (above

ground)18.0 meters

2.2.5aDuty Factor (Cdf) for

flameproof Crane

As crane is handling dangerous materials Duty

factor (Cdf) of 1.7 shall be taken in design of

components in hoist motion.

2.2.6

i) Hoist in meters/minuteMain -2.5 / Creep 0.25 (Through VVVF Drives) and

one stand by redundant drive

ii)Long travel in

meters/minute

Main-3.0 / Creep 0.3 (Through VVVF Drives) and

one stand by redundant drive

iii)Cross travel in

meters/minuteMain-3.0 / Creep 0.3 (Through VVVF Drives)

2.2.7 Side clearance minimum 450 mm (distance from centre of gantry

rail to nearest obstruction )

2.2.8 Head Room available

4 meters (maximum) (Vertical distance from top of

gantry rail to lowest overhead obstruction) - Slant

Operation Speeds (maximum) in meters/min

2.2.8 Head Room available gantry rail to lowest overhead obstruction) - Slant

roof Building

2.2.9Distance from floor to

top of gantry rail~ 20.1 meters

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2.2.10 Bay length in meters 31 meters

2.2.11 CT DSL side/Non DSL side : 3/ 2.1mm

2.2.12 LT Drive side/LT Non-Drive side : ~ 4.5m / 3.5m

2.2.13 CT Wheel diameter Not lesss than 320mm

2.2.14 LT Wheel Diameter Not less than 400mm

2..2.15Location of VVVF Pnales

for 35t EOT crane

VVVF dual drive panles (One for main

operationand one for redundancy), DBR units,

other electrical panels shall be kept in

separate room in ground level at one corner

of building along crane travel . All the power

and control cables shall be routed from this

room to top of flameproof EOT crane.

2.2.16Total Weight of EOT

Crane Vendor to Specify

2.2.17Weight of Bridge Girder

Vendor to Specify

2.2.18Weight of End Carriage

Vendor to Specify

2.2.19 Weight of trolley Vendor to Specify

Hook Appraches

2.2.19 Weight of trolley Vendor to Specify

2.2.20Weight of Electricals/

Panels Vendor to Specify

2.2.21CT Wheel load in tonnes

Vendor to Specify

2.2.22 LT wheel load in Tonnes Vendor to Specify

2.2.23Size of Cross Travel

Bridge Girder Rail

Crane Rails as per IS 3443 only shall be used.

Vendor to specify Size of Rail, position of the rail,

MS palte, Bracket. (Please refer annexure -1)

2.2.24

Size of Crane gantry

rails for Long Travel -

part of Crane vendor's

scope

Crane Rails as per IS 3443 only shall be used.

Vendor to specify Size of Rail.

II

2.15 LT Drive

Central drive with Horizontal type, standard

gearboxes and floating shafts. Single drive with

wheeled motors can be used for cranes with span

more than 16 meters.

2.16Number of wheels for

LT drive4

2.18 CT DriveCentral drive with Vertical type, standard make

gearboxes and floating shafts

PARAMETERS FOR CRANE

2.19Number of wheels for

CT drive4

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2.21

Platform for approach

for maintenance of CT

drives

Required

2.22Type of bearings for

LT/CT wheelsAnti-friction, double row Spherical Roller Bearings

2.23Type of mounting of

LT/CT wheels"L" type brackets

2.24Creep/Inching speed

control

Creep speed 10% of main speed shall be provided

thorugh VVVF drives

2.25Operations required

through

One Floor operated Pendant and two pendents fixed

in the assembly platforms for independent

operation as shown in Annexure-2

2.26 Pendent

One number floor operated pendent shall be

movable type and two fixed on the assembly tower

(Refer:Annexure-2)

2.27 Duty cycle 60% CDF for all motions

2.34Clearance Diagram for

EOT crane

Hook approches and clearances are given in

enclosed figure & values shall be accomplished

3 MECHANICAL ELEMENTS DETAILS3

3.1 Factor of Safety

The design of all mechanical components shall be

done as per IS3177 and technical specifications

given and on the basis of ultimate tensile strength

with factor of safety of not less than 5.

3.2 Hoist hook type

Forged, Ramshorn hook with safety latch, swiveling

on anti friction Thrust Bearing, as per IS: 5749 /

1970 (latest version)

3.2a Hook specification

Rating: 40 tonnes (As per IS5749-1971, Table -1),

Dimenssions, material manufacturing and inspection

shall be as per IS standard IS 5749-1971. (load

testing shall be carried out as per IS)

3.2b Lubrication of hook

Structural Class-II duty (M5) duty as per IS807.

Mechanisms: Class-II (M5) as per IS 3177 of latest

edition

3.3Number of falls for

Hoist4

3.4

Rope Drum shall be of fabricated type of IS2062

steel with stress relieved or heavy duty seamless

pipe as per ASTM A106 . No circumferential weld

joints are allowed.

3.5Rope drum diameter shall be minimum 36 times the

diameter of wire rope.

Rope drum shall be provided with not fewer than Rope Drum

3.6

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. Grooves

shall be finished smooth.

Rope Drum

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3.7

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.

3.8 Hoist wire rope

M/s USHAMARTIN make, Hot dip Galvanized,

6X36, Hyflex wire rope, core IWRC, Grade 1960

MPa. Minimum Factor of safety on wire rope

shall be 6.

3.9 Rope Sheaves

All sheaves shall be of forged steel only. Sheave

diameters shall be minimum 24 times rope

diameter. Sheave guards shall be provided.

3.9 aBearings for Sheaves

/Pulleys

All the sheaves & pulleys shall be provided with

double row sheave bearings

3.9b Lubrication of PulleysArrangement shall be provided for periodical

lubrication/ greasing of pulley bearings.

3.9cEqualizer Pulley

mounting

Equalizer pulley shall be mounted on swivelling

arrangement

3.10 Gear Boxes for HOISTStandard Helical type, parallel shaft gearboxes,

Crane duty shall be used for hoist motion.

3.11 Gear Boxes for CT & LT

Wheel mounted geared motor drives with Hollow

shaft mounted (or) Helical parallel shaft gearboxes,

Crane duty shall be used for CT & LT drives.

3.11 aMaterial of gears &

Pinions, Shafts

All are Forged Alloy Steel (Preferably Case

hardening steels, or En-19 for gears, En-24 for

Pinions and shafts)

3.11b

Torque rating of

Gearboxes/ Pinions /

Gears

Gearboxes shall have torque rating equal to 2

times the Full load torque rating of selected motors.

Braking torque shall also shall be considered in

selection of Gearboxes.

3.11 c Details of gearboxes

with quotation

Details of gearboxes like size, centre distances,

Power in kW, Max. torque rating, and shall be

submitted along with quotation.

3.12Standard make of

Gearboxes

Heavy Crane duty gearboxes of Elecon / Shanti/

GREAVES (Premium transmission)/ Flender-

Siemens only. Other make & Own make

gearboxes are not acceptable. Vendor shall

confirm the acceptance. Tender will be rejected for

not meeting this requirement.

Drawings and Details of gear boxes, selection

3.13Selection/drawigns for

gearboxes

criteria, Power rating & torue rating calculations,

bearing details, data sheets from supplier shall be

submitted for TPIA/ Purchaser approvals during

design phase.

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3.14 HOIST BRAKES

Two nos. of imported electro hydraulic flameproof

thruster brakes with Manual release. Make :M/s

Bubenzer Bremsen, M/s Galvi, Italy, M/s

Wittonkramer, UK / M /s Seigerland Bremsen

(SIBRE) Germany/ M/s SIME Stromag. Thruster :

ATEX/ PTB Certified Ex proof, thrusters make :

EMG-Automation/ Brook crompton/ Galvi only.

ATEX/ PTB Certificates shall be submitted for

Approvals.

3.15 Hoist Brake Rating

Torque rating of Each thruster brakes shall be

minimum 2 times motor full load torque.Hoist

brakes shall be provided with operating delay of 1

sec from brake to brake.

3.16Braking distance/brake

path

Hoist components and brake shall be selected such

that the braking distance for lowering motion shall

not be more than 17mm with one brake at full

rated speed. Necessary calculations shall be

submitted in this regard during design phase.

3.17 Brakes for CT & LT

With Geared motors in built Fail safe Disc Brake

shall be used. (OR) If with separate standard 3.17 Brakes for CT & LT

Gearboxes, EHT brakes of approved make shall be

provided.

3.18

Brake rating/

adjustment for CT and

LT motions

In travel motion retardation with brakes shall not

exceed 7cm/sec2 . Necessary calculations shall be

submitted in this regard during design phase.

3.19 Brake drums

shall be forged/cast steel/ SG iron. Drums shall be

completely machined and Static & dynamically

balanced. Hardness of surface of finished drum shall

be 38-43 Rc Width of the brake drum shall be 5

to10mm more than the width of the brake shoes.

3.20 Mounting of equipment

All the gearboxes, motors, brakes, bearing

pedestals, etc. shall be mounted on machined and

leveled surfaces. If shims are needed only

Stainless steel shims shall be used.

3.21

Couplings between

motor, brake drum and

gearbox

Flexible Full geared couplings. Make of Couplings

shall be of FENNER/ LOVEJOY

3.22

Couplings between

gearbox and rope drum

for hoists

Geared coupling with self alignment provision.

3.23 Travel WHEELS

All crane wheels shall be made from forged steel

C55Mn75 and minimum hardness shall be 320 BHN

for a case depth of 10mm.

3.24 Travel WHEELS

Wheels shall be double flanged with straight tread

with 12 deg taper flanges with adequate flange 3.24 Travel WHEELS with 12 deg taper flanges with adequate flange

thickness.

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3.25 DRIVE SHAFTS

Shafts shall be of forged steel C45. Angular

deflection of the shaft at torque corresponding to

1.33 motor rated torque during acceleration shall

not exceed 0.10deg./m of shaft length.

3.26 Fasteners

Galvanized, high tensile fasteners of tensile quality

8.8 or more 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 ;M/s LPS

3.26aFasteners for Couplings

and Plummerblocks

High tesile Fit bolts (as per IS3640) of Property

class min 8.8 shall be used for Couplings, Plummer

blocks etc.,

3.27 Lubrication of Crane

Localised lubrication system with easy approach for

all pedastal bearings, couplings, wheel bearings

etc.,

3.28Maintenance

accessibility & Safety

Safe access for maintenance and removal of all

mechanical and electrical parts must be ensured

without any additional scaffolding. All parts

requiring replacement or inspection or lubrication

shall be easily accessible.

4.0 STRUCTURAL DETAILS OF EOT CRANE

4.1Design of structural

work

The crane should be rigid, robust, vibration free,

and of sturdy construction. The design of all

structures shall be done as per IS807 - Class -II

and as per this technical specifications.

4.2 Material of structurals

All the structural plates used in fabrication of

Girders, Trolleys and End carriages, machine

bases shall be of minimum 8 mm thick of IS 2062

Gr. A./Gr. B. Checquered plates for trolley and

platforms shall be minimum of 6mm

4.3 Girders Bridge Girders shall be of double Girder, Box Type

construction having Minimum vibrations.

4.4 Deflection of Girders

The bridges shall not deflect more than 1/1000 of

span with safe working load on the trolley, with

trolley stationed at mid span and excluding

deflection due to dead load.

4.5 Girder Joints

No splice joint – Girder is to be of single piece only.

Number of weldable butt joints along the total

length of the girder should not exceed two.

4.6 Ratio of span to depthFor Box Girders Span to Depth ratio shall not

exceed 18.

4.7Local Buckling of top

flange

Local buckling of top flange and compression

members shall be considered and necessary

calculation shall be submitted for approval.

4.8 End Carriages

End carriage shall be fabricated as solid box section

made from rolled steel plates IS2062, except for

essential openings which shall be reinforced.

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4.9 Structural bolted Joints

Fit Bolts (as per IS3640 ) 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.,

4.10 Trolley

The trolley frame shall be built up of rolled sections

and plates to form a rigid structure and shall be

arranged to afford maximum accessibility to

mechanical and electrical parts place on it.

4.11Top chequered plate of

trolley

The top of the trolley frame shall be fully covered

with 6mm chequered plate all over 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 plate

only .

4.12

Safe distance between

trolley & top pulley

block

Trolley and top pulley block 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.

4.13CT maintenance Maintenance platform shall be provided under the

4.13CT maintenance

platform

Maintenance platform shall be provided under the

CT mechanism (i.e below CT gearbox).

4.14 Hand rails for trolleyHandrails of 1000mm height shall be provided on all

the four sides of the trolley.

4.15 CT rail wear plate

Full length wearing plate of minimim 8mm should

be provided under the trolley rails and should be 10

to 12mm lesser in width more than the rail base as

per IS807.

4.16 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 department.

4.17 CT & LT rail clamping

CT & LT Crane rails shall be clamped to the girders

with double bolt clamping plates of M/s GANTREX

make. The rail clamps shall be spaced not more

than 900mm apart. Alignment blocks at spacing of

450mm shall be provided

4.17aRail Clamps for CT & LT

rails

All the rail clamps & fasteners shall be of standard

make of M/s GANTREX only.

4.17bResilient Rubber Pad

under CT & LT rails

M/s GANTREX make, long life, good

quality,continuous resilient rubber pads shall be

provided for CT & LT rails.

4.18Rail stoppers /Wheel

ramps

CT & LT Rails shall be prevented from creeping in

the longitudinal direction by welded rail stops and

Wheel ramps.

4.19 Jacking pads

Suitable jacking pads should be provided on end

carriages and trolley for jacking up the crane for

changing track wheels

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4.20 Safety Pads

Under the end carriages and crab to prevent the

crane from falling more than 25mm in the event of

breakage of a track wheel/axle.

4.21 End buffersSpring/Rubber buffers are to be provided for long

travel and cross travel.

4.22Mertic Component

Systems

All components including fasteners should be in

metric system only

4.23 Locking of fasteners Bolts in rotating parts shall be locked with lock

nuts.

4.24Make of steel raw

materials

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

only.

4.25 Welded joints

All butt joints shall be 100% X- rayed for both

compression and tension joints and in flanges /

Webs. All other weld shall be DP tested

4.26 Platforms

Full length chequered platform of width 750mm

shall be provided on both bridge Griders with hand

rails of height 1000mm. The platforms shall be bolt

jointed. jointed.

4.27 Toe gaurds

Toe gaurds shall be provided for all openings, on

trolley and on bridge platforms with minimum

height of 100mm.

4.27Machine 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.

4.28Cable Drag chian beams

& supportsIn the scope of Supplier

4.29Cable Drag Chain

maintenancecage

Repair cage shall be provided for attending to the

DSL / Cable Drag chain maintenance.To be provided

at suitable height with ladder.

4.30Protection Gaurds for

rotating equipment

Guards: All the moving parts 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.

5

5.1 Hazardous Area Class

All electrical equipments suitable for Hazardous

Area Zone 1, Gas Group II A / II B, T4 as per IS

5572

5.2Electical equipment

environment

All equipments shall be supplied for tropical and

humid climate. Derating of drive motors, power

cables etc., shall be done for ambient temperature

of 50°C.

ELECTRICAL EQUIPMENT

5.3 Power Supply at DSL

Power Supply : 415 ± 10% Volts, 3 phase, 4 wire,

50 ± 3% Hz located at 1meter above FFL at centre

of crane travel bay

5.4 Motors 3 phase, 415 V, 50 Hz / A.C

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5.4.1 Space heaterFor main Hoist motor Space heater shall be

provided.

5.5 Control voltage

1 phase, 110 Volts AC (all the switchgears inside

the panel)deriaved from suitable control

transformer with redundancy

5.6Auxiliary

voltage/Sockets

1 phase, 230 Volts AC (FLP Sockets in case of FLP

Crane or Normal socketes for Non FLP Cranes)

5.7

For Push buttons,

Indication lamps and

limit switches

24V, Intrinsic Safe Package Supply ( M/s P&F) only

for FLP Cranes. For Non FLP Crane it can be of 110

V AC supply

5.8

Power distribution for

Crane along Long

travel

The power supply shall be through PVC flexible

tinned copper conductor cable by means of "Cable

Drang Chain" M/s IGUS / Lapp make shall be

provided.And all the cable shall be routed on a tray

over the gurders.

5.9 Chain for PendantStainless steel chain. No other material is

acceptable.

5.10Power distribution to

trolley(Festonning)

Cable Drag Chain, Make: IGUS/ Lapp make

shall be used for all the trailling cables

5.11 Connection to pendentTrailing cable supported on anti-friction wheeled

trolleys 5.11 Connection to pendent

trolleys

1. Individual panels to be provided as follows.

a. Protective panel - one

b. Hoist panel - one

c. CT panel - 1no

d. LT Panel - one

2. Ferrules (Cable tags) to be provided for cable

connections as per circuit diagram. 3. Individual isolating switch to be provided for each

panel. M/s RITTAL/siemens /ABB make only

5.12 a VVVF Drive

KW rating of the VVVF Drives selected shall be

20% more than the selected motor rating KW.

Necessary line and load chokes and input filters are

to be used. For Hoist motors encoders are to be

used (FLP encoders in case of FLP Crane). The

selected drive should be capable of working in

vector control with suitable DBR. All drives are to be

with redundant drives of same rating fully wired and

ready to change over with suitable selector switch

facility. Make of Drives : M/s Siemens/ ABB

5.12 b

Location of VVVF drives

for 35t Flameproof

Crane

VVVF controls & Panels shall be located in a

separate room with proper ventilation system. This

room is located in building at ground level at one

corner. All power & control cables shall be routed

from this room to motors & brakes on top of crane.

5.12 Panel :

Page:11 of 23


VVVF drive output shall be based on drive motor

output requirement as per the following formula:

VVVF Drive output (kW) = k X Pm

e X P.F

Where k= inverter correction factor i.e. 1.20 as per

point no. 5.12 a

Pm =Motor output (kW)

e = motor efficiency

P.F= motor power factor

Drive continuous rated current must be 20 % more

than full load motor current.

Inverter overload current capacity shall be 1.5

times the full load motor current.

VVVF drive capacity shall be selected by derating it

to ambient temperature condition of 50 deg.

Centigrade.

5.13Mounting of panels and

resistance boxes

To be rigidly mounted on supporting frames

fabricated from ISMC Channels with antivibration

pads

5.14 Switchgears Make: SIEMENS only

5.12 cVVVF drive capacity

selection

5.15 Contactors AC4 Duty

5.16 Protection

The contactors shall be able to withstand 15 times

their rated current for one second without welding /

fusing of the contacts

5.18 TPN MCCB. Manually operable

5.19 Rated ValueCombined full load currents of all the three motions

on the crane having largest power

5.21 Fuses

Hoist, CT and LT motor power supply to be routed

through Semi conductor Fuses of adequate rating

only.

All the live parts to be covered properly in order to

avoid the possibility of in advent touching of the

same during operation and maintenance.

All the insulated materials used in the construction

of the panel shall be non-hygroscopic, duly treated

to withstand the effect of high humidity, high

temperature and tropical ambient service conditions

5.23 Isolating Switches

Separate control is required for the following: 1.

Under Slung Lights (In pendent)

2. Hand lamps socket outlets on the bridge (In

Protective panel)

3. Control circuits (In pendent)

Switchgear and

Terminal Blocks5.22

3. Control circuits (In pendent)

Page:12 of 23


5.24

All Motors shall be heavy Crane duty, squirrel cage

induction motors, INVERTOR duty, 60% CDF, min

of with 300 starts per hours, IP55.

5.24a

Pull out torque of motors shall be not less than

2.75 times of full load torue and shall be specifically

crane duty application

5.24b

Flameproof motors shall be used for 35t FLP EOT

crane. For this crane, all motors shall be provided

with Thermistors for temperature monitoring and

shall have interlock with drive/power supply. If

motor surface temperature is more than T4

classification, the drive shall trip the motor.

5.24c

Maximum permissible operating speed shall be

250% of synchronous speed or 2000 rpm whichever

is less. Over load capacity 150% of full load current

for 2 minutes without damage or permanent

deformation from zero to base speed.

5.24dAll switch gears are to be minimum two times then

the normal rating of the motor rated current

Motors

5.24eAll contactors are to be minimum 150% of the rated

of the motor rated current.

5.25 Speed rating of Motors

Hoist motor shall be 8 pole with ~720 rpm

speed and Travel motors shall be 6 pole with ~980

rpm.

5.26Details of to be

provided

Vendor shall provide other details like No. of

motors, Power of motor, Frame size, make, duty,

no. of starts/hr, type and No. of poles, amb.temp,

as given Annexure-I

5.27Current drawn by

motors

Maximum Current drawn by all motors with SWL

should not exceed 80 % of the full load rated

current

5.28 Torque rating of motorsMotor full load torque rating shall be min. 120% of

calculated torque with duty factors as per IS3177

5.29 Brakes

Electro Hydraulic Thruster Brakes for all motions.

For CT & LT, in case of wheel mounted geared

motors in built disc brakes can be used . Rated

duration and frequency of operation shall be

mentioned.

5.30Socket Outlets at all the

panels.

1. Two nos sockets with ON/OFF switchshall be

provided.

2. 230 V AC work socket for Handlamp

Page:13 of 23


5.31 Push button station

PBS shall be provided with push buttons for

controlling main and creep of all motions, UP/down,

CT : right/left, LT forward/reverse. shall be

provided with Key way switch Lockable at OFF,

Emergency OFF, and Intrinsic Lamp – Powered

through Intrinsic Safe circuit. PBS shall also provide

with 2-way Switch for Under Bridge Lights. At least

30 % Spare Core shall be provided in PBS. For

control ON command push button shall be of

illuminated push button and lamp should glow after

energising the main contactor in protective panel.

Interlock shall be provided as given below for all the

motions as mentioned above

Pendent push button level

Contactor level (which is used for issuing the

command to the VVVF Drive)

Programming logic level in the VVVF drive

Gravity limit switch should control the entire EOT

Crane power supply

Rotary limit switch should control the HOIST

5.31a Interlock

Rotary limit switch should control the HOIST

operation in the respective direction

1. Indication lamps shall be provided for all three

phases for both incomer feeder.

2. Indicating lamps shall be of Cluster LED type

only, provided with translucent lamp covers.

3. Lamps and lenses shall be easily replaceable

from the front.

4.Cluster LED module shall be suitable for direct

operation on 230 V, 50 Hz AC in general

5.32 Limit Switches for Hoist

Rotary Limit Switch – 1no. (to control both UP /

DOWN operation of HOIST)

Gravity Limit Switch – 1no

5.33Limit Switches for CT &

LTLever type - 2nos for CT & 2nos for LT

All wiring for power control, lighting etc., shall be

carried out with 1.1.K.V grade XLPE Armoured

copper conductor cables. Minimum size 4 mm sq. in

power circuit and 2.5 mm sq in control circuit. All

inter connecting wiring to be done neatly through

perforated trays from the panel to the top junction

boxes (if any) fixed in suitable places.

Wiring shall be neatly bunched, adequately

supported and properly routed to allow easy access

5.31b Indication lamps

Power and Control

Cables5.34

and maintenance.

Wires shall be identified by numbered ferrules at

each end.

Page:14 of 23


The ferrules shall be of the ring type and of non-

deteriorating material.

Terminal blocks shall be of 750 Volts grade of the

stud type and shrouded.

Insulating barriers shall be provided between

adjacent terminals.

Provisions shall be made for label inscriptions for

the easy identification of terminal blocks.Labels shall be of anodised aluminium with white

engraving on black background / computerized

labels.

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.

Enamel Danger plates / stickers of size and

descriptions as recommended in the relevant IS,

shall be provided on the Panel inscribed in Telugu,

Hindi and English languages mainly. The same to be

indicated the G.A after getting the order and before

proceeding for fabrication.

Terminal blocks and

labels5.34a

5.35 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 conneted to building earth

though gantry rails.

5.36Identification of Circuit

& Cables

1. Labels of permanent nature to be specified. 2.

All power and control cables, etc are to be tagged at

both the ends.

6.0

6.1 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 .

6.2

Painting with Epoxy

Primer (Total thickness

of 80 microns)

Two coats 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.

6.3

Painting Epoxy Paint (

Total thickness 120

microns)

Two coats of epoxy paint Golden Yellow colour

(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. Paninting quality shall ensure austhetic looking

of crane.

Not less than 200 microns, This will be tested

PAINTING OF CRANE (DFT shall be measured at the time of final

inspection)

6.4Total Paint Thickness

Including Primer

Not less than 200 microns, This will be tested

during final inspection at supplier works/ at the time

of despatch.

Page:15 of 23


7

7.1

7.2

7.3

7.4

7.5

Bidder shall submit following INFORMATION/DOCUMENTS ALONG

WITH QUOTATION : List of documents to be submitted along with

offer (offer will be rejected unless these information/ documents

are submitted) 7.1 to 7.5

GA drawing showing full details of cranes with dimensions, end clearances

(between centre of LT rails to column face of building), overhead clearance

from LT rails, hook approach limits, lift height, etc. with crane weights &

wheel loads.

Technical details of Major components selected/ considered by Vendor for

these cranes for quotation. As per Annexure -I

Submission of Prices along with cost of two year spare parts strictly as per

the PRICE BID FORMAT given in Annexure -II.

Technical Specifications with Point-wise Specifications to all points as

given in this specification ( in given this FORMAT). Generalized statements

like crane shall be manufactured as per your specifications or as per IS

standards etc. are not adequate. Otherwise, it may result in rejection of the

tender. Vendor shall comply with this & submit quotation in this format only.

Any deviations with respect to this specifications are not acceptable.

However Bidder can submit / suggest improvements, which increas safety &

reliability of crane, if any, seperately by indicating the caluse no. in this

specifications.

8.0

8.1

8.2

8.3

8.4

8.5

8.6

8.7

All the drawings and caclulations and data sheets shall be submitted at a

time within one month from Order date for verification & approvals.

All the load bearing structure & drive mechanisms shall be designed by

taking dead loads, operational loads, erection loads, loads due to sudden

actuation of brakes and acceptance testing loads.

Bidder shall submit following list of drawings/ calculations / documets for

approval before manufacture of crane within one month after palcement of

purchase order. (8.6 to 8.23)

Note: It is the responsibility of the supplier to get the drawings/documents

approved from TPIA/ Purchaser.

DESIGN APPROVALS : DRAWINGS /DOCUMENTS TO BE SUBMITTED

AFTER PLACEMENT OF ORDER

specifications.

Design of load bearing structures shall be as per IS 807 and drive

mechanisms as per IS 3177 and also as per technical specifications in to

consideration.

At the same time, Supplier shall be responsible for proper submisssion of

following drawings & calculations along with technical specifications to Third

party inspection agency and get Deisgn Approvals from them .

General Arrangement (GA) drawing of crane to scale with dimensions, Bill of

materails & makes

Three sets of following drawings/ calaclations shall be submitted to

Department/ Purchaser (ISRO) for review.

GA Assembly Drawing of Trolley with all components8.7

8.8 GA Drawing of individual drive mechanisms for Hoist, CT and LT

GA Assembly Drawing of Trolley with all components

Page:16 of 23


8.9

8.10

8.11

8.12

8.13

8.14

8.15

8.16

8.17

8.18Electrical/electronic circuit diagrams for total crane containing details of

componenets with rating, make, type and settings

Claculations for drive shafts and plummer block bearings.

Quality Assurance Plan for total crane manufacture, erection & testing as

given in Annexre-I.

Claculations for selection of wheels, bearings and Calculations for

selection of CT & LT rails.

Constructional Drawings of Girder, end carriage, and trolley their

connections

Sub-assembly drawings for rope drum assembly, wheel assemblies, hook

blocks, pulley system etc.,

GA drawings, details and selection criteria, power & torue calculations for

gear boxes with manufaturer data sheets

Calculation for bridge girder with deflection & camber, trolley frame, end

carriage, with weight breakup and wheel loads.

Calculation for selection of motors and brakes with manufacturer motor

/brake datasheets & Exproof certificates.

Claculations for selection of Mechine elements like wire rope, rope drum,

couplings, wire ropes, pulleys etc.,

8.19

8.20

8.20a

8.21

8.22

8.23

9.1

9.2

9.3

9.4 2 No. spare parts manuals

4 sets of as built Drawings of all systems of crane as mentioned above

GA drawing of electrical, VVVF panels, DBR Panels and layout of components

within the panels.

QAP/Inspection reprot 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 & clearance

report.

Bridge Girder CT rail arrangement drawing to scale with BOM.

Test certificates of all items like rawmaterials, hooks, wire ropes, motors

etc and for all crane parts certified by "Competent person of third party

agency" as per QAP & standards.

4 sets of Cranes operation & maintenance manuals

LT rail arrangement (on Ganrty Girders) drawing to scale with Bill of

Materials (BOM).

Bidder shall submit following along with supply of EOT Crane : List of

Manuals / drawings/ documents/ certificates to be submitted at the time

of inspection of crane at supplier's works and at the time of commissioning

at ISRO, SHAR ( clause 9.1 to 9.10 )

Flameproof approval certificates for motors, all electrical componets and

brake thrusters

Selection criteria/ calculations for VVVF drives and related components

Selection of Cable sizes selection and ratings

9.5

9.6

4 sets of as built Drawings of all systems of crane as mentioned above

aprroval drawings.

Manufacturer maintenance manuals, test certificates and Warranty /

Guarantee Cards for all Bought-Out-Items.

Page:17 of 23


9.7

9.8

9.9

9.10

10

10.1 Span over LT wheels + 4mm maximum

10.2 Diagonal on wheels ± 5mm maximum

10.3 Parallelism of Girders<1/1000 of wheel gauge (measured at every 1m

interval)10.4 Verticality of Girders <2mm (measured at every 1m interval)

10.5Verticality of End

Carriages< 1mm (measured at every 1m interval)

10.6 Trolley wheel gauge ± 2mm (measured at every 1m interval)

10.7Difference in height

between trolley rails<1/1000 of wheel gauge maximum at 1m interval

10.8CT Rail alignment w.r.t

Girder centre±1 mm (measured at every 1m interval)

Final test certificate of EOT crane from TPIA with inspection report

Trouble Shooting Chart for Main and all Sub-Systems.

VVVF drive drives manuals soft copy & Hardcopy.

VVVF drive parameters list soft copy and hard copy

Tolerances : Vendor shall ensure that the crane shall be

manufactured as per the tolerances specified below.

Girder centre

10.9Tilt of wheels ( both

horizontal & vertical)< D/ 1000mm where D = diameter Of wheels

10.10CT/LT wheel

displacement<2mm (measured at all wheels) Wheel alignment

10.11Squareness of Girders

to End carriageswithin 1.60mm ( for wheel base of ~4000mm)

10.12 Travelling speed +10% -5% of specified speed.

10.13 Hoisting speed +10% -5% of specified speed.

10.14 Lowering speed +20%-5% of specified speed

11.

11.1

DESIGN / DRAWINGS

APPROVALS &

CERTIFICATE from TPIA

before crane

manufacture.

Supplier shall obtain APPROVALS for all design

calculations & drawings from third party inspector

(TPIA) and/or ISRO 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.

11.2QAP & Thirdparty

agency

INSPECTION and testing shalll be carried out as

per QAP enclosed here with in Annexure -III .

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

INSPECTION & TESTING DURING MANUFACTURE OF CRANE

agency be witnessed by THRID PARTY and/or ISRO. All the

critical inspections and load testing shall be done in

the presence of TPIA and /or ISRO

Page:18 of 23


11.3

Raw materials

identification &

stamping

Raw material identification for structures, wheels,

hoist members, 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.

11.4Welding 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 documentation.

11.5Inspection major parts

and records

Inspection of Bridges, End – Carriages, trolley,

railsgauge, Wheels and Measurement of Camber,

mechanical assemblies checking as per QAP.

11.6

Dimensional inspection

& alignment checking &

records

Inspection of Span & Diagonal Dimensions (10 Kg

pull should be applied while checking), Checking

bridge & end carriages' squareness, Checking of

Wheel Alignments, Mechanical drive Assemblies

alignment and Pulley blocks alignmentt.

11.6 a Record of inspection

All the inspections made shall be made with drawing

representation like span, diagonal, wheel

strightness, rail alignement, with dimensions &

tolerances mentioned.

11.7

No load test, Dynamic tests at Rated Load and

Deflection measurement as per as per QAP and as

per IS 3177

11.8

Testing of Crane at OVER-LOAD (125% SWL)

capability Check and Permanent Set Measurement.

All motions of the crane shall be tested with 25%

over load in which case the specified speeds need

not be attained but the crane shall show itself

capable of dealing with the over load without

difficulty.

11.9 Clearance for despatch

The equipment shall be despatched only after

satisfactory testing/ inspection at supplier's works

and on written clearance from ISRO

12

12.1 At ISRO- SHAR worksPart of supplier's scope. Inspection/testing during

erection & commissioning as per QAP

12.2 Erection Supervision

Supplier shall depute qualified personnel i.e., one

supervisor, one fitter, two riggers, and one

electrician and two helpersfor carrying out quality

erection work at our site.

12.3

Material (lifting

equipment, lifting

tackles, etc) required

Part of supplier's scope. All lifting machines/tackles

of standard make used shall be tested & certified

as per standards before their use for lifting the

Load tests

ERECTION & COMMISSIONING OF EOT CRANE

12.3tackles, etc) required

during erection.

as per standards before their use for lifting the

crane.

Page:19 of 23


12.4

Initial lubricants and

commissioning spares

Initial filling of lubricants and spare parts required

for commissioning at site shall be provided by the

supplier.

12.5

Performance Proving &

Smooth running of EOT

crane

Proving out for the Crane’s Capacity and Smooth

Functioning of the Crane at Full load (SWL) and

Over load (125%SWL) shall be the responsibility of

the supplier.

12.6Test/Clearance

certificates for crane

Part of supplier's scope. To be inspected and

certified by "Competent Person of Thrid party

Inspection Agency " as per Industrial Laws and shall

provide Certification from Third Party Inspection

Agency for fianl clearance & regular usage of EOT

crane .

13

13.1GEAR BOXES and

Geared Motors

Elecon / Shanti/ GREAVES (Premium transmission)

/ Flender- Siemens only.

13.2

Structural Steel

Materials Plates, rolled

sections

SAIL/ JINDAL/ TATA/ ESSAR/ VIZAG-RINL

MAKE OF THE BOUGHT-OUT ITEMS

13.3

Forged steel materials

like wheels, shafts,

keys, gears,

SAIL/ JINDAL/ TATA/ ESSAR/ VIZAG-RINL/ BHARTH

FORGE/ VIKRANT FORGE

13.4 Wire Rope Usha Martin 6x36, Grade 1960 Mpa

13.5 Bearings SKF / FAG / TIMKEN/ INA

13.6Thruster Brakes for

Hoist Motion

BUBENZER-BREMSEN(Thrusters of EMG-

Automation)/ SIBRE/ WITTON KRAMER/ GALVI /

SIME-Stromag

13.7Thruster Brakes for

Travel Electromag, KATEEL

13.8 HooksEEK/Hercules-INDEF/IRIZAR-FORJAS/SMRITHI

FORGINGS/ VIKRANTH FORGE/ CROSSBY

13.9 Couplings FENNER/ LOVEJOY

13.10 Crane RailsSAIL/JINDAL/TATA/ESSAR/IISCO/ ACCELOR-

MITTAL

13.10a Rail clamps Gantrex

13.11 Motors (Squirrel cage)Kirloskar, Crompton Greaves, Bharat Bijilee, LHP,

Siemens, Havells

13.11a VVVF Controls M/s SIEMENS/ABB Only

13.12 Connectors Elmex / Wago/ Connect Well

13.13 SWITCH GEAR SIEMENS only

13.14 Grounding SystemAll the panels and the electrical apparatus shall be

double grounded

13.15 Limit Switches Siemens/SPEED-O-CONTROL/EMM

13.16 Intrinsic Safe realys MTL/ P&F

Page:20 of 23


13.17 Flameproof Panels BALIGA/FCG make only

13.19 CablesIGUS/LAPP/Polycab/Finolex/Incab as approved by

the department

13.21 Paints Asian Paints/Berger

14

14.1

14.2

14.3

14.4

The successful Vendor is required to visit our site and measure all necessary

dimensions i.e. Span, Head Room, Clearances between rail center to existing

column and rail size etc, at site before starting of the crane design /

manufacturing.

General TERMS & CONDITIONS during supply and installation :

Delivery Schedule:The cranes shall be supplied with in 6 months from date

of Order and shall be erected & commissioned with in 2 months from date of

supply.

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

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.

14.4

14.5

14.6

14.7

14.8

14.9

14.10

14.11

14.12

Free electricity and water will be provided by the purchaser for the erection,

testing and commissioning of the crane at the site.

The supplier should satisfy himself about the site condition beforehand to

avoid any difficulty during erection and commissioning of the crane

Dimensions of all parts used on crane shall conform to metric standards

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 on chargeable basis, if

available.

No cast iron part should be used 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. Open gears should not be used in any

drive / motion.

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.

materials till the completion of the crane by the SDSC,SHAR and/or Third

Party Agency at the suppliers site as per the QAP schedule.

Before starting the site work, the contractor shall provide insurance to crane

parts and to all his personnel working at site in Sriharikota against accidents/

or loss of material.

Assembly at site is to be kept as minimum as possible to enable early

commissioning of the crane. Welding at site is to be avoided as far as

possible.

or loss of material.

Page:21 of 23


14.13

14.14

15

15.1

15.2

The transfer of title of Crane to the purchaser/ISRO will take place only after

satisfactory erection, testing and commissioning of the crane by the supplier

and fully acceptance by the purchaser/ISRO.

The quotation for all these crane should be submitted in two parts.

1) Part –I: Technical and commercial bid along with copy of the price

bid without prices but indicating % of taxes & duties

2 ) Part –II: Price bid. as per format given in Annexure- B.

Note : Each part should be in separate sealed covers superscripted as Part I

and Part II respectively. Both parts should be submitted at the same time

before the tender due date.

Supply Prices shall be at Ex- works. Transportation charges shall be indicated

A toolbox containing all necessary tools (e.g., torque wrench, hand grease

gun, set of spanners, screwdrivers, hyd jack etc.) required for the

maintenance of the crane should be furnished along with the Crane.

Delivery : 8 months for total work. The crane (35t) shall be supplied

within 6 months from date of Order and shall be erected & commissioned

with in 2 month from date of supply.

COMMERCIAL TERMS & CONDIONS :

15.3

15.4

15.5

15.6

15.7

15.8

15.9

15.10

15.11Advance along with

Order30% of supply value against Bank guarantee

15.12Payment after crane

reciept at site 60% of supply value along with taxes and duties

Supply Prices shall be at Ex- works. Transportation charges shall be indicated

seperately as given in Price Bid Format Annexure - B

Guarantee period shall be for a period of 12 calendar months, commencing

from the date of acceptance & taken over by the purchaser at our site.

During this period any defect noticed on design, materials, workmanship

shall be replaced/rectified by the supplier at free of any cost.

Payment Terms in three stages. Vendor shall comply with.

Performance Bank guarantee (PBG) for 10% of total cost of the crane

shall be provided by the Vendor for a period of 12 months from the date of

commissioning and acceptance of the crane at purchaser’s site at

Sriharikota,

All Taxes (like sales tax, VAT, service tax etc.,) and duties applicable shall

be indicated clearly in quotation.

Excise duty (ED) exemption Certificate will be issued by the purchaser 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.

Liquidates Damages (LD) : Department will levy a penalty for delayed

delivery @ 0.5% per week and part thereof subject to a maximum of 10% of

the value of unexecuted portion of the order.

15.13

Final & Balance Pament

after completion of

erection &

commissioning

10% of supply value+ 100% TPIA charges +100%

errection & comissioning charges againest

submission of performance Bank guarantee as per

clause 15.9

Page:22 of 23


15.14

15.15

Validity of Offer shall be minimum period of 3 (Three) months from the

tender due date.

Kind attention to the Vendors EARNEST MONEY DEPOSIT (EMD) is included

in continuation to the attached RFP under the Arrangement of Bid. a.

EARNEST MONEY DEPOSIT (EMD)/BID SECURITY • The tenderer has to

submit an Earnest Money Deposit (EMD) for Rs. 1 lakhs in a single

installment through Demand Draft (DD)/Banker’s Cheque/ Fixed Deposit

Receipts or Bank Guarantee from any of the Scheduled Banks executed on

non-judicial stamp paper of appropriate value. In case of Bank Guarantee, it

shall be valid for a period of 45 days beyond the final tender validity date. It

shall be taken in favour of Sr. Accounts Officer, SDSC SHAR payable at State

Bank of India, Sriharikota branch. Any tender not accompanied with EMD

shall be treated as invalid tender and rejected. • Foreign vendors, registered

vendors or vendors who have already applied for renewal of registration,

Central PSUs/PSEs/Autonomous Bodies, Micro and Small Enterprises, KVIC,

National Small Industries Corporation, etc., shall be exempt from the

payment of EMD. Vendors seeking exemption from payment of EMD shall

submit necessary documentary proof. • EMD of a vendor shall be forfeited if

the tenderer/Contractor withdraws or amends his tender or deviates from

the tender in any respect within the period of validity of the tender. Failure

to furnish securitydeposit/performance bond by a successful vendor within

the specified period shall also result in forfeiture of EMD. • EMD shall be

refunded to all the unsuccessful vendors within thirty days after placement of

Date

Signature & Office Seal of

the bidder

the Purchase Order. EMD shall be refunded to the successful

tenderer/Contractor after payment of the Security Deposit or may be

adjusted against the Security Deposit. EMD shall be refunded to all the

participants in cases where the tender is cancelled or withdrawn by the

Centre/Unit, within thirty days from the date of such cancellation or

withdrawal.

specifications cum compliance statement …...cable system as per the following specifications,...

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