PLC BASED FILM POSITIONING SYSTEM · sdsc shar, sriharikota request for proposal for design,...

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SDSC SHAR, Sriharikota

REQUEST FOR PROPOSAL

For

DESIGN, MANUFACTURE, TESTING AT SHOP FLOOR, SUPPLY,

INSTALLATION AT SITE, TESTING AND COMMISSIONING

OF

PLC BASED FILM POSITIONING SYSTEM

Satish Dhawan Space Centre SHAR Indian Space Research Organization

Sriharikota - 524 124, A.P

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Contents

S.NO DESCRIPTION PAGE

NO.

1.0 PROPOSAL DOCUMENT …………………………………………............................. 1

2.0 ADDENDA / CORRIGENDA………………………………………………………….. 3

2.1 AMBIGUITY ………………………………………………………………................... 3

3.0 PREPARATION OF BIDS……………………………………………………………... 3

3.1 SITE VISIT …………………………………………………………………………….. 3

3.2 VALIDITY OF OFFER ……………………………………………………................... 3

3.3 COST OF BIDDING ………………………………………………………………….. 4

3.4 PROJECT MONITORING ……………………………………………….................... 4

3.5 APPLICABLE LANGUAGE …………………………………………….................... 4

3.6 ARRANGEMENT OF BID ……………………………………………………………. 4

3.7 SCHEDULE OF PRICES ………………………………………………….................... 5

3.8 DOCUMENTS COMPRISING THE BID ……………………………………………... 5

3.8.1 PART – I TECHNICAL AND UNPRICED COMMERCIAL PART………………….. 5

3.8.2 PART – II PRICED COMMERCIAL BID …………………………………………….. 6

3.8.3 BID SUBMISSION …………………………………………………………………….. 6

3.8.4 BID EVALUATION……………………………………………………………………. 7

4.0 EXCLUSION OF TENDERS ……………………………………………................... 8

5.0 DRAWINGS ………………………………………………………………………….. 8

6.0 PUBLICITY RELATING TO TENDERS ……………………………………………. 9

7.0 MINIMUM CRITERIA FOR QUALIFICATION ……………………………………. 10

8.0 DETERMINATION OF RESPONSIVENESS ………………………………………… 11

9.0 VENDOR EVALUATION FORMAT …………………………………….................... 11

9.1 FOR INDIGENOUS VENDORS ………………………………………….................... 11

9.2 FOR FOREIGN VENDORS …………………………………………………………… 14

SECTION A: GENERAL TERMS AND CONDITIONS OF CONTRACT

1.0 INTRODUCTION ……..……………………………………………………………….. 19

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2.0 SCOPE OF WORK AND TECHNICAL SPECIFICATIONS…………………………. 19

3.0 SUPPLIER'S OBLIGATIONS & FUNCTIONS ………………………………………. 19

3.1 SPECIFICATIONS AND DRAWINGS ……………………………………………….. 19

3.2 APPROVAL OF TECHNICAL DOCUMENTS / DRAWINGS………………………. 19

3.3 DESIGN & SUPPLY OF EQUIPMENT …………………………………................... 20

3.4 INSPECTION AND TESTING ………………………………………………………... 20

3.5 DELIVERY AND STORAGE ………………………………………………………… 21

4.0 INSTALLATION ……………………………………………………………………… 22

4.1 GENERAL ……………………………………………………………………………... 22

4.2 SETTING OUT, LEVELLING AND GROUTING OF EQUIPMENT ………………. 23

4.3 RECORDS ……………………………………………………………………………... 23

4.4 EQUIPMENT ERECTION ……………………………………………………………. 24

5.0 DRAWINGS AND O&M MANUALS ……………………………………………….. 24

6.0 MAINTENANCE SERVICES …………………………………………………………. 25

7.0 TRAINING …………………………………………………………………………….. 25

8.0 SCHEDULE OF PRICE ……………………………………………………………….. 25

9.0 DISCOUNTS …………………………………………………………………………... 26

10.0 MODE OF PAYMENT…………………………………………………………………. 26

11.0 TERMS OF PAYMENTS ……………………………………………………………… 27

12.0 DELIVERY SCHEDULE ……………………………………………………………… 27

13.0 LIQUIDATED DAMAGES ………………………………………………………......... 27

14.0 EXTENSION OF TIME ……………………………………………………………….. 28

15.0 TAXES AND DUTIES ………………………………………………………………… 28

15.1 GST ……………………………………………………………………………………. 28

15.2 CUSTOMS DUTY ……………………………………………………………………... 28

15.3 INCOME TAX ………………………………………………………………………… 29

15.4 EARNEST MONEY DEPOSIT (EMD) ……………………………………………….. 29

16.0 RISK COVERAGE ……………………………………………………………………. 30

17.0 SECURITY DEPOSIT …………………………………………………………………. 30

18.0 PACKING AND FORWARDING …………………………………………………….. 30

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19.0 WARRANTY …………………………………………………………………………... 30

20.0 GUARANTEE …………………………………………………………………………. 31

21.0 PERFORMANCE BANK GUARANTEE ……………………………………………. 31

22.0 DISCLOSURE AND USE OF INFORMATION BY THE SUPPLIER ………………. 32

23.0 ARBITRATION ………………………………………………………………………... 32

24.0 APPLICABLE LAW AND JURISDICTION …………………………………………. 33

25.0 FORCE MAJEURE ……………………………………………………………………. 34

26.0 GENERAL ……………………………………………………………………………... 34

26.1 SITE DETAIL …………………………………………………………………………. 34

26.2 SAFETY ………………………………………………………………………………... 34

26.3 POWER SUPPLY ……………………………………………………………………… 34

26.4 WORK RULES ………………………………………………………………………… 34

26.5 SITE CLEARANCE …………………………………………………………………… 35

26.6 ACCOMMODATION ………………………………………………………………… 35

26.7 MEDICAL FACILITIES ………………………………………………………………. 35

26.8 WORK PROGRAMME ………………………………………………………………. 35

26.9 SUB-CONTRACTS ……………………………………………………………………. 35

26.10 CHANGES AND MODIFICATION TO SPECIFICATIONS, DESIGNS,

DRAWINGS AND QUALITATIVE / QUANTITATIVE REQUIREMENTS ………. 36

26.11 ACCEPTANCE AND REJECTION …………………………………………………… 37

26.12 SUSPENSION …………………………………………………………………………. 37

26.13 CANCELLATION ……………………………………………………………………... 38

27.0 EQUIPMENTS AND SERVICES ……………………………………………………... 39

28.0 CODES AND STANDARDS …………………………………………………………. 40

29.0 GENERAL SPECIFICTIONS RELATED TO FABRICATION ……………………… 40

30.0 PAINTING ……………………………………………………………………………... 41

SECTION-B : SCOPE OF WORK

1.0 INTRODUCTION ……………………………………………………………………… 43

2.0 SCOPE OF WORK ……………………………………………………………………. 43

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3.0 VENDOR’S SCOPE OF WORK ………………………………………………………. 43

4.0 WORKS UNDER PURCHASER’S SCOPE …………………………………………... 45

SECTION-C : TECHNICAL SPECIFICATIONS

SECTION-I : GENERAL TECHNICAL SPECIFICATIONS

1.0 SCOPE …………………………………………………………………………………. 47

2.0 DESCRIPTION OF NDT PROCESS………………………………………………….. 48

3.0 FUNCTION OF FPS & ESS AND USER’S REQUIREMENT………………………. 51

3.1 FUNCTIONS OF FPS & ESS…………………………………………………………. 51

3.2 OTHER CONSIDERATIONS……………………………………………………….... 54

3.3 USER’S REQUIREMENTS…………………………………………………………… 54

4.0 DESIGN CRITERIA…………………………………………………………………… 55

5.0 EQUIPMENT AND SERVICES TO BE PROVIDED BY THE SUPPLIER ……….. 55

6.0 EQUIPMENT & SERVICES TO BE PROVIDED BY PURCHASER …………........ 57

7.0 CODES AND STANDARDS…………………………………………………………... 58

8.0 CONFIGURATION OF FPS & ESS…………………………………………………… 59

8.1 FPS X-TABLE ASSEMBLY……………………………………………….................... 60

8.2 FPS Y-TABLE ASSEMBLY…………………………………………………………… 60

8.3 CASSETTE HOLDER ………………………………………………………………… 61

8.4 FPS ROOM …………………………………………………………………………….. 62

8.5 CASSETTE SLIDE OR C-SLIDE …………………………………………………….. 63

8.6 LOADER AND UN-LOADER CABINETS …………………………………………... 63

8.7 END SUPPORT SYSTEM DRAWINGS ………………………………….................. 64

9.0 FPS AND ESS CABLE SYSTEM ……………………………………………………... 65

10.0 OPERATION SEQUENCE AND INTERLOCKS …………………………………….. 65

10.1 FILM POSITIONING SYSTEM……………………………………………………….. 65

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10.2 END SUPPORT SYSTEM……………………………………………………………... 65

10.3 PRELIMINARY PREPARATION……………………………………………………... 65

10.4 PREPARATION FOR PROPELLANT RADIOGRAPHY…………………………….. 65

10.5 FOR TANGENTIAL RADIOGRAPHY……………………………………………….. 66

11.0 PRELIMINARY SPECIFICATIONS OF MAJOR SUB-SYSTEMS………………….. 67

12.0 INTERFACE DETAILS BETWEEN ITEMS / SUB-SYSTEMS / SYSTEMS……….. 69

13.0 COMPLIANCE OF SPECIFICATIONS & USER REQUIREMENTS……………...... 69

14.0 ERECTION SEQUENCE………………………………………………………………. 69

15.0 PAINTING……………………………………………………………………………… 70

16.0 SUMMARY OF DATA TO BE FURNISHED ALONG WITH BID AND AFTER

PLACEMENT OF ORDER……………………………………………………………. 70

17.0 DETAILED ENGINEERING DOCUMENTS AFTER ISSUE OF LETTER OF

INTENT (LOI)………………………………………………………………………….. 71

17.1 FINAL DOCUMENTS…………………………………………………………………. 71

18.0 BOUGHT OUT ITEMS………………………………………………………………… 72

19.0 GENERAL INSTRUCTIONS / REQUIREMENTS………………………………........ 72

SECTION-II : ELECTRICAL SPECIFICATIONS 74

SECTION-III : SPECIFICATIONS OF INSTRUMENTATION & CONTROL SYSTEMS

1.1 LOCAL OPERATING STATION……………………………………………………… 97

1.2 FILM POSITIONING SYSTEM (FPS)……………………………………………….. 97

1.2.1 FPS X TRAVEL MOTION…………………………………………………………….. 97

1.2.2 FPS Y-TRAVEL……………………………………………………………................... 98

1.2.3 FPS C-SLIDE……………………………………………………………........................ 99

1.2.4 LOADER & UN-LOADER CABINET SYSTEM……………………………………... 100

1.2.5 FPS BOOM……………………………………………………………………………... 101

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1.2.6 OTHER INSTRUMENTS……………………………………………………………… 102

1.3 END SUPPORT SYSTEM (ESS)………………………………………………………. 102

1.3.1 ESS Y-TRAVEL ……..................................................................................................... 102

1.3.2 ESS Z-SLIDE…………………………………………………………………………… 103

2.0 SPECIFICATIONS OF I & C ITEMS…………………………………………………. 104

2.1 PLC …………………………………………………………………………………..... 104

2.2 SCADA & HMI REQUIREMENTS…………………………………………….......... 105

2.3 POWER SUPPLY ITEMS……………………………………………………………… 105

2.4 FIELD INSTRUMENTS ………………………………………………………………. 106

2.4.1 EX-PROOF ABSOLUTE ENCODERS ……………………………………………….. 106

2.4.2 PROXIMITY SENSORS ………………………………………………………………. 106

2.4.3 DIGITAL INPUT ISOLATOR ………………………………………………………… 106

2.4.4 DIGITAL OUTPUT ISOLATOR ……………………………………………………… 106

3.0 EX-PROOF CAMERAS AND CCTV SYSTEMS ……………………………………. 107

4.0 OVERALL CONTROL SYSTEM …………………………………………………...... 107

5.0 SPARES TO BE SUPPLIED …………………………………………………………... 108

SECTION-D : ANNEXURES

ANNEXURE –I: SCHEDULE OF PRICES …………………………………………………… 110

ANNEXURE –II: EXCEPTIONS AND DEVIATIONS ……………………………………….. 112

ANNEXURE –III: CHECK LIST ……………………………………………………………….. 113

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Acronyms

ISRO Indian Space Research Organization

SDSC Satish Dhawan Space Centre

CISF Central Industrial Security Force

CCW Counter Clockwise

CW Clockwise

PCC Power Control Centre ( electrical )

PLC Programmable Logic Control

LC Letter of Credit

CCTV Close Circuit Television

AMC Annual Maintenance Contract

GA(drawing) General Arrangement ( drawing )

SS Stainless Steel

IP Ingress Protection

UPS Uninterrupted Power Supply

ECS Electronic Clearance System

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PLC BASED FILM POSITIONING SYSTEM ��

PROPOSAL DOCUMENT, CLARIFICATION AND ADDENDUM

Proposals are invited from the interested Suppliers for the enclosed scope of work in two-part

bid. Part-1 Technical and Unpriced part of the work and Part-2 Priced Commercial part.

The RFP document is organized in four sections as follows.

Section –A General Terms and Conditions of the Contract

Section –B Scope of Work

Section –C Technical Specifications

Section –D Annexure

Title of the Entity: SDSC SHAR , SRIHARIKOTA

Title of the proposal: “PLC BASED FILM POSITIONING SYSTEM”.

Date of Public Notification issued:

Last Date of purchase / downloading tender Document:

Last date of submission of tender documents:

Place of submission of tender documents: SDSC SHAR, Sriharikota

1. PROPOSAL DOCUMENT

a) One set of proposal document along with the drawings is issued. Bidder shall sign and

stamp each page of tender as token of his acceptance & submit along with his offer.

Document shall be scanned and uploaded in e-procurement portal. In case it is not

possible to upload due to higher file size, hard copy of the balance documents (without

any price figures) shall be submitted physically before due date.

b) Transfer of tender document issued to one Bidder to another is not permissible.

c) Tender documents shall remain the property of Department and if obtained by one

intending Bidder shall not be utilized by another without the consent of the Department.

d) The proposal shall be completely filled in all respects and shall be submitted together

with requisite information. Any offer incomplete in any particulars is liable for rejection.

e) Bidders shall set their quotations in firm figures and without qualifications or variations

or additions in the terms of the Tender documents. Proposal containing qualifying

expressions such as "subject to minimum acceptance" or "subject to prior sale" or any

other qualifying expressions or incorporating terms and conditions at variance with the

terms and conditions incorporated in the Tender documents are liable to be rejected.

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f) Cost quoted shall be firm and fixed.

g) Price may be quoted in Indian National Rupee or foreign currency as applicable.

h) Satish Dhawan Space Centre – SHAR (SDSC-SHAR) Sriharikota is declared as

prohibited place under official secrets act 1923. Hence during execution of site works

necessary security requirements enforced by the department from time to time shall be

followed strictly.

i) Defects in the material like fractures, cracks, blow holes, laminations, pitting, etc., are

not allowed.

j) During the erection, testing and commissioning of structure at site in Sriharikota, the

supplier has to make his own arrangements for boarding, lodging and transportation of

his men and materials. However, subject to availability, hostel accommodation may be

provided by the Purchaser (SDSC SHAR) on chargeable basis.

k) Free electricity and water will be provided by the Purchaser (SDSC SHAR) for the

erection, testing and commissioning works at the site. Bidder shall take into this while

quoting the price.

l) Tools and tackles, other than those mentioned under free issue items, required shall be

arranged by the party.

m) Before starting the site work (at SDSC SHAR), the party shall provide insurance as per

workman compensation act to all his personnel working at site in Sriharikota against

accidents. Till commissioning of structure, the safe storing and handling of structure is

in the scope of supplier. Insurance for the same shall be borne by the party.

n) Quote shall be based on DDP / DAP Sriharikota.

o) All applicable taxes (like CGST/SGST/IGST/UGST, etc.) and duties applicable shall be

indicated clearly in quotation.

p) Transportation & Transit Insurance are fully in the scope of supplier and the same shall

be borne by the party.

q) Necessary care shall be taken during erection and commissioning of Film Positioning

System (FPS) and End Support System (ESS) at our site. Any damage to the property of

Department shall be adequately compensated by the Party.

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2. ADDENDA /CORRIGENDA

Addenda/corrigenda to the tender document may be issued by SDSC SHAR prior to the

date of opening of the tenders, to clarify or reflect modifications in the contract terms

and conditions.

Such addendum/corrigenda will be distributed to each firm or person who had

purchased the tender documents.

2.1. AMBIGUITY

Should there be any ambiguity or doubt as to the meaning of any of the tender

clause/condition or if any further information is required, the matter shall be

immediately brought to the notice of Sr. Head, Purchase & Stores, SDSC SHAR in

writing for necessary clarifications prior to the opening of the tenders.

3. PREPARATION OF BIDS

3.1. SITE VISIT

a) Bidders visit and examine the site and its surrounding to familiarize them self of the

existing facilities and environment and may collect all other information which they may

require for preparing and submitting the Bid and entering into the tender if required.

Bidders shall visit within 15 days from the date of tender enquiry.

b) Claims and objections due to ignorance of existing conditions or inadequacy of

information will not be considered after submission of the Bid and during

implementation.

3.2. VALIDITY OF OFFER

a) Bid shall remain valid for acceptance for a period of six months from the due date of

submission of the Bid.

b) The Bidder shall not be entitled during the said period to revoke or cancel his Bid or to

vary the Bid except and to the extent required by Department in writing.

c) Bid shall be revalidated for extended period as required by Department in writing.

d) In such cases, unless otherwise specified, it is understood that validity is sought and

provided without varying either the quoted price or any other terms and conditions of

Bid finalized till that time.

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3.3. COST OF BIDDING

All direct and indirect costs associated with the preparation and submission of Bid

(including clarification meetings and site visit, if any), shall be to Supplier's account

and the Purchaser will in no case be responsible or liable for those costs, regardless of

the conduct or outcome of the Bid process.

3.4. PROJECT MONITORING

a) Bidder shall provide details of project team.

b) Party shall depute their Project team/ engineers for meeting to review the status and

discuss/ resolve minor issues related to project execution at our site based on mutual

agreement on mutually agreeable dates.

3.5. APPLICABLE LANGUAGE

The Bid and all correspondence incidentals to and concerning the Bid shall be in the

English Language. For supporting document and printing literature submitted in any

other language, an accurate English Translation shall also be submitted. Responsibility

for correctness in translation shall lie with the Supplier.

3.6. ARRANGEMENT OF BID

The Bid shall be neatly presented on white paper with consecutively numbered pages.

It should not contain any terms and conditions which are not applicable to the Bid.

The Bid and all details submitted by the Supplier shall be signed and stamped on each

page as token of acceptance by a person, legally authorized to enter into agreement on

behalf of the Supplier. Corrections/ alteration, if any, shall also be signed by the same

person. Supplier shall submit Power of Attorney in favor of the person who signs the

Bid and subsequent submissions on behalf of the Supplier.

Purchaser will not be bound by any Power of Attorney granted by the Supplier or

changes in the constitution of the firm made subsequent to submission of the Bid or

after the award of the contract. Supplier may however, recognize such Power of

Attorney and changes after obtaining proper legal advice, the cost of which will be

borne by the Supplier.

The cancellation of any document such as Power of Attorney, Partnership Deed etc

should be communicated by the Supplier to the Purchaser in writing well in time,

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failing which Purchaser shall have no responsibility or liability for any action taken by

Supplier on the strength of the said documents.

Should the Supplier have a relative or relatives or in the case of firm or company one or

more of its shareholders or a relative or relatives of the share holder (s) employed in a

senior capacity in Purchaser's organization, the authority inviting Bids shall be

informed of the fact at the time of submission of the Bid, failing which the Bid may be

disqualified or, if such fact subsequently comes to light, Purchaser reserves the right to

take any other action as it deems fit in accordance with any applicable law, Rules,

Regulations of the like in force for the time being.

3.7. SCHEDULE OF PRICES

The schedule of prices shall be read in conjunction with all the sections of proposal

document.

For Lump sum contract, the lump sum prices quoted by the Supplier shall be firm and

fixed for the completion of the work, unless stated otherwise. The price must be filled

in the format for ‘Schedule of Prices’ – Annexure-I in section D.

3.8 DOCUMENTS COMPRISING THE BID

This is e-procurement tender. All the documents need to be scanned and attached to the bid

under “documents solicited from Vendor” form. In case it is not possible to upload due to

higher file size, hard copy of the balance documents (without any price figures) shall be

submitted physically before due date.

a) Offers shall be sent online only using standard digital signature certificate of class III

with encryption / decryption. The tenders authorized online on or before the open

authorization date and time only will be considered as valid tenders even though the bids

are submitted online.

b) The tenderer must authorize bid opening within the time stipulated in the schedule by

SDSC SHAR. Otherwise the online bid submitted will not be considered for evaluation.

On-line bids shall consist of the following:-

3.8.1) Part – I: Technical and Un-priced Commercial Part

a) Technical and un-priced commercial part shall comprise the following documents /

information. All the documents shall be scanned and uploaded in the ISRO e-

procurement portal.

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b) Submission of bid letter along with one set of tender document duly signed and stamped

as token of acceptance. Scanned copy shall be uploaded in the ISRO e-procurement

portal.

c) Power of attorney shall be in favour of authorized signatory of the bid/ proposal

documents.

d) Audited balance sheet including profit and loss account for last three financial years

(2014-2015, 2015-2016 & 2016-2017) showing annual turnover.

e) Latest income tax clearance certificate.

f) Latest solvency certificate from a scheduled bank for a value of 50 lakhs.

g) List of projects in hand & completed during last five financial years indicating the name

of client with contact details.

h) Any other relevant document, bidder desires to submit.

i) Confirmation with respect to bid qualification criteria

j) Compliance statement

k) Deviations, if any, with respect to technical and commercial terms & conditions shall be

clearly brought out. If deviations are not listed separately, it will be presumed that you

are adhering to all the specification and terms & conditions given in this document.

Note: All the above documents shall be uploaded in the ISRO e-procurement portal.

3.8.2) Part – II Priced Commercial Bid

Priced commercial bid shall contain schedule of prices and shall be filled in ISRO e-

procurement portal. No deviations, terms and conditions, assumptions, discounts etc. shall be

stipulated in price bid. Department will not take cognizance of any such statement and may at

their discretion reject such bids.

3.8.3) Bid Submission

a) Bid shall be submitted in two parts

Part -1 Techno-Commercial Part of the Bid

Part-2 Price Part of the Bid

b) Offers should be submitted On-line using standard digital signature of class -3 with

encryption/decryption options.

c) The tenders authorized online on or before the open authorization date and time will

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only be considered as valid tenders.

d) Prices shall be mentioned in the space / column provided in the ISRO e-procurement

portal only for such purpose.

e) Physical copy of the bid will be accepted only in case if the file size is bigger and not

possible to upload the same. In such case, the hard copy shall be submitted within due

date. Documents received after due date will not be considered.

f) Prices quoted should be on the basis of F.O.R. Sriharikota.

g) The purchaser will not pay separately for transit insurance and same shall be included in

the cost quoted by the Bidder.

h) All risks in transit shall be exclusively borne the contractor and the purchaser shall pay

only for such items as are actually received in good condition in accordance with the

purchase order.

i) Bids duly filled in by the Bidder should invariably be submitted as stipulated in the e-

procurement portal.

j) Department may open Part – I of the bid on the due date of opening at convenience.

Price Bid (Part-II) of the bid of the technically and commercially acceptable bids shall

be opened at a later date.

k) Department reserves the right to reject any or all the Bids without assigning any reasons

thereof.

3.8.4) Bid Evaluation

a) The bidder shall provide all the relevant data / information / details required for evaluating

the bid technical and commercially in the specific formats enclosed with the tender. Apart

from this, Bidder is free to add any other relevant information.

b) During evaluation, Department may request Bidder for any clarification on the bid /

additional documents / information required. Bidder shall submit all clarifications /

additional documents / information requested in original. If not submitted within the

stipulated time department has right to reject such bids.

c) Techno-commercial discussion shall be arranged with Bidder, if needed. Bidder shall

depute his authorized representatives for attending discussions.

d) The complete scope of work is defined in the Tender document. Only those Bidders who

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undertake total responsibility for the complete scope of work as defined in the Tender

document only will be considered.

e) In case Bid does not fully comply with the requirement of Tender document and the bidder

stipulates deviations to the clauses of the tender, which are unacceptable to the Department,

the Bid will be rejected.

f) Performance of Bidder on similar nature of works executed / under execution shall be taken

into consideration before selecting the Bidder for opening his price bid.

g) The time schedule for completion is given in the Tender document. Bidder is required to

confirm the completion period unconditionally.

h) Department shall not be obliged to furnish any information / clarification to unsuccessful

bidder as regard non-acceptance of their Bids.

i) Overall lowest offer will be considered for placement of Order.

4. EXCLUSION OF TENDERS

The following tenders shall be summarily rejected from the procurement process

a) Tenders of vendors who are already removed from vendor list from having any business

dealing.

b) The tenders that materially depart from the requirements specified in the tender

document or which contain false information.

c) The tenders that are not accompanied by prescribed EMD.

5. DRAWINGS

a) Each drawing submitted by the Bidder (after placement of Order) shall be clearly

marked with the following details.

i. Name of the Owner: Satish Dhawan Space Centre SHAR, ISRO

ii. Project Title: PLC Based Special purpose equipment for NDT Facility, SPP

iii. Purchase Order No:

iv. Title of the Drawing clearly identifying the system, equipment or part.

v. Drawing, Revision Number and Date.

vi. Name of the Bidder:

vii. Drawings duly signed in "checked" and “approved" columns.

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viii. Scale to which the drawing is drawn.

ix. Cross references to all relevant drawings.

x. All relevant notes to the drawing:

All notes necessary for understanding and execution of work shown on a

drawing shall be presented on the same drawing.

xi. All legends to all notations.

xii. Details of revisions carried out

xiii. Bill of materials shall be tabulated, wherever required.

xiv. All titles, markings and writings on the drawing shall be in English

xv. All the dimensions shall be in metric units.

b) If standard catalogues are submitted, the applicable items shall be highlighted therein.

c) The drawings shall indicate all dimensions and details of equipment, materials of

construction etc.

d) For all revisions of the drawing, Bidder shall ensure that all revisions are clearly

encircled with revision numbers marked on the drawing.

e) Bidder shall also ensure that general details of revisions are indicated for each revision

in the revision block of the drawing along with the date and signed by the approving

authority.

6. PUBLICITY RELATING TO TENDERS

a) Advertisements, press release or other specialized publicity documents, which are

related to or reveal the existence of a tender and are intended by the Bidder for public

distribution and / or the press, broadcasting, or television, shall be cleared/approved by

the Department.

b) The Department may direct the Bidder to withhold such publicity or to require

modifications to the publicity material. The Bidder shall comply with such direction.

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7. MINIMUM CRITERIA FOR QUALIFICATION

S.

No

CRITERIA Vendor

Compliance

(YES*/NO)

7.1. Tenderer shall have at least 5 years experience in the field of design,

manufacture, testing, packing & forwarding and erection, testing &

evaluation and commissioning of PLC based special purpose

equipments.

7.2. Average annual financial turnover of the tenderer during the last

three years, should not be less than Rs.3.75 crores INR or equivalent

amount in foreign currency and it should be supported by Audited

Annual Financial Accounts Report (Last three years (2015-2016,

2016-2017 & 2017-2018) balance sheet / profit or loss account

statements shall enclosed).

7.3. Experience of having successfully completed similar works of 2.5

crores INR or equivalent amount in foreign currency, in a single

order value or 1.5 crores INR or equivalent amount in foreign

currency, of two orders each during last 5 Years (2013-2014,

2014-2015, 2015-2016, 2016-2017 & 2017-2018).

SDSC SHAR reserves right to inspect the manufacturer site for

validation/verification.

7.4. Latest solvency certificate from a scheduled bank for a value of 55

lakhs.

7.5. Copies of the completion certificate/performance certificate and one

reference for contact from your client organization shall be furnished.

Performance demonstration of similar kind of machine supplied by

tenderer at manufacturer site shall be arranged, if called.

Purchaser reserves the right to evaluate vendor & its sub contractor

capability to supply the indented PLC based Special purpose

11


equipments to this tender specification and reject, if not capable.

7.6. Tenderer shall submit other information in the enclosed vendors

evaluation format. The bid submitted without the evaluation format

will not be considered for evaluation.

*if YES please support with valid documents as proof.

8. DETERMINATION OF RESPONSIVENESS

The bid which does not satisfy the pre-qualification criteria as mentioned above (refer point

no. 7) shall summarily be rejected and shall not be considered for further evaluation. SDSC

SHAR will scrutinize bids to determine whether the bid is substantially responsive to the

requirements of the tender documents. For the purpose of this clause, a substantially

responsive bid is one which inter-alia conforms to all the terms and conditions of the entire

Tender document without any deviations and reservations. The decision of purchaser shall

be final in this regard.

9. Vendor Evaluation Format

SDSC SHAR seeks response to the following questionnaire for assimilating data which

would be used for evaluating the capability of the vendor for executing the referred work.

Hence, the vendor is requested to provide only genuine data and any discrepancy found at

a later point of time may result in rejection of the vendor from purchase process.

Furnishing of data cannot be construed as automatic qualification for participation in the

tender. Questionnaire should be signed by a responsible and authorized person of the

Company / Agency.

9.1. For Indigenous vendors

S. No Description Vendor Response

1. Name of the company :

2. Type of the Company

(Proprietary/ Pvt. Ltd/Public Ltd/ Joint

Venture/Consortium)

:

12



3. If Company is Consortium please

provide the signed copy Consortium

Agreement document.

:

4. Registration number & certificate :

5. Name & Address of the Office of the

Chief Executive of the Company

:

6. Contact person for this tender with

name & address and contact number

:

7. Locations of the Branches of Company

(if any)

:

8. From which year the Company is in

operation

:

9. Current Annual turn-over of the

company

:

10. IT returns for the last 3 years :

11. The Profit & Loss Account details for

the last 3 years which is duly audited

and Submitted as part of the Annual

Report.

:

In Rs. Lakhs only 2014-15 2015-16 2016-17

Total assets (i) :

Current assets (ii) :

Total liabilities (iii) :

Current liabilities (iv) :

Net Worth (i-iii) :

Working capital (ii-iv) :

Turnover ` in lakhs :

Profit/Loss in Rs. lakhs :

12. The major lines of business: :

13



13. Details of availability of design and

analysis software

: Software No. of

licenses

No. of

Persons

familiar to

work on

software

14. Details of availability of machinery

Testing equipments

and

: Machine

Type

Qty No. of Persons

familiar to

work

15. Manpower details

(technician, Supervisor, QA,

Inspection)

: Description No. of

Persons

Remarks

Admin. &

Acct.

Design &

Analysis

Workmen

(floor)

Supervisor

16. The major customers for whom

similar works are provided (Enclose

copies of the Purchase Orders)

:

17. Any customers feedback on the

services which is in writing (Pl.

enclose copies)

:

18. Shop floor area & Handling system

availability

14


9.1.1 Details of last 5 years experience of contractor in executing similar type of works

which are completed

Sl. No

Full postal

address of the

client with

Contact Person

Description of

the work

Value of

the work

(Rs. in

Lakhs)

Completion

Time as per

PO

Actual

period of

completion

Reasons

for delay

1

2

3 1

4

Note: In order to consider as valid experience, all the experience has to be supported with the

completion certificate and purchase order

9.1.2 Details of present works being executed by the contractor

Sl. No Full postal address of the client

with Contact Person

Description of the work Value of the work

(Rs. in Lakhs)

Note: copy of purchase orders may be enclosed.

Signature of Authorized Person with Seal

9.2 For foreign vendors


1. Name of the company :

2. Type of the Company

(Proprietary / Pvt. Ltd. / Public Ltd. /

Joint Venture / Consortium)

:

3. If Company is Consortium please

provide the signed copy Consortium

Agreement document.

:

4. Registration number & certificate :

15


5. Name & Address of the Chief Executive

of the Company

:

6. Contact person for this tender with name

& address and contact number

:

7. Do you have any Indian Agent (If YES)

please provide percentage of Agency

Commission.

:

8. Name & Address of the India Agent

details of contact person

:

9. Locations of the Branches of Company

(if any)

:

10. From which year the Company is in

operation

:

11. Current Annual turn-over of the

company

:

12. The Profit & Loss Account details for

the last 3 years which is duly audited and

Submitted as part of the Annual Report.

:

Currency ( ) : 2014-15 2015-16 2016-17

Total assets (i) :

Current assets (ii) :

Total liabilities (iii) :

Current liabilities (iv) :

Net Worth (i-iii) :

Working capital (ii-iv) :

Turnover :

Net Profit/Loss :

13. The major lines of business :

16


9.2.1 Details of last 5 years experience of contractor in executing similar type of

work which are completed

Sl. No

Full postal

address of the

client with

Contact Person

Description of

the work

Value of

the work

(Rs. in

Lakhs)

Completion

Time as per

PO

Actual

period of

completion

Reasons

for delay

1

2

3

4

Note: In order to consider as valid experience, all the experience has to be supported with

the completion certificate and purchase order

14. Details of availability of design and

Testing equipment analysis software

: Software No. of

licenses

Persons

familiar to

work on

software

15. Manpower details

(technician, Supervisor, QA,

Inspection)

: Description Qty Remarks

Admin. &

Acct.

Design &

Analysis

Workmen

(floor)

Supervisor

16. The major customers for whom similar

items were supplied (Enclose copies of

the Purchase Orders)

:

17. Any customers feedback on the services

which is in writing (Pl. enclose copies)

:

18. Shop floor area & Handling system

availability

:

17


9.2.2 Details of present works being executed by the contractor

Sl. No Full postal address of the client

with Contact Person

Description of the work Value of the work

(Rs. in Lakhs)

Note: copy of purchase orders may be enclosed.

Signature of Authorized Person with Seal

18


SECTION -A

GENERAL TERMS AND

CONDITIONS OF CONTRACT

19


1. INTRODUCTION

SDSC SHAR invites e-tenders from reputed firms with proven ability to design,

preparation of detailed drawings, manufacture, testing, inspection at manufacturer’s

works, packing, forwarding, transportation to site, unloading, installation, testing, carrying

out process trials and commissioning of PLC based Film Positioning System for S139 Bay

in Solid Propellant Plant, SDSC SHAR, Sriharikota, India as per the scope and

specifications.

2. SCOPE OF WORK AND TECHNICAL SPECIFICATIONS

The detailed scope of work and technical specifications is given in Section B & C of

RFP document. The general terms and conditions are given below.

3. SUPPLIER's OBLIGATIONS & FUNCTIONS

3.1. SPECIFICATIONS AND DRAWINGS

The Supplier shall execute the works in compliance with the provisions of CONTRACT,

good engineering practices and code requirements.

3.2. APPROVAL OF TECHNICAL DOCUMENTS / DRAWINGS

Supplier shall prepare and submit to Purchaser for approval following documents and

drawings:

3.2.1. Drawings of equipment and Auxiliary sub- system supplied by the party.

3.2.2. Quality Assurance Plan (QAP): The QAP shall list down various stages of inspection

and inspection agency namely supplier quality Control agency & 3rd party inspection

agency, if engaged. Elaborate Quality Assurance Plan (QAP) is to be prepared &

furnished for review & approval

3.2.3. Layout drawings

3.2.4. Fabrication drawings

3.2.5. Erection Sequence Schedule (DESS) along with erection drawings.

3.2.6. No activity shall be executed unless Purchaser’s approval is obtained. The above

documents / drawings shall be submitted in a format approved by Purchaser. Quality

Assurance Plan shall be strictly in accordance with Quality Control Manual and Formats

to be provided after the award of CONTRACT.

20


3.3. DESIGN & SUPPLY OF EQUIPMENT

3.3.1. The supplier shall provide overall general arrangement of the machine with all major

dimensions.

3.3.2. The details / designs and GA drawings given in the tender for various systems /

equipments are of minimum requirement and are for guidance only. Contractor is free to

modify / improve / redress the design if required to meet the guaranteed performance of

the systems / equipments being supplied. Design and fabrication drawings of the

machine tool and auxiliary systems shall be prepared and sent by the Bidder for scrutiny

/review/clearance by Purchaser. The Bidder shall incorporate necessary

changes/revisions in the design based on the suggestions made by the Purchaser or its

authorized representatives and shall submit the drawings for clearance prior to

undertaking fabrication/manufacturing. Scrutiny /review/clearance of the drawings by

SDSC, SHAR shall not absolve the responsibility of the Bidder from proper

performance of the machine and from the guarantee/warranty clauses. However, any

modification / improvement shall be carried out after approval by the Purchaser.

3.3.3. Supplier shall carry out detailed engineering, manufacture / procure and supply the

equipment in accordance with the scope, technical specifications and terms & conditions

of contract.

3.3.4. Any item which may not have been specifically mentioned herein but are needed to

complete the equipment / system shall also be treated as included and the same shall also

be supplied and erected at no extra cost, unless otherwise specifically excluded as

indicated.

3.3.5. Supply of bought out items shall be as mentioned in the technical bid.

3.3.6. All these goods or material shall be supplied or used shall be new and of first quality.

Where imported or partly imported goods or material are offered or intended to be used,

the fact must be specifically stated and brought to the notice of Purchaser.

3.4. INSPECTION AND TESTING

3.4.1 The supplier shall identify various stages of inspection and quality control of the system

including sub systems, components and bought out items etc., and inform the same to

SDSC, SHAR in advance. The approved QAP shall be followed during course of

Manufacture, Erection & Testing.

21


3.4.2 Purchaser reserves the right to inspect all phases of Supplier’s operations through its

representatives and/or third-party inspection agency approved by the Purchaser.

Therefore, it is the responsibility of the supplier to provide the necessary support for the

inspection agency and get the works inspected at all stages of work as identified in

quality assurance plan. The presence or absence of a Purchaser’s representative does not

relieve the Supplier of the responsibility for quality control in all phases of the work. In

the event that any of the work being done by the Supplier or any Sub-Supplier is found

by Purchaser’s representatives to be unsatisfactory or not in accordance with the

drawings, procedures, specifications, and standards the Supplier shall, upon verbal notice

of such discrepancy or deficiency, take immediate steps to revise the work in a manner to

conform to the relevant drawings, procedures and specifications. The Supplier shall carry

out required supervision and inspection as per Quality Assurance Plan and furnish all

assistance required by the Purchaser in carrying out inspection work during this phase.

3.4.3 The authorized inspectors of the purchaser shall have access to the premises of the

supplier and its sub-contractors at all reasonable times. All the equipments, instruments,

tools that are necessary for the inspection shall be provided by the supplier on demand by

purchaser’s own inspectors or a third party authorized by purchaser. Inspection by

purchaser’s own inspectors or by third party authorized by purchaser shall not absolve the

responsibility of the supplier from proper performance of the machine and from the

guarantee/warranty clauses stipulated in the contract.

3.5. DELIVERY AND STORAGE

3.5.1 Dispatch Instructions given in the Contract shall be strictly followed. Failure to comply

with the instructions may result in delay in payment apart from imposing any other

charges as may be deemed to fit.

3.5.2 The Supplier shall be responsible for transporting all the equipment to site, unloading

and storage. No equipment shall be delivered without obtaining dispatch clearance from

Purchaser. All the equipment shall be properly packed to avoid any damage during

transportation / handling / storage.

3.5.3 Party shall undertake the responsibility of the machine and its components during

transportation to Sriharikota and during erection, testing and commissioning of the same

at suitable location identified by SDSC, SHAR and until handing over the machine to

SDSC, SHAR after its acceptance. SDSC, SHAR will provide sheltered area for storage

22


of the machine and its components. Supplier shall take proper care while storing the

equipment and shall provide watch and ward at his own cost.

3.5.4 First fill of hydraulic oil, lubricating oil, coolant oil & other consumables as required are

to be provided in seal packed at purchaser site.

4. INSTALLATION

4.1. GENERAL

4.1.1 Supplier’s staff shall include adequate number of competent erection engineers with

proven experience on similar works to supervise the erection works and sufficient

skilled, unskilled and semi-skilled labour to ensure completion of work in time.

4.1.2 Supplier's erection staff shall arrive at site on date agreed by Purchaser. Prior to

proceeding to work, Supplier shall however, first ensure that required/sufficient part of

his supply has arrived at site.

4.1.3 EOT crane will be made available by purchaser in the building where Crane based

handling system is to be installed. This EOT crane may be used for installation work.

4.1.4 60 t capacity EOT Crane, Material handling equipments viz. 3, 5 & 12 ton Forklift, 15 &

12 ton hydra systems, 300 kg capacity scissor lift, 1 ton capacity pallet truck etc.

available with purchaser will be provided free of cost subjected to availability &

approval.

4.1.5 Special equipments / Material handling equipments other than above mentioned

equipments required for erection work shall be arranged by the supplier.

4.1.6 Piping / cable trench / embedded plate etc. required in the building shall be made

available by purchaser.

4.1.7 Purchaser will make ready the machine foundation, trenches and provision of water

supply to a place identified near the building as per the details furnished by the party.

4.1.8 Erection of equipment may be phased in such a manner so as not to obstruct the work

being done by Other Suppliers and / or operating staff that may be present at that time.

4.1.9 During erection, Purchaser's engineer will visit site from time to time with or without

Supplier’s engineer to establish conformity of the work with specification. Any

deviations, deficiencies or evidence of unsatisfactory workmanship shall be corrected as

instructed by Purchaser.

23


4.1.10 Tank, pipe flushing / purging is in supplier scope.

4.1.11 Supplier shall carry out work in a true professional manner and strictly adhere to the

approved drawings. Any damage caused by Supplier during erection to new or existing

building shall be made good at no extra cost to Purchaser.

4.2. SETTING OUT, LEVELLING AND GROUTING OF EQUIPMENT

4.2.1 Supplier shall check the civil works where the equipment is to be erected in advance for

their correctness / conformity to the approved drawings for erection of equipment with

respect to their lines, levels, pockets, openings, cut outs etc. and shall notify Purchaser

of any major deviation.

4.2.2 Supplier shall mark precisely the centre lines and datum reference on civil works where

the equipment is to be erected with reference to benchmark given by Civil Supplier.

Any minor adjustment necessary to structure (on which equipment is to be erected) for

making them plumb and level shall be carried out by Supplier at his cost.

4.2.3 All the grout for equipment shall be carried out using non-shrinkable grout. Surfaces

receiving grout shall be prepared to receive grout. All block outs for pipes (puddle

pipes), sleeves etc. shall be grouted by using cement concrete of the same grade as that

of the parent structure. All associated civil works such as cutting of re-bar, chipping or

dressing of foundation or widening openings in R.C.C. Work and brick work, drilling

holes in concrete work or brick work shall be carried out by Supplier as part of the scope

of contract.

4.3. RECORDS

Supplier shall maintain records pertaining to the quality of erection work in a format

approved by Purchaser. Whenever erection work is complete, Supplier shall offer

erected equipment for inspection to Purchaser's engineer who along with Supplier's

engineer will sign such records on acceptance.

The complete construction of machine right from component level till the complete

machine assembly performance tested including sub – assembly shall be properly

documented with drawing, raw material, Test certificate etc.

There shall be time to time submission of information /clearance / approval by the

purchaser and all comments shall be duly incorporated.

24


All such drawing will become part of PRODUCTION MASTER FILE which shall also

contain as built drawing, Final Erection, Testing & Commissioning report done at site.

Three copies of PRODUCTION MASTER FILE shall be supplied.

4.4. EQUIPMENT ERECTION

4.4.1 Supplier shall carry out the works in accordance with the specific instructions given on

the approved drawings, method statements, manufacturer’s drawings / documents or as

directed by Purchaser. Equipment shall be erected in neat workmen like manner so that

they are level, plumb, and square and properly aligned and oriented. Tolerances shall be

as established in manufactures drawings or as stipulated by Purchaser. No equipment

shall be grouted or bolted down to the foundation, until its alignment is checked and

found acceptable by Purchaser.

4.4.2 Supplier shall provide all supervision, labour, tools, machines, cranes, slings, wire rope,

D-shackle etc., equipments, scaffolding, rigging material and incidental material such as

bolts, wedges, anchors, concrete inserts, grout material etc. required to complete the

works. Supplier shall also provide at his own cost all such consumables like oxygen -

acetylene gas welding rods, grinding wheels, temporary supports, shims etc. required to

complete work.

4.4.3 Supplier shall take utmost care while handling instruments, delicate equipments, panels

etc., and protect all such equipments on erection.

5. DRAWINGS AND O&M MANUALS

5.1. Supplier shall submit three hard copies & one soft copy of all the approved drawings

incorporating any modification / changes made during the execution of CONTRACT. All

these drawings shall be marked as 'As Built'.

5.2. Supplier shall submit three hard & one soft copy of the following documents:

5.2.1 Operations manual of the machine.

5.2.2 Programs manual.

5.2.3 Maintenance manual with drawings, circuit diagrams, interfacing instructions, trouble

shooting and maintenance instructions and spares list with source of supply.

5.2.4 Lubricating chart with oil /grease type, quantity, changing interval, brand name should

be indicated clearly.

25


5.2.5 Manuals of PLC based Special purpose equipments from the original equipment

manufacturer (OEM) or supplier.

5.2.6 Control system Documents on DVD

5.3. Submission of the drawings and manuals shall be a precondition for releasing of any final

payment due to Supplier.

6. MAINTENANCE SERVICES

During the post commissioning period for at least 05 Years, supplier has to provide the

following services:

6.1. Maintenance visits on call basis or as required by Purchaser for observing the

performance of Machine.

6.2. Repair charges like replacement of spares.

6.3. The supplier shall undertake to maintain the machine on “Annual maintenance contract”

basis as per mutually agreed terms, which will be entered after expiry of warranty.

Supplier shall quote the Annual Maintenance Contract charge per year for minimum of 05

years.

6.4. The party shall extend support for all spares for a period of ten years.

7. TRAINING

The supplier shall provide training in the operation, maintenance and trouble shooting of

PLC based Special purpose equipments two departmental personnel free of cost at

purchaser’s site.

8. SCHEDULE OF PRICE

8.1. CONTRACT price shall include all costs of “design, preparation of detailed drawings,

manufacture, testing, inspection at manufacturer’s works, packing, forwarding,

transportation to site, unloading, installation, testing, carrying out process trials and

commissioning of PLC based Special Purpose equipments”. Shop floor testing, packing,

forwarding, transport to site, unloading, storage, all risk coverage, erection, installation,

training, testing & evaluation and commissioning of equipment including associated civil

work and any other cost for proper and complete execution of the CONTRACT.

8.2. CONTRACT prices shall also include all travelling expenses, living expenses, salaries,

overtime, benefit and any other compensation for engineers, supervisors, skilled,

semiskilled workmen, watch and ward staff, laborer and other staff employed by the

26


Supplier, cost of tools and tackles required for erection and other consumable material

required, and all taxes, duties, and levies as applicable on the date of submission of bid.

8.3. Price shall be firm & fixed.

8.4. Supplier shall quote the prices as per the price bid format enclosed as Section-D

Annexure - I

8.5. The rate quoted shall be on FOR SDSC SHAR, Sriharikota basis.

8.6. All rates of taxes/duties/levies applicable with details of percentage and applicable portion

of the price should be spelt out clearly in the offer.

8.7. The taxes applicable for supply and erection & commissioning shall be indicated

separately in terms of percentage in the price bid. If the offers submitted by the suppliers

are silent on taxes, it will be presumed that quoted rates are inclusive of taxes & duties and

no claim in this regard will be entertained later.

8.8. Purchaser is eligible for concessional exemption of Customs Duty for imported items.

Necessary exemption certificate will be provided to the suppliers against request. This may

be taken into account while quoting for items.

8.9. In case of foreign suppliers the prices shall be quoted on DDP / DAP, SRIHARIKOTA

basis. In case of any change, supplier shall identify the Indian agent and responsibilities

related to clearing the consignment, transport of equipment to destination and erection &

commissioning at site and all the necessary works till the equipment is commissioned and

accepted by Purchaser as per the mutually agreed acceptance plan in the contract

document.

9. DISCOUNTS

Supplier shall not indicate any discount separately and quoted price should be after

deducting the discount.

10. MODE OF PAYMENT

10.1. In case of indigenous suppliers, all the payments due to Supplier shall be made in Indian

currency by crossed “Account Payee” cheque sent to the registered office of the Supplier.

Supplier can submit the banker details and payments can also be made through Electronic

Clearance System (ECS).

10.2. In case foreign suppliers LC will be established for supply portion and erection &

commissioning portion separately. The agency commission shall be paid in Indian Rupee

27


based on the suppliers authorization. Any other mode of payment shall be stipulated by the

tenderer clearly in the deviation statement attached in section-D Annexure - II of the

proposal document.

11. TERMS OF PAYMENTS

a) 20% as advance against Bank guarantee and invoice if required.

b) 70% on receipt of items and on inspection by CLIP at our site

c) 10% within 30 days from the date of commissioning and final acceptance.

d) Wherever advance payment is requested, Bank Guarantee from any Nationalized

Bank/Scheduled Bank should be furnished. In case of advance payments, if the party is not

supplying the material within the delivery schedule, interest will be levied as per the Bank

Lending Rate plus 2% penal interest.

e) Interest will be loaded for advance payments/stage payments as per the lending rate of Bank

and will be added to the landed cost for comparison purpose. In case of different milestone

payments submitted by the parties, a standard and transparent methodology like NPV will

be adopted for evaluating the offers.

12. DELIVERY SCHEDULE

a) The PLC based Special Purpose Equipment shall be supplied to SDSC SHAR within ten

months from the date of receipt of purchase order. Upon clearance from the purchaser, the

party shall finish commissioning, testing and handing over the system in working condition

as per the specifications within two months.

b) Delivery date is essence for this contract. Party shall adhere to the delivery date mentioned

in this tender and same shall be confirmed along with the offer. In case Party is unable to

meet the delivery schedule, the offer is liable for rejection.

c) Intermediate milestones as identified mutually after placement of order shall be met with.

13. LIQUIDATED DAMAGES

In the event of the Supplier failing to complete the work within the delivery period specified

in the contract agreement or any extension agreed thereto, the Purchaser shall reserve the

right to recover from the Supplier as liquidated damages, a sum of 0.5 percentage per week

or part thereof of the undelivered portion of the total contract price of equipment or work.

The Total liquidated damages shall not exceed the 10.0 percentage of the total Contract

price.

28


14. EXTENSION OF TIME

14.1. If the completion of deliveries of equipment, work is delayed due to reason of Force

Majeure the Supplier shall without delay give notice to the Purchaser in writing of their

claim for an extension of time. The Purchaser on receipt of such notice may agree to

extend the Contract period or delivery date as may be reasonable but without prejudice to

other terms and conditions of the Contract.

14.2. Both parties shall keep a record of the circumstances referred to above which are

responsible for causing delays in the execution of the services and shall give notice to the

other party of any such cause as soon as it occurs. An event of Force Majeure, where so

ever it occurs, provided it affects either party in fulfilling its obligations under this

contract, shall justify the affected party's claim of Force Majeure. Should one or both the

parties be prevented from fulfilling their contractual obligations by a state of Force

Majeure lasting continuously for more than a month, the parties shall consult with each

other regarding the future execution of the contract.

15. TAXES AND DUTIES

15.1. GST

The applicable rate of GST (CGST / SGST / IGST / UGST) shall be clearly mentioned

along with the concerned HSN code / SAC.

As per the Notification No.47/2017 - Integrated Tax (Rate) dated.14th November, 2017

issued by the Government of India, Ministry of Finance (Department of Revenue), we are

eligible for 5% IGST. Exemption Certificate as required under the said notification will

be provided along with the Purchase Order.

15.2. CUSTOMS DUTY

a) The Purchaser is eligible for Concessional Customs Duty exemption as per Notification

No.05/2018 dated 25-01-2018. This may be taken into account while quoting for import

items.

b) In case tenderer offering items considering the customs duty exemption, they shall

indicate the list of items and its quantity.

29


15.3. INCOME TAX

Income tax at the prevailing rate as applicable and if applicable from time to time shall

be deducted from the supplier's bills as per Income Tax Act and a certificate issued

(TDS Certificate).

15.4. EARNEST MONEY DEPOSIT (EMD)

a) Party shall submit EMD of Rs. 5.0 Lakh. EMD shall be submitted in a single installment

through Demand Draft / Banker’s Cheque / Fixed Deposit Receipts or Bank Guarantee

from any of the Scheduled Banks executed on non-judicial stamp paper of appropriate

value.

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

National Small Industries Corporation, etc., will be exempted from the payment of

EMD.

c) Parties who are registered (registered and empanelled) with Satish Dhawan Space

Centre e-procurement portal are also exempted from the payment of EMD.

d) In case of bank guarantee, it shall be valid for a period of 45 days beyond the final

tender validity date.

e) Any tender not accompanied with EMD shall be treated as invalid tender and rejected.

Vendors seeking exemption from payment of EMD shall submit necessary proof like

registration number, etc.

f) EMD of a vendor shall be forfeited if the vendor withdraws or amends his tender or

deviates from the tender in any respect within the period of validity of the tender.

g) Failure to furnish security deposit/performance bond by a successful vendor within the

specified period shall also result in forfeiture of EMD.

h) EMD shall be refunded to all the unsuccessful vendors within thirty days after

placement of the Purchase Order.

i) EMD shall be refunded to the successful vendor after payment of the Security Deposit or

may be adjusted against the Security Deposit.

j) 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.

30


16. RISK COVERAGE

The Supplier shall arrange comprehensive risk coverage at his own cost covering the

value of equipment including transportation to the site from manufacturer’s works,

storage at site, fabrication, erection, testing and commissioning at site. The period of

such coverage shall be up to contractual completion period or any extension granted by

Purchaser thereof.

17. SECURITY DEPOSIT

a) Party shall submit security deposit, within 15 days from the date of order placement, for

10% of the total order value. Security Deposit shall be obtained through Bank Guarantee

or fixed deposit receipt from any of the Scheduled Banks executed on non-judicial

stamp paper of appropriate value, and shall be valid for a period of sixty days beyond

the date for completion of the Purchase Order.

b) In case the vendor fails to furnish the security deposit within the specified date or

extended due date, the Purchase Order/Contract shall be cancelled, and the EMD, if any,

made earlier shall be forfeited, and, in addition, appropriate penal action will be

considered.

c) Central PSUs / PSEs / Autonomous Bodies / MSEs shall be exempted from the payment

of Security Deposit, and instead, an Indemnity Bond shall be submitted by them in lieu

of the Security Deposit.

18. PACKING AND FORWARDING

a) The tenderer will be held responsible for the stores being sufficiently and properly

packed for transport by rail, road, sea or air, to withstand transit hazards and ensure safe

arrival at the destination.

b) The packing and Marking of packages shall be done by and at the expenses of the

Contractor.

19. WARRANTY

The supplier shall provide twelve months warranty for the entire system for a defect

liability, after final official handing over at his cost. During this period supplier has to

provide and adhere to the following:

19.1. This period shall include maintenance, replacement of defective / failed parts at free of

cost.

31


19.2. Supplier has to attend unlimited breakdown calls.

19.3. Purchaser will not provide any transport/accommodation for this purpose.

19.4. Upon oral or written notification of defects in or malfunctioning of the goods during the

warranty period which require corrective action, Supplier shall send the necessary

personnel to job site to supervise and assume responsibility for repairs and/or

replacement, if necessary, of the defective goods or material at his own cost. If Supplier

does not, within seven (7) days after receipt of notification, take steps to correct the

breach, Purchaser may do so at the cost and expense of Supplier. Supplier shall reimburse

Purchaser all expenses incurred by Purchaser to repair or replace malfunctioning or non-

conforming goods.

19.5. Purchaser has no obligation to discover defects, patent or otherwise, and this shall be sole

responsibility of Supplier. Inspection and clearance for shipment by Purchaser’s

inspectors or Inspection agency appointed by Purchaser shall not relieve Supplier of any

of his obligation and duties under the terms and conditions herein.

19.6. Where defects in items are remedied under warranty, the period for which the warranty

operates shall be extended by such period, as the items were not available to the

Purchaser. Where defects items are replaced by new ones, the full warranty period

stipulated in the contract shall apply to such replacement items as from the date of their

delivery.

19.7. Supplier shall obtain similar warrantee from each of his sub-suppliers. However, the

overall responsibility shall lie within the Supplier.

20. GUARANTEE:

a) The PLC based Special Purpose Equipment shall be guaranteed against any

manufacturing defects for a period of 12 months from the date of commissioning.

b) For defects noticed during the guarantee period, replacement rectification should be

arranged free of cost within a reasonable period of such notification.

21. PERFORMANCE BANK GUARANTEE

PBG at 10% of the value of the Purchase Order shall be submitted through bank guarantee

from any of the Scheduled Banks executed on non-judicial stamp paper of appropriate

value, and shall be valid for a period of sixty days beyond the date for completion of

warranty period.

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22. DISCLOSURE AND USE OF INFORMATION BY THE SUPPLIER

• If the documents supplied by the Purchaser are marked 'restricted use' the Supplier shall

take all necessary steps to ensure that the requirements of the contract or any

specification, plan, drawing, pattern, sample or information supplied by, or on behalf of,

the Purchaser in connection therewith shall not be disclosed to any person other than a

person employed or engaged by the Supplier, whether under sub-contract or otherwise,

for the performance of the contract.

• Supplier shall guarantee that all information and data received during execution of

Contract from Purchaser shall be classified as confidential within the meaning of the

Official Secrets Act and will not be divulged to any third party without prior written

permission of Purchaser. All drawings & documents shall be returned after execution of

work.

23. ARBITRATION

a) In the event of any question, dispute of difference arising under these conditions or any

conditions contained in the Purchase Order, (except as to any matters the decision of

which is specially provided for by these conditions) the same shall be referred to the sole

arbitration of the Director SDSC SHAR Office or some other person appointed by him,

it will be no objection that the arbitrator is a Government Servant that he had to deal

with matter to which the contract relates or that in the course of his duties as

Government Servant he had expressed views on all or any of the matters in disputes or

difference. The award of the arbitrator shall be final and binding on the parties of this

contract.

(b) If the arbitrator be the head of the purchase office.

i. In the event of his being transferred or vacating his office by resignation or

otherwise, it shall be lawful for his successor-in office either to proceed with the

reference himself, or to appoint another person as arbitrator, or.

ii. In the event of his being unwilling or unable to act for any reason, it shall be lawful

for the Head of the Purchase Office to appoint another person as arbitrator: or

(c) If the arbitrator be a person appointed by the Head of the Purchase Office in the event

of his dying, neglecting or refusing to act, or resigning or being unable to act, for any

reason, it shall be lawful for the Head of the Purchase Office either to proceed with the

33


reference himself or to appoint another person as arbitrator in place of the outgoing

arbitrator.

(d) Subject as aforesaid, the Indian Arbitration and Conciliation Act, 1996 and the rules

there under and any statutory modifications thereof for the time being in force shall be

deemed to apply to the arbitration proceedings under this Clause. The arbitrator shall

have the power to the extent with the consent of the Purchaser and the Contractor the

time making and publishing the award.

(e) The venue of arbitration shall be place as the purchaser in his absolute discretion may

determine. Work under the purchase order shall, if reasonably possible, continue during

arbitration Proceedings.

(f) In case order is concluded on the public-Sector Undertakings, the following Arbitration

Clause will be applicable.

i. In the event of any dispute or differences relating to the interpretation and

application of the provisions of contracts, such dispute or difference shall be

referred by either party to the Arbitration of one of the Arbitrator in the

Department of Public Enterprises to be nominated by the Secretary to the

Government of India in-charge of the Bureau of Public Enterprises.

ii. The Indian Arbitration and Conciliation Act, 1996 shall not be applicable to the

Arbitration under this clause.

iii. The award of the arbitrator shall be binding upon the parties to the dispute

provided; however, any party aggrieved by such award may make a further

reference for setting aside or revision of the award to the Law Secretary,

Department of Legal Affairs, Ministry of Law & Justice, Government of India.

Upon such Additional Secretary when so authorised by the Law Secretary whose

decision shall bind the parties finally and conclusively.

iv. The parties to the dispute will share equally the cost of arbitration as intimated

by the arbitrator.

24. APPLICABLE LAW AND JURISDICTION

The laws of India shall govern this contract for the time being in force. The Courts of

Andhra Pradesh, India only shall have jurisdiction to be with and decide any legal matters

or disputes what so ever arising out of the contract.

34


25. FORCE MAJEURE

Should a part or whole work covered under this agreement be delayed due to reasons of

Force Majeure which shall include legal lockouts, strikes, riots, civil commotion, fire

accident, quarantines, epidemic, acts of God and Government, embargoes, the

completion period for work, equipment referred to in this agreement shall be extended

by a period not in excess of the duration of such Force Majeure. The occurrence shall be

notified by either party within reasonable time.

26. GENERAL

26.1. SITE DETAIL

SDSC SHAR, Sriharikota is prohibited place. Hence, no contractor, working personnel

will be allowed to stay and they have to be accommodated in Sullurpeta by his own

arrangement.

All the working personnel shall comply with code of conduct during there stay inside

the SHAR campus.

26.2. SAFETY

Supplier shall follow the safety regulations / codes or safety instructions issued by

PURCHASER and shall take necessary measures at his own cost.

26.3. POWER SUPPLY

Electrical power provided by the purchaser during installation of PLC based Overhead

Crane handling system is NOT chargeable subjected to availability & approval.

Reasonable quality of normal power will be made available at one point (415V, 3 phase,

50 Hz). However, onward distribution shall be done by the supplier.

All electrical installation by the supplier shall be as per safety regulation & standard and

will be subjected to purchaser inspection & approval.

26.4. WORK RULES

Generally, NO work shall be carried out during night or public holidays unless a written

permission is obtained from Purchaser.

The contractor may have to transport working personnel on day to day basis by his own

arrangement. Location of the site is worked out to be 23 km from Sullurupeta.

The contractor personnel has to under go security checks by security force i.e. CISF

35


26.5. SITE CLEARANCE

Upon completion of work, Supplier shall remove all his equipment and material from

the site within one month or time mutually agreed. Supplier at all times shall keep site in

clean condition and remove all unwanted material at regular intervals. In case supplier

fails to remove all his equipment and material within the mutually agreed time it is

deemed that Purchaser will arrange to remove the same at the supplier’s cost besides

imposing penalty for failure.

26.6. ACCOMMODATION

Very limited accommodation may be provided by Purchaser to senior supervisory staff

of the Supplier on chargeable basis subject to availability.

Supplier shall make his own arrangement for accommodation & canteen facility for all

its staff, technicians, labor & workers. Transportation shall be arranged by Supplier at

his own expenses for entire staff.

26.7. MEDICAL FACILITIES

No medical facilities will be provided by Purchaser at site for Supplier's site personnel.

Supplier shall make his own arrangement at his own expenses for medical facilities for

site personnel.

26.8. WORK PROGRAMME

The supplier along with proposal shall give a preliminary programme schedule for

executing the contract as per the scope of work. Upon award, supplier shall prepare a

detailed programme schedule for review / approval by Purchaser. Supplier as per

exigencies of work shall revise and update programme periodically.

Monthly progress review meeting will be conducted alternatively at purchaser / supplier

site.

26.9. SUB-CONTRACTS

27.9.1 Whole of the work shall not be subcontracted.

27.9.2 The portion of the work for which the supplier is not expert, shall be sub -contracted to

proven / reputed OEM in that field. Such sub- contract if any shall be given with prior

approval of the purchaser including choice of subcontractor.

36


27.9.3 The supplier shall be responsible for the proper execution of any sub-contract placed by

him in connection with this contract.

27.9.4 Unless otherwise authorized by the Purchaser, the conditions of the sub-contracts shall

be secured to the Purchaser any rights provided for it under the terms of the main

contract.

27.9.5 Written permission, if given, shall not relieve Supplier from his obligations under the

Contract and he shall take full responsibility for all work done by Sub-Suppliers.

Supplier shall be responsible for transmitting pertinent data of all Contract terms and

conditions to Sub-Suppliers. Supplier shall furnish to Purchaser copies of all un-priced

sub-orders showing promised delivery dates and places.

26.10. CHANGES AND MODIFICATION TO SPECIFICATIONS, DESIGNS,

DRAWINGS AND QUALITATIVE / QUANTITATIVE REQUIREMENTS.

27.10.1 Supplier shall obtain approval for the designs and drawings from the Purchaser before

initiating the action for procurement / fabrication.

27.10.2 Change in make/model for bought item is NOT allowed unless approved by purchaser.

27.10.3 Purchaser is free to modify the designs or drawings during design review. Party has to

carryout one time modifications at each stage with out any extra cost and obtains the

approval from Purchaser. Two levels of design reviews are contemplated viz. preliminary

design review and detailed design review to meet overall specification of the machine &

sub system.

27.10.4 The Purchaser reserves the right at any time to modify the Quantitative Requirement,

Specifications, patterns or drawings relating to the work covered by the contract. The

Supplier shall inform the Purchaser, within 15 days, of any objection/reservation to the

modifications required.

27.10.5 Unless the Purchaser directs otherwise, the Supplier shall in either case, submit within a

reasonable time limit to be specified by the Purchaser, an estimate of the effect of any

such modification in the cost of performance of the contract and/ or on the delivery

schedule.

Any amendment to the contract, which may be necessary in this respect, will be

established within a reasonable time in the form of an Amendment to Contract to be

signed by both parties.

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26.11. ACCEPTANCE AND REJECTION

ACCEPTANCE AND REJECTION:

On completion of the work or part of the work as specified in the contract, the representative of

the Purchaser referred to, shall check as soon as possible, but in any event within the month of

notification of readiness for acceptance that the work performed complies with the contract

requirements as regards quantity and quality.

In the event of rejection of any of the articles, whereby the Supplier feels himself aggrieved, he

may within eight days of the receipt of notification of rejection and before such articles have

been removed from the place of inspection, give the Purchaser notice of objection. Such

objection shall be considered by a Board of Appeals of the Purchaser. The Purchaser shall,

without prejudice to the arbitration clause in the contract, take a decision upon presentation of

the Board's findings.

Following test shall be conducted at SDSC SHAR after installation for acceptance:-

a) Supplier shall demonstrate performance of the system as per the scope and PO specifications at

the site (NDT Facility, SPP, SDSC SHAR, Sriharikota - 524 124).

On completion of tests, the members of the Inspection Organization of the Purchaser or

Inspection agency appointed by Purchaser shall prepare a report, which must be countersigned

by the Supplier.

26.12. SUSPENSION

27.12.1 Purchaser may notify the Supplier to suspend performance of any or all of his

obligations under the Contract. Such notice will specify the reasons for suspension

and the effective date of suspension. Supplier there upon shall suspend the

performance of such obligations until ordered in writing to resume performance of

Contract by Purchaser.

27.12.2 If Supplier’s performance or his obligations remain suspended or the rate of

progress is reduced, then, the time of completion will be suitably extended and all

costs incurred by Supplier as a result of suspension or reduction in rate of progress

will be paid to Supplier provided that the suspension or reduction in the rate of

progress is not by reasons of Supplier's default or breach of Contract.

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26.13. CANCELLATION

GENERAL RULE:

The Purchaser shall have the right at any time to cancel a contract either wholly or in

part by giving written notice by registered mail. From the time of receipt of the written

notice the Supplier shall undertake to observe the instructions of the Purchaser as to the

winding up of the contract both on his own part and on the part of his sub-suppliers.

WITHOUT FAULT OF SUPPLIER:

In the case of cancellation of a contract by the Purchaser without any fault of the

Supplier, the Supplier shall on receipt of Purchaser's instructions forthwith take the

necessary steps to implement them. The period to be allowed to implement them shall be

fixed by the Purchaser after conclusion with the Supplier and, in general, shall not

exceed three months.

Subject to the Supplier confirming, Purchaser shall take over from the Supplier at a fair

and reasonable price all finished parts not yet delivered to the Purchaser, all unused and

undamaged material, bought-out components and articles in course of manufacture in

the possession of the supplier and property obtained by or supplied to the Supplier for

the performance of the contract, except such material, bought-out components and

articles in course of manufacture as the supplier shall, with the agreement of the

Purchaser, elect to retain.

WITH FAULT OF SUPPLIER:

The Purchaser reserves the right, after full consideration of all relevant circumstances,

including the observations of the supplier, to cancel a contract in any of the following

circumstances.

(a) In the event of the Supplier's failure to meet

(i) The Technical requirements of the Supplier.

(ii) The Progress and/or delivery requirements.

(b) If the Supplier has not observed the provisions of the contract concerning the

disclosure and use of information provided by the Purchaser.

(c) If the Supplier fails to comply with the provisions of the contract concerning the

equipment, supplies and technical documents made available by the Purchaser.

39


(d) If the Supplier transfers his contract without the Purchaser's authorization or

concludes sub-contracts against the Purchaser's explicit directives.

(e) In the event that Supplier unjustifiably repudiates the Contract or fails to ship or

dispatch all or part of the goods ordered for reasons other than those attributed to the

Purchaser’s actions or as provided in the Force Majeure clause, the Purchaser may, by

giving an appropriate notice in writing to the Supplier, fix a Date of Essence by which

the Supplier shall complete the dispatch in full. If the Supplier fails to do so, the

Purchaser, in addition to his right to recover Liquidated Damages in terms of the

Contract, shall also have the right to cancel this Contract and make substitute purchases

from other sources. If the goods are in a partial state of fabrication, Purchaser may have

the fabrication completed by other means, in which event Supplier shall be liable to

Purchaser for the additional expenses incurred thereby, but shall not have any claim on

savings, if any, in such cases.

In the event of such cancellation, the Purchaser shall unless otherwise specified in the

contract, only pays.

- In the case of a fixed-cost contract for the supply of equipment or material. The

contractual value of items delivered and accepted under the contract before receipt of

notification of cancellation, or to be accepted under the special conditions of

cancellation.

- In the other cases.

A fair and reasonable price in respect of such work as has been carried out prior to the

receipt by the Supplier of notification of cancellation.

27. EQUIPMENT AND SERVICES

To be provided by the vendor

• Operation and maintenance manuals

• The Party’s scope of work shall include erection, testing and commissioning, operational

trials covered in this specification.

• Any other system not indicated herein, but required to make the system complete shall be

included and provided by the bidder at no extra cost unless otherwise specifically excluded

as indicated.

To be provided by Department

40


The equipment and services will be made available by the Department:-

• EOT cranes for erection and commissioning at site.

• Locations for PLC based Special Purpose Equipments.

Free electricity and water required for erection at SDSC SHAR.

28. CODES AND STANDARDS

a) All equipments covered under this specification shall comply with all currently applicable

statutes, regulations, standards and safety codes in the locality where the equipment will be

installed.

b) Other national standards established to be equivalent or superior to the codes and standards

specified are also acceptable.

c) In the event of any conflict between the codes and standards referred to in the specification

and the requirements of this specification, the more stringent of these requirements shall

govern.

d) Unless indicated otherwise, all codes and standards referred to in this enquiry specification

shall be understood to be the latest version on the date of offer made by the bidder.

29. GENERAL SPECIFICATIONS RELATED TO FABRICATION

a) All welds shall be ground.

b) 100% DP test for root and final weld pass shall be carried out.

c) 100% Ultrasonic test for plates of thickness above 20mm.

d) 100% Radiography test for all butt welds for plate thickness 20mm and above.

e) The entire fabrication activity shall be performed in a planned / sequential manner to

achieve desired dimensional / geometrical tolerance specified in the drawing or functional

requirement mentioned in this document. It is suggested to add sufficient number of

fixtures and tools to control the distortion during welding process.

f) Dimensions shown in the drawing are final acceptance dimensions. Allowances for

machining and thinning due to fabrication process shall be added to arrive at material sizes.

Party is wholly responsible for realizing the finished product. Allowances mentioned in the

drawing are indicative. Party shall study the requirement and provide proper machining

allowances required based on the fabrication procedure adopted.

41


g) Dimensional tolerance wherever not specified shall follow the standard open dimension

tolerances provided in the drawing. Wherever welded attachments are used to facilitate

fabrication, same shall be removed carefully by cutting or chipping and surface of material

shall be finished smooth by grinding. As far as possible, hammering shall be avoided.

h) Edge preparation shall be carried out for all joints as mentioned in the drawing or as per

standard fabrication procedure.

30. PAINTING

All the exposed carbon steel surfaces shall be painted as per following:-

a) Surface Preparation: Cleaning by wire brush or power tools to remove any loose dirt or mill

scales from the surface.

b) Sand blasting shall be carried out to clean the surfaces before painting operation.

c) Spray painting shall be carried out for primer and paint.

d) Primer: One coat of zinc rich primer with red oxide and zinc phosphate pigments to

42


SECTION -B

SCOPE OF WORK

43


1. INTRODUCTION

1.1.Satish Dhawan Space Centre SHAR is one of the units of Indian Space Research

Organization (ISRO), Govt. of India, is now planning to augment its SDSC

SHAR, Sriharikota, SPSR Nellore Dist. Andhra Pradesh.

1.2. This plant produces solid rocket motors required for the satellite launch vehicles.

2. SCOPE OF WORK

Design, preparation of detailed drawings, manufacture, testing, inspection at

manufacturer’s works, packing, forwarding, transportation to site, unloading,

installation, testing, carrying out process trials and commissioning of PLC based Film

Positioning System for S139 Bay at our site in Solid Propellant Plant, SDSC SHAR,

Sriharikota, India.

1 PLC based Film Positioning System for S139 Bay� 01 set

2 Annual Maintenance Contract for Five years (optional)

after warranty period.

Five

Years

3. VENDOR’S SCOPE OF WORK

The details of vendor’s scope of work for “PLC based Film Positioning System for S139

Bay” for SDSC SHAR, Sriharikota are given below.

3.1. The party shall provide overall general arrangement of the machine & sub system with

all major dimensions

3.2. Technical documents to be furnished by successful bidder.

A) Following drawings is to be provided after placement of order: -

1. Floor space required for offered machine & equipments detail layout for

review / comments & approval.

2. GA drawing of the complete machine indicating overall physical dimensions.

3. GA drawing of sub-system & sub-assembly & major components

4. Foundation drawing of Machine

5. Foundation drawing of Auxiliary system

44


B) Following drawing/details to be submitted during course of realization for approval

1. Fabrication drawings of Machine & its sub-assemblies.

2. Electrical & Instrumentation cables routing with schedule.

3. All electrical panel drawings including auxiliary systems , if any

4. Schedule/rating of electrical machines / appliance etc

5. Schedule/rating of Instrumentation & specifications

6. Details of Remote Control Panel & Local Control Panel.

7. List of process parameter & their details.

3.3. Required handling systems for transportation and erection at site.

3.4. Submission of Quality Assurance Plan.

3.5. Fabrication clearance from Purchaser.

3.6. Packing and forwarding machine, subsystems, spares, accessories and other materials

to site.

3.7. Upon the clearance from Purchaser for site erection, supplier has to erect all the

materials/equipments.

3.8. Providing all other material handling equipment required for site erection of machine

and other subsystems.

3.9. The fully commissioned machine and its subsystems are to be subjected to Test and

Evaluation by the Purchaser Committee. This is to ensure that machine is meeting all its

intended requirements as per the given specifications. If any deviations obtained shall

be resolved by the tenderer at no extra cost within the scope of the work under this

contract.

3.10. Submission of detailed work break down structure with schedules and resources.

3.11. Sub system wise inspection and clearance by Purchaser. Supplier shall carry out

inspection at identified stages and the copies of such reports after inspection shall be

forwarded to Purchaser. The original copies of certificates shall be submitted along with

other documents at the time of acceptance testing.

3.12. Supply of documents and user manuals.

3.13. The supplier has to provide one-year warranty for the entire system.

45


3.14. The scope of the work is not limited to the above but also include all the

requirements for the fully functional of machine to meet all the requirements regardless

of whether they are explicitly mentioned or not.

3.15. The supplier shall be given pre-defined time to complete the action points raised

during various reviews such as design review, fabrication drawings, etc. The action

points have to be closed within the given time. Otherwise it is considered as delay from

supplier side and time will be considered to impose LD.

4. WORKS UNDER PURCHASER’S SCOPE

4.1. Clearance for Quality Assurance Plan

4.2. Clearance for manufacture of machine and its subsystems

4.3. Stage inspections or third-party inspection.

4.4. Pre-delivery / dispatch inspection.

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SECTION –C

TECHNICAL

SPECIFICATIONS

47


SCETION-I : GENERAL TECHNICAL SPECIFICATIONS

1.0 SCOPE

(a) The scope of this enquiry covers special equipments for NDT facility such as Film

positioning system (FPS) and End support system (ESS) complete with electrical works and

associated Instrumentation & control system (optional).

(b) The scope covers design, submission of discussion drawings, preparation of fabrication

drawings after approval by the purchaser, procurement of materials and bought out items,

manufacture, inspection and testing at supplier’s works, packing for delivery, transportation

to site, unloading and storage at site, site fabrication if any, erection, testing and cleaning

including commissioning of all systems and work defined at site and carrying out

performance test and process trails of the special equipments.

(c) The supplier shall perform tests on individual subsystems first and fully integrated

equipments at the end of mechanical completion in the facility after obtaining prior

permission from purchaser.

(d) Testing and evaluation of equipment shall be carried out by the supplier to meet the

functional requirements.

(e) After ensuring that the testing and evaluation of individual equipments is completed in the

facility, each system shall be operated to ensure that design specifications are met by the

supplier.

(f) For Film Positioning System, the supplier shall demonstrate at his shop floor smooth

operation of the following: X-Table motion, Y-Table motion, motion of boom in the vertical

direction, motion of C-slide on the boom, motion of Loader and Un-loader cabinet system,

smooth loading and un-loading action of cassette holders. For ESS, the supplier shall

demonstrate the for smooth operations of Y-table and hoist motion at supplier’s shop floor.

During operation trials at our site purchaser will make available the following: A dummy

segment or hardware, Linac, Linac crane, instrumentation & control system (in the event of

not forming part of purchase order) and film cassettes to the supplier to carry out operation

trials. Actual process trials using live rocket segment will be carried out by the purchaser

with participation of the supplier.

48


(g) It is not the intent to specify completely herein all details of the design, supply, manufacture

and construction of ‘equipment’ / ‘work’. However, the equipment, materials and services

shall conform in all respects to high standards of engineering design, workmanship and be

capable of performing in continuous commercial operation in a manner acceptable to the

purchaser who will interpret the meaning of drawings and specifications and shall have the

power to reject any ‘work’/’equipment’ or material which in his judgement are not in full

accordance therewith.

(h) The Film positioning system (FPS) and End support system (ESS) with accessories shall be

designed, supplied, erected and commissioned within ten months from the date of release of

purchase order. Supplier shall submit project execution plan along with their offer, detailing

the methodology of execution.

(i) In the event of excluding instrumentation & control system from the scope of supply, the

supplier shall extend assistance not only for interfacing of instrumentation items with FPS &

ESS but also for final commissioning of FPS & ESS using PLC and dummy segment.

2.0 DESCRIPTION OF NDT PROCESS

(a) Non-Destructive Testing (NDT) Facility at our site is configured to carry out high energy X-

Ray Radiography of finished solid propellant segments in horizontal attitude on a set of high

capacity Roller stands. The Roller stands are aligned and mounted on a large four-legged

table called Horizontal support structure (HSS) prior to loading of the solid rocket segment.

(b) Prior to radiography each rocket segment is received inside the Exposure hall in horizontal

condition on a Special Purpose Utility (SPU) vehicle. The combination of segment, HSS

and Roller stands is positioned at the designated position in the Exposure hall of NDT

Facility (Figure-A). After driving away of SPU, the concrete sliding door of the hall will be

closed.

(c) After completion of radiography of rocket segment, the sliding door will be opened and

SPU vehicle will be allowed inside the hall. SPU will move underneath the HSS and lift it

along with segment and Roller stands to a height of 300 mm from finished floor level (FFL)

and transport to a nearby facility for tilting the segment to vertical condition and storage

subsequently.

(d) Two types of radiography techniques namely Propellant radiography and Tangential

Radiography are employed for inspection of any rocket segment.

49


(e) The details of the propellant radiography process are as given below:

(i) The ESS is brought to the position close to the axis of the segment from its parking position

by activating the drive of its Y-Table.

(ii) The FPS is brought to the designated position close to the axis of the segment.

(iii)The FPS X-Table drive is activated to insert the boom of FPS into the port of the segment

till it emerges out on the other end of the segment where ESS is brought and positioned. The

boom is configured to carry and transport a Cassette Slide or C-Slide to and fro along its

entire length.

(iv)The Y-Table of ESS is moved to align with respect to segment axis by operating from the

Local push button station.

(v) The Z-slide with its end adapter is raised through the activation its drive until it comes into

contact with FPS boom. There is a counter weight linked to the Z-slide of end adapter

through wire ropes and pulleys and moves in the opposite direction.

(vi)The Linac is moved by activating the X-drive of its crane manipulator to position for the

first X- ray shot.

(vii) The Loader and Un-Loader system of FPS is brought to its lowest position and Cassette

Holders loaded with four film cassettes each are stacked in the Loader cabinet. The

combined system is then raised to a height so that the loader cabinet aligns with the C-Slide

of the boom for the purpose of loading.

(viii) The Exposure hall is vacated and its two doors (Personnel Access door and Concrete

sliding door) are closed. From now on all operations will be controlled from Control Room

and film exposure sequences will be carried out either in semi-auto mode with manual

operation of Linac system or in automatic mode in case the linking of X-ray Linac system

with the PLC is incorporated by the Purchaser.

(ix)First the Cassette holder with fresh cassettes is loaded from the Loading cabinet into the C-

Slide by operating the corresponding Loader air-cylinder

(x) The C-Slide is moved along the length of the boom by chain-sprocket arrangement to the

first X-ray shot position of the rocket segment, locating the cassette holder opposite to the

Linac head.

(xi)X-ray exposure is given to the films of the cassette holder, the C-Slide then moves to the

position opposite of Un-loader cabinet. The exposed cassette holder is unloaded into to the

50


Un-loader cabinet, the C-Slide moves to the position opposite to the Loader cabinet and

second fresh cassette holder is loaded into C-Slide by air-cylinder.

(xii) Linac head is moved to the next position by the PLC based carne manipulator along the

X axis, which is parallel to the segment axis. The supplier shall assist the purchaser in

integrating the crane manipulator and Roller stands with the FPS and ESS systems to enable

automation of radiography process.

(xiii) The cycle is repeated till one sector of the segment is imaged using ten Cassette holders.

(xiv) The Linac crane, FPS and ESS are brought into manual operation mode by transferring

the control from Man-Machine-Interface (MMI) of the PLC system to respective Local push

button stations. Personnel Access door to Exposure hall is opened. A new batch of cassettes

loaded with fresh X-ray films are transported into the Exposure hall. The Loader and Un-

loader cabinet system is lowered and exposed Cassette holders are taken out from Un-

Loader cabinet and re-loaded with new cassettes. The cabinet system is raised back and

aligned with the C-Slide of the boom. The segment is rotated to its next sector position by

remote operation of the Roller stands.

(xv) The Exposure Hall is vacated and the personnel access door is closed. The exposure

cycle as described above is repeated

(xvi) Similar Exposure Cycles will be carried out till complete propellant volume of the

segment is imaged as per approved radiography plan for propellant.

(xvii) After the completion of each cycle, the films are processed using automatic film

processors and inspected to see if any repeat shots are needed. If needed same will be

carried out.

(xviii) On completion of the segment radiography, the FPS is moved to its parking position

such that its boom is completely pulled out of the port of the segment.

(xix) The FPS Y-Table drive and boom drives are activated to locate the boom in the

tangential region of the segment outside and subsequently ESS Y & Z-drives are activated

such that its end adapter supports the free end of the boom. The tangential radiography is

then carried out.

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(f) Tangential Radiography Process

For tangential radiography the sequence of film exposure process as described for the

propellant radiography is similar except that the FPS boom is located outside of the

segment.

3.0 FUNCTION OF FPS & ESS AND USER’S REQUIREMENTS

3.1 FUNCTIONS OF FPS & ESS

(a) The function of the film positioning system (figure 1) is to position the X-ray film cassettes

at proper position inside the segment for propellant Radiography and outside of the segment

for Tangential Radiography.

Figure 1: Film Positioning system (Subsystems: 1. FPS X-Table, 2. FPS Y-Table, 4. Cassette

frame assembly, 5. FPS boom Assembly, 6. FPS boom drive system, 7. Loader & Un-loader

Cabinets, 8. Loader & Un-loader drive system (Film Lift) and 9. Colum Assembly)

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The Film positioning system has following motions:

(i) Movement of FPS along the X-axis: Considering the maximum length of 7535 mm of

segment and various clearances, approximately 9500 mm stroke will be required.

(ii) Movement of FPS along the Y-axis: Considering the adjustments required during

propellant and tangential radiography the movement of about 4000 mm shall be provided.

From the propellant radiography position, a margin of about 1000 mm shall be provided

for the Film Y-Table to accommodate the inaccuracies of segment placement in the

Exposure hall.

(iii)Movement of Boom along the Z-axis: Considering the adjustments required during

propellant and tangential radiography and for the maintenance purpose the movement of

the boom from 2 meters to 7 meters shall be provided above the FFL.

(iv)Movement of Cassette slide along the X-axis: Considering the maximum length of 7535

mm of segment the movement of approximately 14000 mm may be required.

(v) Movement of Loader & Un-loader drive system (Film Lift) along Z-axis: Considering the

boom movement along Z-axis, the movement of film lift shall be planned accordingly.

(b) Function of the End support as shown in the figure 2 below is to support the FPS boom at

another end of the segment. The End support has provision to move along the Y-direction as

well as in Z-direction. This gives flexibility to align the end support with FPS boom.

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Figure 2: End Support System and its subsystems

(c) End support system has following motion provisions:

(i) Movement of ESS along Y-axis. When the SPU enters the Exposure hall the ESS is parked

away from the path of SPU. Considering this a stroke of about 7000 mm shall be provided.

(ii) Movement of the ESS end adapter along the Z-axis is provided to cater to different height

levels of FPS boom for propellant and tangential radiography. The ESS Y-Table length shall

be about 1900 mm so that it can be parked in the designated corner of the Exposure hall.

(d) Speed limits of FPS subsystems are as follows:

(i) FPS X-Table : 2000 mm/min.

(ii) FPS Y-Table : 2000 mm/min.

(iii) Boom along Z-axis : 1000 mm/min.

(iv)Loader & Un-loader cabinet system along Z-axis : 1000 mm/min.

(v) C-Slide along boom length (X-axis) : 5000 mm/min.

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(e) Speed limits of ESS subsystems are as follows:

(i) ESS Y-Table : 2000 mm/min.

(ii) ESS Z-Slide : 1000 mm/min.

3.2 OTHER CONSIDERATIONS

(a) Allowable stresses for the design of structures shall be as per IS: 800. Allowable stresses of

structural steel shall not exceed 120 MPa for body metal and 100 MPa for welds.

(b) The rocket segment will be positioned at the designated location in the Exposure Hall

parallel to X-axis within ± 5 mm using SPU.

(c) The Rails required for FPS X-Table and ESS Y-Table motions is in the scope of purchaser

and already available in the bay floor.

3.3 USER’S REQUIREMENTS

(a) Refer figure 3 for the General Arrangement of Exposure hall.

(b) Centerline of the rocket segment in horizontal orientation along its length when placed on

high capacity roller stands may be at about 5400 mm from FFL.

(c) Approximate cassette dimensions are 430 mm length x 330 mm width x 15 mm thickness.

(f) Cassette weight is approximately 40 N.

(g) FPS & ESS shall be configured to carry out both propellant radiography and tangential

radiography of rocket segments.

(h) For propellant Radiography the cassettes are to be kept inside the propellant port of segment

for single wall single image radiography.

(i) For Tangential Radiography, cassettes are to be kept outside of the segment in its top

tangential region as close as possible for imaging of interfaces.

(j) Four cassettes are to be kept in vertical plane at a time in a cassette holder frame along the

length of segment with an overlap of about 50 mm between the cassettes.

(k) Horizontal distance of the cassette holder from the Linac X-ray source is about 7 m for both

propellant and tangential radiography.

(l) Cassette positioning using Film positioning system shall cover the entire length of the

segment for imaging the propellant and interfaces as per the approved radiography plans.

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4.0 DESIGN CRITERIA

(a) All structures shall be as per provisions of IS: 800

(b) Pneumatic system shall be designed for 5 bar maximum. The components shall however be

suitable for 10 bar design pressure.

(c) Speed limits for different subsystems of FPS and ESS shall be as in 3.1 (d) & (e).

(d) Standard off-the-shelf pneumatic elements shall be used.

5.0 EQUIPMENT AND SERVICES TO BE PROVIDED BY THE SUPPLIER

(a) Detailed Design Drawings, fabrication drawings and Assembly drawings.

(b) Quality assurance plan for manufacture and testing.

(c) Quality records, history dockets, as built drawings and all documentation related to

manufacturing, inspection, testing and erection.

(d) Assembly Procedures, maintenance procedures and operating procedures.

(e) Manufacture and Supply of the following systems.

(f) Film Positioning System (FPS) broadly comprising of following sub-systems:

(i) FPS X-Table.

(ii) FPS Y-Table

(iii) FPS Columns with linear guides

(iv) FPS Boom Z- Slide system

(v) FPS Boom

(vi)Cassette Slide

(vii) Loader and Un-Loader Cabinet system.

(viii) All electric and pneumatic drive components,

(ix) Controllers and position sensing devices (optional)

(x) Rails for movement of FPS Y-Table.

(g) End Support System (ESS) broadly comprising of the following:

(i) ESS Y-Table

(ii) ESS Column

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(iii) ESS Z-Slide

(iv) ESS Boom Adapter

(i) Electrical works as per Section II

(j) All instrumentation & control systems (Optional) as per SECTION-III and cabling

required in order to facilitate manual, semi-automatic or automatic operation of FPS &

ESS from the Control room apart from manual operation of the same locally in the

Exposure hall using corresponding Local push button stations.

(k) Air compressor (Optional) required for loading cassette holders with fresh film cassettes

from Loader cabinet into the C-Slide and unloading of exposed cassette holders from the

C-slide into the Un-Loader cabinet shall be provided at a designated location in one of

the service rooms of the NDT Building at a distance of ~160 m from FPS.

(l) Necessary piping required for compressed air from service room to fixed location inside

the bay shall be provided by the supplier. From the fixed location to pneumatic circuit

on FPS shall be planned by flexible PU hoses. Required online instrumentation, pressure

reducing valves, FRL units shall be in the scope of supplier. (Optional)

(m)Painting of all the equipments and structures listed above.

(n) Necessary equipments required for testing, cleaning and flushing of the system.

(o) Grouting of the equipments if required.

(p) First fill of oil, grease, lubricants as required during start-up and commissioning.

(q) Operation and maintenance manuals for the complete system.

(r) Auxiliary steel / structural steel for supporting the equipment, piping, cabling, etc.

(s) All anchor bolts / foundation bolts, nuts, washers and inserts to be embedded into the

concrete for the cable chain systems of FPS & ESS and piping.

(t) All hardware e.g. Nuts, bolts & gasket, anchor fasteners etc., including breaking of walls

are included in the supplier's scope. No separate claim shall be entertained, in this

respect. At least 10% extra hardware shall be provided for any installation / fixing work.

This is to ensure ready availability of hardware in case of loss of some hardware during

installation.

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(u) Power, control and signal cables are to be routed through cable drag chain of IGUS

make or equivalent. The length of the cable drag chain shall be planned in such a way

that it shall meet the requirement of all motions of FPS and ESS. For providing supports

for cable chain systems, rails and the equipments the supplier shall supply suitable EP

and fix to RC Walls using anchor fasteners.

(v) Structural steel supports for piping and cable chain systems.

(w)Drawings for review and approval by the purchaser.

(x) Operation and maintenance manuals.

(y) For standard bought out components (gear box, motor, pneumatic cylinder, etc.), the

supplier may use the specific make as indicated in the GA drawing / specification.

Alternatively, the supplier may use equivalent component of a different make of

repute. In such cases the supplier shall submit calculations / justification showing

adequacy of the selected component for approval from the purchaser before

procurement. The supplier shall also carry out required design modifications to suit the

mounting of the selected components.

(z) Shop floor inspection and tests shall be as per the specifications. Wherever not specified,

the shop floor inspection tests shall be as per recent codes applicable.

(aa) The supplier’s scope of work shall also include erection, testing, start up,

commissioning, operational & process trials covered in this specification.

(bb) Training of purchaser’s personnel.

(cc) Any other system not indicated herein but required to make the system complete shall

be included and provided at no extra cost.

6.0 EQUIPMENT & SERVICES TO BE PROVIDED BY PURCHASER

The following are the equipments and services that shall be provided by others:

(i) NDT Facility consisting of Exposure hall and service rooms.

(ii) Power control centre (PCC) for tapping of electrical power

(iii) Linac X-Ray Machine

(iv) PLC based Overhead crane handling system with Linac.

(v) Rails of Film Positioning System (X-motion) and End Support system (Y-motion).

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(vi) Cable trenches connecting service rooms and Exposure hall.

(vii) Cassettes with fresh X-Ray films for performing Radiography process trials.

(viii) 60 t capacity EOT crane inside the Exposure hall.

(ix) Handling tackles.

(x) Horizontal Support Structure (HSS) for mounting Roller stands

(xi) Dummy rocket segment or hardware

(xii) Roller stands for rotating solid propellant rocket segments.

(xiii) Fire protection system for the entire facility.

7.0 CODES AND STANDARDS

(a) All equipments / systems and works covered under this specification shall comply with all

currently applicable statutes, regulations, standards and safety codes in the locality where

the equipment will be installed.

(b) In particular, the latest editions of the following standards are applicable

Steel for general structural purposes IS 2062

Plates and Stiffeners IS 2062 GR-B

SQ. Hollow sections IS 4923 YST 310 grade

Rolled sections and special sections IS:808, IS:1161, IS:1173,

IS:1252, IS:1730, IS:1731,

IS:1732, IS:1863, IS: 1864,

IS:2314

(c) Other national standards established to be equivalent or superior to the codes and

standards specified are also acceptable. The supplier shall furnish English translation of

all standards specified in this specification.

(d) In the event of any conflict between the codes and standards referred to in the

specification and the requirements of this specification, the more stringent of these

requirements shall govern.

(e) Unless indicated otherwise, all codes and standards referred to in this enquiry

specification shall be understood to be the latest version on the date of offer made by the

supplier.

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8.0 CONFIGURATION OF FPS & ESS

The configuration of Film Positioning system and End Support System may be made in the

following sequence:

(i) Fresh Cassette in Cassette Holders shall be placed in the Loader cabinet

(ii) Exposed Cassette Holders shall be placed in the Un-Loader cabinet

(iii)Loader and Un-Loader cabinets shall be mounted on Film Lift

(iv)Film Lift shall be mounted on Y-Table

(v) Cassette Holder shall be held in C-Slide

(vi)C-Slide (along the length of segment) shall be supported on the boom of the Z Travel

arrangement.

(vii) Boom Vertical Travel Arrangement shall be on Vertical Column Assembly.

(viii) Vertical Column Assembly shall be mounted on FPS-Y Table Assembly.

(ix)FPS Y-Table shall be mounted on FPS X-Table.

(x) FPS X-Table shall be placed on FPS Rails embedded in the floor of Exposure Hall.

(xi) ESS Adapter shall be mounted on ESS Vertical Slides

(xii) ESS Vertical Slides shall be mounted on ESS Column.

(xiii) ESS Column shall be mounted on ESS Y-Table.

(xiv) ESS Y-Table shall be placed on the ESS rails embedded in the floor of Exposure Hall

Note: FPS boom shall be configured to cover the entire length of the longest rocket

segment. The free end of the boom shall be supported using ESS.

Conceptual drawings of FPS and ESS are provided. Detailed design and fabrication drawings

shall be provided to the purchaser for necessary approval. Fabrication shall be carried out only

after obtaining clearance from the purchaser.

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8.1 X-Table

The film X-table is a rectangular structural frame. It has wheel assemblies at four corners and

also in the middle of the long members. Both wheel assemblies are suitable for driving by drive

modules.

8.2 Y-Table

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The Film Y Table is a rectangular structural frame having interconnecting structural members.

It has wheel assemblies at the four corners. Both wheel assemblies are suitable for driving by

drive modules

8.3 Cassette Holder

(i) Cassette holder is specially configured to hold the loaded X-Ray film cassettes for

propellant and tangential radiography.

(ii) It shall have four slots with an effective film area of about 1100 mm x 400 mm.

(iii) Cassettes when loaded in the Cassette holder shall have an overlap of 50 mm between

them.

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8.4 FPS Boom

(i) The boom moves inside the segment for propellant radiography and outside the segment

for interface radiography. The cross section of the boom is limited by the size of the

propellant port of the rocket segment.

(ii) The length of the cantilever portion of the boom shall be approximately 9500mm to

cover the radiography of longest segment. The allowable deflection at the end of the

boom shall be less than 15mm.

(iii)The boom is supported at other end by the End adapter of ESS, which is movable to

clear the passage for SPU entry.

(iv) The end face of the boom at its free end shall be provided with at least 9 numbers of

intrinsic safe photo sensors for the purpose of detection of propellant surface and safe

travel through the propellant port

(v) The boom shall be provided with a drive module for the Cassette Slide and an air

cylinder for unloading the exposed cassette holder in the Un-Loader cabinet. The

Cassette Slide shall be accurately positioned at the Un-loader cabinet for this function.

(vi)The supplier shall design and provide removable cover (Aluminium) for the boom

assembly entering the propellant port of rocket segment meeting the following

requirements. The boom shall be provided with covers for enveloping the moving parts

to prevent egress of dirt, oil etc. on the port surface. Each cover shall be made in two

parts. One part shall be screwed to front portion of half of the boom assembly and other

part shall be screwed to the back half of the boom. The covers shall be easily removable

for inspection and maintenance. The covers shall not hinder free movement of the

cassette slide with cassette holder on the boom. The maximum diameter of the boom

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enveloped with covers shall not exceed 800mm. The cover design of the supplier shall

be approved by purchaser before manufacture.

8.5 Cassette Slide or C-Slide

(i) C-Slide moves the cassette holder loaded with fresh X-Ray film cassettes to the desired

position along the length of the boom.

(ii) Cassette slide shall be guided along the FPS Boom with LM guides.

(iii) The movement of the Cassette slide or C-Slide is by chain sprocket/alternative

arrangement.

(iv) The C-Slide is driven by a suitable drive module.

8.4 Loader and Un-Loader cabinets

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(i) Loader and Un-Loader cabinets are designed to hold minimum 10 cassette holders (10 x 4 =

40 Film cassettes) at a time.

(ii) The cabinets shall be provided with a Lead (Pb) shielding of thickness 40mm (front and

sides) and 15mm (top) as illustrated in the figure.

(iii)When loaded with a cassette holder the C-Slide transports it along the boom length and

locates it at any desired position by PLC program.

(iv)Loading of cassette holder into the C-Slide and unloading of cassette holder from the C-

Slide into the Un-loader cabinet is by respective pneumatic cylinders.

(v) The sprockets shall be made up of non-sparking material such as copper-beryllium or

phosphor-bronze.

(vi)At the end of radiography process involving 10 cassette holders, the Loader and Un-loader

cabinet system is lowered to a suitable height. Exposed cassette holders are collected from

the Un-loader cabinet and the film cassettes are taken out from them. Fresh cassettes are

then loaded into the cassette holders and the same are stacked into the Loader cabinet

manually.

(vii) At the end of reloading of Loader cabinet, the system is again raised and positioned to

align with the C-Slide of the boom by manual operation.

8.5 End Support System (ESS)

(i) The ESS comprises of Y-Table, Column, Vertical Slides and Boom Adapter mounted on

the vertical slides.

(ii) ESS boom Adapter is dimensioned to provide propped support to the adapter on the

Boom. The fit is loose to avoid loads due to flexing of the boom.

(iii) The boom of the FPS passes through the segment port for propellant radiography (and

gets positioned outside of the segment for tangential radiography) and the end of the

boom is supported using the ESS boom adapter.

(iv) When the SPU arrives, the ESS is moved and parked at a distance close to the wall of

Exposure Hall. After the SPU leaves the NDT facility, the ESS is brought to the desired

position.

(v) The height of the ESS adapter is adjusted to suit to the height of boom.

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9.0 FPS and ESS Cable System

The details of cables required are described in Sections II and III.

10.0 OPERATION SEQUENCE AND INTERLOCKS

The operating sequence during radiography is as follows. Home position of the FPS is defined

by following status of the various subsystems.

10.1 Film positioning system

(a) X-Table parking at the mechanical stop away from the door entry.

(b) Y-table parking at the mechanical stop away from the segment location.

(c) Z-slide parking at the bottom-most position.

(d) Loader & Un-loader cabinet system is at the lowest position

(e) C-Slide parking at Un-loader cabinet.

10.2 End Support system

(f) ESS parking at its home position away from the sliding door entry.

10.3 Preliminary preparation

(a) Rocket segment is transported to NDT facility from Inhibition facility on 400 t capacity

roller stands mounted on HSS by Self Propelled Unit (SPU) in horizontal attitude.

(b) Entry door of the exposure bay of Exposure hall is opened. It gives audio-visual alarm

indicating that the door of the exposure hall is opened. The operators enter into the exposure

hall.

(c) Rear end of SPU enters Exposure hall and the SPU halts such that the front of the SPU is at

the designated position in the facility from the entry door.

(e) SPU positions itself above the location specially prepared for accepting HSS. HSS is

lowered by lowering the SPU. Support structure aligns itself such that it is located within ±5

mm of its desired position. SPU is taken away from the Exposure hall and the door is

closed.

10.4 Preparation for Propellant Radiography

(i) For propellant Radiography, the boom of the Film Positioning system needs to be inserted

into the port of the rocket segment.

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(ii) Film exposure by X-ray beam activation is possible automatically when the film cassettes &

Linac have reached their designated positions and a signal to that confirmation is available

from the PLC.

(iii)The automatic activation of X-Ray beam from Linac control console could be given after a

time lapse of about 2 minutes to allow the dampening of vibrations of the Linac head.

However, it is supplier to attempt a complete automated operation involving exposure of

films over one complete length of the segment after manual activation of the beam is tried

sufficient number of times and results are confirmed satisfactory. Till then this provision in

the programming can be put on hold.

(iv) The C-Slide moves and aligns with the Un-loader. The cassette holder is unloaded into the

Un-Loader cabinet. If the number of film cassettes in any cassette holder is less than 4, as

sensed by the film cassette proximity switches an audio / visual alarm is raised and the

operator can carry the operation only in manual mode. This provision is made to warn the

operator that less than required film cassettes are being exposed for a special case such as

re-shots or additional shots.

10.5 For tangential radiography

(i) All the operations for the tangential radiography are similar to that of propellant

radiography except that the FPS, ESS and Linac crane are positioned and manually

locked in the tangential radiography mode.

(i) Following interlocks shall be provided for the slides of FPS & Linac crane:

• Z-slide shall not move unless the Y-slide is aligned & locked in position.

• X-slide shall not move unless the Z-slide is aligned & locked in position.

The above interlocks shall be achieved in the PLC in both auto & manual modes.

(iii) The C-slide shall move only after the X, Y & Z-slides of the film positioning system and

X, Y & Z-slides of the Linac crane are in aligned positions.

(x) Full Cassette Holder is detected at the Film Loading position by proximity switches. If

all 4 cassettes are missing further operation of FPS will not take place. If one or two

cassettes are missing, loud audio and/or clear Visual warning system will be actuated.

Under this condition the exposure can take place only under manual operation. The

automated system is bypassed for the manual operation.

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(xi) If the boom passing through the segment port hits the end limit switch on other side or if

obstruction is sensed in the segment port for movement of the boom, the movement of

the X-slide shall be stopped immediately. To detect obstruction in the passage of the

boom through the segment port in order to avoid rubbing on the propellant in the

segment 9 numbers of photoelectric sensors need to be mounted at the free end of the

boom. With the usage of photoelectric sensors, if any obstruction sensed in the path of

movement of the Boom, the PLC can be programmed to automatically stop the

movement of the boom. Hence no operator intervention is required in this option.

(xii) Linac crane shall be in off position till new position of cassette holder is achieved after

picking new cassette holder.

11.0 PRELIMINARY SPECIFICATIONS OF MAJOR SUB-SYSTEMS

(a) Preliminary specifications for the major items of the recommended alternative are given

below:

Review of material test certificates Category C

UT of plates for thickness greater than 20mm Category C

(b) The following are the minimum in-process tests that shall be carried out:

Welding procedure & welder / welding operator’s

performance qualification

Category C

100% MT / PT for flame cut edges for plate thickness

exceeding 38mm.

Category B

100% MT / PT for butt welds greater than 25mm thickness. Category A

100% PT after back gouging Category B

100% MT / PT for fillet welds when both plates exceed

25mm thickness.

Category A

100% MT / PT for fillet welds between tension flanges &

webs.

Category A

100% RT for butt welds when thickness exceeds 32mm. Category A

(c) Heat treatment shall be carried out on the following:

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For carbon steel plates where thickness exceeds 50mm. Category C

All tension members referred to in the drawings. Category C

Wheels and Axles of the Wheel Modules Category C

(d) The following are the final inspection / tests that shall be carried out:

Visual and dimensional inspection Category A

Trial assembly (if any) Category A

Blue matching for bolted components Category A

(e) Inspection and testing procedures and scope of inspection of third party inspection agency /

purchaser for all systems with methods of testing

(i) Raw Material Inspection shall be carried out at the supplier’s work for compliance of the

raw materials to the specified standards.

(ii) Bought Out components shall be inspected at supplier’s premises for compliance with the

specifications.

(iii)Fabricated components shall be inspected at the supplier’s works for compliance with the

component drawings. Sub-Assemblies shall be inspected at the supplier’s works for

compliance with the Sub-Assembly drawings and for performance requirements.

(iv)Full Assembly of the FPS and ESS shall be inspected at the supplier’s works for

compliance with the Assembly Drawings and performance requirements.

(v) Drive units (electric motors, pneumatic cylinders, gear boxes, linear guides, etc.) will be

inspected in the supplier’s works at assembly stage and performance test stage for

compliance with the drawings, specifications and performance requirements.

(vi)The performance test of the assembly of FPS and ESS is carried out at the supplier’s shop

floor by making a mock test set-up. Following parameters are checked for the

performance of the assemblies.

(vii) Smooth travel of subsystems of FPS and smooth loading and un-loading of Cassette

holders.

(viii) Smooth travel of ESS subsystems in Y- Table and Z- slides of end adapter and counter

weight.

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(ix)Travel of film positioning system in the dummy segment having ID of 900 mm, without

touching the dummy segment. Alignment of ESS to suit the location end of the boom

when boom travels totally inside the dummy segment. Travel of cassette holder inside the

segment.

(x) Travel and alignment of the Linac system to suit the location of the Cassette Slide.

12.0 INTERFACE DETAILS BETWEEN ITEMS / SUB-SYSTEMS /SYSTEMS

(a) The segment is required to be placed in its position correctly on the horizontal support

structure. The location of the horizontal support structure is required to be within ± 5

mm in horizontal and also within ± 5 mm in vertical direction.

(b) Embedded Parts (EPs) for the FPS & ESS cables from the concrete walls of the

Exposure hall.

(c) Embedded parts (EPs) for cable chain systems of FPS and ESS.

(d) The SPU is required to cross the rails (provided for movement of ESS Y-Table).

(e) Compressed air for the Cassette Loader Cylinder and Cassette Un-loader Cylinder is

drawn from the compressor through pipes and flexible hoses.

13.0 COMPLIANCE OF SPECIFICATIONS & USER REQUIREMENTS

(a) The designs made by the supplier shall comply with the requirements expressed in the

drawings and write-ups related to the designs.

(b) For designs changes required in mounting of pneumatic cylinders due to dimensional

differences in different makes and models, the supplier shall make the necessary design

drawings and submit them to the purchaser for approval. The design changes made thus

shall be similar to the designs shown in the drawings.

14.0 ERECTION SEQUENCE

(a) The FPS & ESS are erected similar to machine tools. The erection of FPS & ESS means

assembly of the different sub system installation on the rails laid in the Exposure hall

floor.

(b) The sub assemblies are made from the manufactured modules and parts. The sub-

assemblies are brought together to form the assemblies of Film Positioning and End

Support systems.

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(c) The rails to be laid on the floor of the Exposure hall shall act as the installation and

operational references.

(d) The Boom deflection shall be within ± 10 mm.

The supplier shall submit along with his proposal detailed erection sequence for Film

positioning system and End support system.

15.0 PAINTING

All the exposed, un-insulated carbon steel surfaces shall be painted as per following:

(a) Surface Preparation: Cleaning by wire brush or power tools to remove any loose dirt or

mill scales from the surface.

(b) Primer: One coat of zinc rich primer with red oxide and zinc phosphate pigments to

achieve total DFT of 70 to 75 micron.

(c) Final Coat: Two coats of epoxy paint of total 100 micron DFT.

(d) Total DFT shall be 175 microns (min.)

(e) The grade of paint shall be chosen such that it will withstand the maximum temperatures

to which the components painted will be subjected.

(f) Any intermediate cleaning required between successive coats of paint shall also be

carried out as per manufacturer’s standard.

16.0. SUMMARY OF DATA TO BE FURNISHED ALONG WITH BID AND AFTER

PLACEMENT OF ORDER

Along with Technical Bid

(xi) Proposed Quality Assurance Plan

(xii) Proposed Project execution plan

(xiii) Bar chart for supply & erection schedule indicating the date of completion of various

activities so as to complete the execution of the contract within the time frame

stipulated in the tender specification.

(xiv) List and Makes of the bought out components that the contractor has considered in the

proposal.

(xv) List of manufacturing drawings to be made by contractor based on the enclosed

drawings.

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(xvi) Write up of the equipment offered by the contractor based on the Tender Document

along with the catalogues, drawings, etc. and with deviations from Technical

Specification and proposed Design modifications.

(xvii)Compliance Statement for Clause by Clause compliance.

(xviii) Electrical and I&C equipment list planned by the contractor based on the Tender

Document.

(xix) Fabrication and erection sequence proposed to be adopted.

(xx) Names of suppliers for steel materials.

(xxi) Performance curves/rating charts used for selection of equipment for all the systems

shall be furnished along with the bid, with the duty points duly marked on them.

(xxii)All sheets of Section F duly filled in, signed and stamped.

(xxiii) Electrical load list indicating rating and quantity.

17.0 DETAILED ENGINEERING DOCUMENTS AFTER ISSUE OF LETTER OF

INTENT (LOI)

(a) The detail data and drawings, as per schedule indicated in the following clause of this

section.

(b) Final Quality Assurance Plan.

(c) Pneumatic Circuit Diagram as finalized for placement of order

(d) Final Purchase orders for bought out components

(e) Test Certificates for Steel Materials

(f) Procedures for Welding, Qualifications of Welders, Painting and Finishing

(g) Packaging and Transportation Plan

(h) Erection Plan

(i) Inspection and Testing Plan

(j) Commissioning Plan

(k) Final data sheet B.

(l) Spare parts list.

17.1 Final Documents

(i) Operation and maintenance manuals.

72


(ii) Quality assurance documentation specific for the project.

(iii) Final as built documentation folder containing all items for future reference.

18.0 BOUGHT-OUT ITEMS

The bought-out items shall be of following make only. If for any reason, the supplier plans to

use different make(s), prior approval for the same shall be obtained from the purchaser.

(a) FASTENERS : TVS, GKW, UNBRAKO

(b) BEARINGS : SKF, FAG

(c) FLAME-PROOF MOTORS WITH IN-BUILT BRAKES: SEW EURODRIVE

(d) GEAR BOXES : SEW EURODRIVE

(e) PLUMMER BLOCKS : FYH, NTN. ALL-FLEX, HI-CLIFF

(f) COUPLINGS : FENNER, ELECON, RADICON, SHANTHI,

(g) VFD : SIEMENS

(h) EX-PROOF ABSOLUTE ENCODERS : P & F

(i) INTRINSIC SAFE RELAYS : P & F

(j) PLC : SIEMENS

(k) CABLE DRAG CHAIN : IGUS

(l) CABLES : LAPP

(m) SWITCH GEARS : SIEMENS

(n) PAINTS : ASIAN PAINTS, BERGER PAINTS

19.0 GENERAL INSTRUCTIONS / REQUIREMENTS

(a) The supplier shall submit GA mechanical, electrical drawings, giving overall dimensions,

etc., for approval by the purchaser within three weeks of receipt of Purchase Order.

(b) The party shall use structural steel of SAIL, Jindal or Vizag steel plant make only.

Necessary test certificates for mechanical properties and chemical composition shall be

submitted.

(c) As the instrumentation is optional, provisions shall be made in the shafts of all motors of

FPS & ESS to smoothly interface absolute position encoders, the details of which will be

provided by the purchaser during design phase. Minor provisions for mounting other

instrumentation items such as limit switches, proximity sensors, photo sensors, flame proof

and non-flame junction boxes shall be carried out during erection phase of FPS & ESS.

73


(d) The party shall not offload the contract or part of i t to any sub-contractor without prior

permission from the purchaser.

(e) Detailed fabrication drawings shall be submitted to the purchaser once the tender is awarded

for approval.

(f) Any minor changes in the design to be pointed out by the purchaser shall be incorporated

with no extra cost.

(g) The fabrication shall start only after clearance of GA, fabrication drawings and design

calculations by the purchaser.

(h) It is not the intent to specify completely herein all details of supply, manufacture and

construction of equipment. However, the item shall conform in all respects to high standards

of workmanship and be capable of performing in continuous commercial operation in a

manner acceptable to the purchaser who will interpret the meaning of drawings and

specifications and shall have the power to reject any ‘work/equipment’ or material which in

his judgement is not in full accordance therewith. The Purchaser's approval of the drawings

shall not relieve the party from his responsibility for errors or omissions, which may exist,

even though work is done in accordance with such approved drawings. When such errors

or omissions are discovered later, they shall be made good

by the party at his expense irrespective of any approval of the purchaser.

(i) All welding shall be DP tested after final weld. All welds shall be free from cracks or any

other defects.

(k) Greasing nipples shall be provided at required lubrication points.

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SECTION –II : ELECTRICAL SPECIFICATIONS

1.0Electrical Equipment Environment

a)

Items supplied should be suitable for Hazardous Area:

Zone1, Gas Group IIA /IIB, T4asperIS5572, IS 5571, IS 2148 and IS 5780 or equivalent

IEC standards.

b)Item supplied should be suitable for tropical and humid climate:

Temperature of 50°C & RH not less than 95%.

c)De-rating:

All the drive motors, power cables etc., shall be done for ambient temperature of 50°C.

d)Item supplied should be suitable for the following power supply variation:

Voltage ±10 % and Frequency ±3 %.

2.0 Voltage

a)Power supply to motors:

3 Ph, 4 Wires, 415 V AC ± 10%, 50 Hz ± 3%.

b)

Control Voltage inside the Electrical Panel:

(i) 1 Ph, 2 Wires, 110 V AC for all contactors, relay, indication lamps, etc.

(ii) 1 Ph, 3 Wires, 230 V AC for all lights, power sockets, etc.

(iii) 24 V, DC supply for Drive auxiliary supply (if required).

c)Control Voltage in the Pendant push button:

8.9 V, Intrinsic safe supply (interfacing of hazardous with safe area).

d)

Auxiliary supply for multifunction meter, VVVF drives and related Control unit(s), etc.,

need to be extended using suitable UPS power supply. UPS power needs to be extended

with the identified and suitable rated circuit breaker and terminal.

3.0 Electric Motor

3.1Should accept the input from VVVF drive, 60% CDF, min of with 300 starts per hours,

IP55, Inverter Duty, Class ‘F’ insulation, suitable to hazardous area mentioned above.

3.2 All the motors shall have provision to connect ex-proof absolute encoders in their shafts.

3.3 Thermistor

(a) All the motors shall be housed with inbuilt

THERMISTOR.

(b) Independent thermistor relay shall be used.

(c) Alarm and Trip input shall be wired separately as an input

to VVVF control unit.

(d) Protection like switch OFF / TRIP the motor in case of

increase in surface temperature more than T4

classification.

(e) Quantity: 2 sets per motor (if applicable) or 1 set per motor

– will be decided based on the motor rating.

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3.4 Bearing

(a) Type: ‘ZZ’ bearing.

(b) If not suitable lubrication provision shall be provided.

(c) Insulated bearing shall be used in case of motor rating

more than 55 kW.

3.5 Torque rating of Motors

(a) Pull out torque of motors shall be not less than 2.75 times

of full load torque.

(b) Motor full load torque rating shall be minimum 120% of

calculated torque with duty factors as per IS: 3177.3.6 Speed rating of Motors Shall be of 750 RPM.

3.7Current drawn by the

Motors

Maximum Current drawn by all motors (rating more than 2 hp)

with SWL shall not exceed 80 % of the full load rated current.

3.8 Over load capability 150% of full load current for 2 minutes without damage or

permanent deformation from zero to base speed.

4.0 VVVF Drives

(a) The power (kW) rating of VVVF drive shall be one step

higher than the selected or finalizing electrical power

(kW) rating of the motor.

(b) All the VVVF drives shall be controlled by a centralized

PLC system via suitable means of communication only.

(c) It shall have a capability for accepting the encoder signals

either from the sensor module or directly from the

encoder.

4.1FPS X -Travel

(a) Shall be supplied with 2 Numbers. (1 Working; 1

Standby).

(b) Each drive shall have a capability to drive two motors.

(c) Each motor power shall be routed through suitably rated

MPCB independently with type-2 co-ordination.

(d) Three positions maintained selector switch shall be

provided for the drive selection.

(e) The selected drive shall be indicated by means of

indication lamp.

(f) It shall have a provision for communicating to the

automation system via. PROFINET/Ethernet protocol.

4.2FPS Y- Travel

(a) Shall be supplied with 2 Nos. (1 Working; 1 Standby).







indication lamp.

(f) It shall have a provision for communicating with the


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4.3FPS Boom Z-Travel








indication lamp.

(f) It shall have a provision for communicating with the


4.4

FPS Loader & Un-

loader Cabinet system

Z- Travel








indication lamp.

(f) It shall have provision for communicating with the


4.5Cassette Slide


(b) Three positions maintained selector switch shall be


(c) The selected drive shall be indicated by means of

indication lamp.

(d) It shall have a provision for communicating to the


4.6 ESS Y-Travel


(b) Motor power shall be routed through suitably rated MPCB.

(c) Three positions maintained selector switch shall be


(d) The selected drive shall be indicated by means of

indication lamp.

4.7

ESS Z-Slide for end

Adapter & counter

weight


(b) Motor power shall be routed through suitably rated MPCB.

(c) Three positions maintained selector switch shall be


(d) The selected drive shall be indicated by means of

indication lamp.

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4.8 Drive Software

(a) Suitable software (for drives, logic building and MIMIC

development) needs to be supplied along with the system.

(b) Supplied software shall have a valid license for its

operation.

(c) This software shall be loaded on the programming tool

(which is in the scope of supplier).

(d) Drive communication cable suitable for support either

USB or RJ45 of the laptop shall be supplied.

4.9Make & Model of

VVVF Drives 1. M/s SIEMENS & Model is S-120.

5.0 Drive Control Unit– 1


(b) Working control unit shall be used for “X” and “Y” Travel

(c) Individual drives shall be accessed via DRIVE CLiQ

cables only.

(d) Shall be supplied along with suitable memory module.

(e) Three positions maintained selector switch shall be

provided for the above selection.

(f) The selected control unit shall be indicated by means of

indication lamp.

6.0 Drive Control Unit – 2


(b) Working control unit shall be used for “Z” Travel (Both

Film Lift and Boom Lift operations)

(c) Working control unit shall also be used for “Cassette”

Slide.

(d) Individual drives shall be accessed via DRIVE CLiQ

cables only.

(e) Shall be supplied along with suitable memory module.

(f) Three positions maintained selector switch shall be


(g) The selected control unit shall be indicated by means of

indication lamp.

7.0 Drive Control Unit – 3

(h) Shall be supplied with 2 Nos. (1 Working; 1 Standby).

(i) Working control unit shall be used for Y-Travel and Z-

Slide of ESS

(j) Individual drives shall be accessed via DRIVE CLiQ

cables only.

(k) Shall be supplied along with suitable memory module.

(l) Three positions maintained selector switch shall be


The selected control unit shall be indicated by means of

indication lamp.

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8.0 Network HUB

(a) Suitable Network HUB shall be considered for supply

(b) All the Drive CLiQ cables shall be routed through this

HUB only except the cables from the Sensor Module.

(c) Shall be supplied with 2 Nos. (1 Working; 1 Standby) for

each of the above control unit (Ref. 5.5, 5.6 & 5.6.1).

9.0 Encoder Module

(a) All the encoder signals shall be routed through this

module only.

(b) Each drive shall have 2 nos. of sensor module.

(c) Two signals from the same encoder need to be connected

to these sensor modules.

(d) Both the encoder signals to be assigned to the respective

drive.

(e) However only one will be considered for evaluation and

control.

10.0 Terminal modules

(a) All the field status and command for brakes are to be

routed through the terminal module DI / DOs only.

(b) All the DI / DOs shall have the onboard status LED lamps.

(c) Shall be supplied with respect to the system configuration

with respect to each control unit.

(d) 100 % spare shall be considered for the supply as per the

configured terminal module as per the system requirement.

11.0 DI & DOs 20 % additional DI / DOs (with respect to that to be

used/assigned terminals) for future usage.

12.0 Operator Panel as HMI

(a) Combined advanced operator panels (HMI) needs to be

provided independently for FPS and ESS.

(b) Each HMI shall be capable of commissioning the

individual drive.

(c) Provided with fault history read and logging facility.

(d) MIMIC needs to be developed for the operation as per

user requirements.

(e) Minimum 10 numbers of screens shall be developed as

MIMIC for each control unit.

(f) It needs to be mounted on the panel with adjustable

support arm.

(g) Support arm should be of rigid enough to accommodate

either 19” or 22” HMI panel.

13.0 Location of Panel

(a) Distance: 160 m away from the crane shall be control.

(b) Hence all the cabling systems shall be planned for the

same length.

14.0 Input and Output Choke

Suitable input choke for controlling the harmonics and output

choke for reducing dv/dt and terminal peak voltages at

MOTOR.

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15.0Incremental Encoder

for Motor

Apart from ex-proof absolute encoders for position

measurement of subsystems of FPS & ESS, Flame proof

hollow shaft incremental encoder shall be used to achieve

vector control mode of operation for Hoist application.

All Encoders signals shall be suitable for VVVF drive input.

Screened cable as per manufacturer recommendations and as

decided by purchaser shall be used for all encoders.

The supplied encoder shall have provisions to send two signals

from the single encoder.

Encoder shall have a terminal strip termination for connecting

the cables.

All the encoder signals shall be routed to VVVF drive via

appropriate sensor module only.

16.0 Mechanical Brakes

All the brakes shall be supplied with OPEN / CLOSE limit

switches.

The same shall be wired individually up to panel to enable for

the interlocks.

All the brakes need to be powered with suitably rated Motor

Protection Circuit Breaker (MPCB)

Suitably rated current measuring module shall be provided and

the same to be interfaced to PLC via intelligent module called

SIMOCODE with PROFINET protocol.

These measured currents will be monitored and control the

operation of the motor during requirement.

17.0 Control scheme

(a) All the field status like limit switches, pendant signals may

be wired to PLC system via intrinsic safe relay.

(b) However, a parallel status shall be taken directly from the

field to VVVF drive panel except for pendant signals.

(c) Each drive may be operated using the command from the

centralized automation system.

18.0Limit Switches As per the design.

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19.0Junction Boxes

19.1Non-Flame Proof

Junction Boxes

(a) Non-FLP junction boxes shall be planned for interfacing

of all equipments which are powered through intrinsic

safe supply (pendant control, limit switches, etc)

(b) Make: M/s Rittal / M/s President.

19.2Flame Proof Junction

Boxes

(a) FLP junction boxes shall be planned for interfacing of all

the equipments which are not powered through intrinsic

safe supply (i.e., > 8.9 V)

(b) All the terminals inside this box shall have provision for

connecting ring type lugs only.

(c) Make: M/s FEPL / M/s BALIGA / M/s FCG / M/s

STAHL.

20.0Scheme to be followed for powering the Brakes

20.1 All Brake

(a) Logic for operation (if all motors are healthy with respect

to the selected motion):

(i) Opening: Monitoring minimum of 20% of current built

in the motor.

(ii) Closing: Monitoring minimum of 0% speed of the

respective motor.

(b) Logic for operation (if any one motor alone is healthy with

respect to the selected motion):

(i)Opening: Monitoring minimum of 20% of current built

in the motor for the working motor. However, brake

shall be opened for the motor which is not working

irrespective the current value.

(ii) Closing: Monitoring minimum of 0% speed of the

working motor.

(c) Number of power contactors: 2 Numbers per brake.

(d) Controlling of power contactors:

(i)One number of digital output/contactor from the

control unit.

(ii) One number of intrinsic safe relay/contactor.

(e) All the brake contactor status shall be monitored.

(f) In case of any one power contactor gets fused the system

shall operate with flash indication.

(g) If both the power contactors get fused, main (line)

contactor shall be switched OFF.

(h) Similarly MPCB trip status shall be wired as one digital

input to control unit for logic evaluation.

20.2Power Socket (a) Inside the Panel: 1 Number of 230 V AC power sockets

with ON / OFF switch for all the panels.

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20.3Light Fittings

(a) On the Mechanical Structure:

(i) Suitable FLP, 100 Watts LED light fitting needs to be

planned to achieve the proper illumination towards

positional accuracy. .

(b) Inside the Panel: 1 Number of 230 V AC LED light fittings

shall be planned for all the panels.

(c) Make of LED light fitting : M/s FEPL / M/s BALIGA /

M/s FCG / M/s STAHL

21.0Cables All the cables shall laid and end-terminated as per the site

requirements.

21.1Encoder Cable

The following cables shall be supplied:

(a) The Encoder cables shall be minimum of 8 core only.

(b) The cable shall be of screened cables and it shall have the

provision of connecting the shield to earth.

(c) No joint of cable is allowed between the panel end to the

encoder end. Hence cables shall be of flexible cables only.

(d) Quantity of cables with full length: 2 Number shall be

connected to both the signals of the proposed encoder.

(e) Make: M/s LAPP or M/s IGUS

21.2Power Cables

The following area cables shall be supplied:

(a) All the power cables shall be of 4 core only.

(b) Minimum size shall be of 4 sq.mm.

(c) The cable running between panel to field equipment other

than the cable running in Drag Chain are of 1.1 kV Grade,

XLPE insulated, copper conductor, G.I. armoured cables

only.

(d) From power supply source at SDSC SHAR to Protective

Panel Incomer. Quantity/Length: �160 m.

(e) From Protective panel to all other panels, field equipments

like motors, brakes, lights, etc.

Power cables for motors shall be selected as follows:

(a) Selected / approved motor electrical kW and rated current

to be selected for the voltage drop calculation.

(b) Maximum 3% of voltage drop only will be acceptable for

the selected cables.

(c) Out of used cores, 30% of core shall be kept as spare with

respect to each size of the cables from panel to junction

boxes.

82


In addition to the power cables utilized for the motors and

other equipments to power/control the following shall be

supplied:

(a) Refer Annexure – 1 for detailed specification of required

power cables.

(b) Make: Same as per the cable supplied for the EOT Crane

power and control.

21.3Control Cables

The following area cables shall be supplied:

(a) All the control cables shall be minimum of 12 core only.

(b) The cable running between panel to field equipment, other

than the cable running in Drag Chain are of 1.1 kV Grade,

XLPE insulated, copper conductor, G.I. armoured cables

only.

(c) From Protective panel to all the other panels, field

equipment like brake limit switches, various limit switches,

pendant, etc.

21.4Cable Identification

(a) Cable tags indicating the source and destination shall be

provided for all the cables.

(b) The material used for cable tags shall be of stainless steel

only.

(c) The source and destination shall be engraved.

(d) The ferrules shall be of ring type and of non-deteriorating

material.

21.5Earthing

The following area cables/strips shall be supplied:

(a) Earth strip (min. 25 x 6 mm) shall be supplied (Material:

CU).

(b) Rails at both ends shall be earthed.

(c) All the equipment including the mechanical structure shall

be grounded effectively with double earthing.

(d) Suitable bridge clamp shall be positioned on the crane for

tapping of earth points.

(e) Panel shall be provided with earthing provision at both the

ends. Same shall be connected with plant earth (which is 20

m. away from the panel location).

21.6Drag Chain

(a) Suitable Drag chain systems shall be planned for all

motions.

(b) Necessary supports (like beam / angles, guided cable tray,

etc) for running the drag chains along the motion paths

shall be supplied.

(c) All the cables running inside the drag chain shall be of

same make as that of the drag chain.

(d) Make: M/s IGUS / M/s LAPP

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22.0Cable Tray

(a) Perforated G.I. cable trays shall be planned for routing the

cables from the panel to top of the crane.

(b) Necessary supports (like beam / angles, etc) for running the

cable tray inside the trench (bottom of the panel), on the

wall, on the crane, etc., shall be supplied.

(c) Entire length of the cable trays shall be covered with G.I.

sheet cover with bolts and nuts as per the manufacturers

recommendations.

(d) No cables shall be routed without cable trays and covers.

(e) The cable trays shall also to be earthed with respect to the

common ground.

23.0Pendant (Smart station)

Push Button Station (PBS) with respect to each system:

(a) Shall be provided with Key way switch Lockable at OFF

(used for Control ON), Mush room head Emergency OFF.

(b) Control ON & OFF indication lamp powered through

Intrinsic Safe circuit.

(c) Shall be provided with push buttons for controlling main

and creep of all motions (FPS) & (EPS) independently.

i.e., X-Travel: LEFT/RIGHT; Y-Travel: FRONT/BACK;

Z-Travel: UP/DOWN

(d) It shall have a provision for local display of positions and

speed parameters for all motions.

(e) All the push buttons shall have an indication lamp powered

through Intrinsic Safe circuit to confirm its selection.

(f) All the push buttons shall be of modern / micro switch

operated - Avoid conventional push button for the

selection.

(g) All the push buttons command shall be interlocked with

respect to the interlock scheme provided in this

specification elsewhere.

(h) Shall also provide with 2-way Switch for Under Bridge

Lights.

(i) Minimum 50 % Spare push button shall be considered for

the supply.

(j) Minimum 30 % Spare Core shall be provided in PBS with

respect to the used cores.

(k) All push buttons are to be powered through intrinsic safe

module only apart from other control elements like limit

switch, etc..,

(l) Enclosure for the pendant shall be Stainless-steel only.

Connection to pendent:

(a) Trailing cable supported on anti-friction bearings wheeled

trolleys.

(b) The pendant control cables are to be routed properly in

suitable cable trays along the building structure.

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24.0Inside the panel

The following cable management shall be planned:

(a) Power circuit : Minimum size: 4 Sq.mm

(b) Control circuit : Minimum size: 2.5 Sq.mm

(c) Signal wire (for Control Unit and Encoder module) : 0.5

Sq.mm (Maximum size)

(d) Colour coding shall be followed as:

(i) 110 V AC Phase – Grey without sleeve.

(ii) 240 V AC Phase – Grey with RED sleeve.

(iii)110 V &240 V AC Neutral– Grey with BLACK sleeve.

(iv)415 V AC – Black with RED, YELLOW, BLUE and /

BLACK.

(v)24 V DC Positive : Red.

(vi)24 V DC Negative : Blue.

(vii)8.9 V DC : Orange.

(viii)Signal cable shall be as per the standard of

LAPP/IGUS cable.

(ix)Earth cable : Green & Yellow.

(e) All the limit switch terminals shall be wired up to the

25.0MCCB

(a) Protective Panel - MCCB with adjustable overload,

adjustable short circuit protection, adjustable ground fault

and Instantaneous protection shall be provided.

(b) It shall be provided with 230 V Shunt trip coil.

(c) Protective Panel - MCCB handle (door operated) shall have

a illumination kit for indicating ON / OFF / TRIP

26.0Switch Disconnector

Fuse (SDF) unit

(a) All motion Panel - Switch Dis-connector Fuse unit where

OEM recommending to route through fast acting semi-

conductor fuse if not Suitable rated MCCB shall be

planned.

(b) If SDF is planned, all shall be provided with semi-

conductor fuse with fuse indication cum monitoring device.

(c) If either SDF or MCCB is planned, all shall be provided

with auxiliary switch to ensure the ON / OFF status of SDF

Unit / MCCB. Same shall be wired up to drive input to

enable the drive for operation.

(d) All the isolating switches shall be provided with door

interlocking and defeating provision.

(e) All the isolating switches (either MCCB / SDF) shall be

located uniformly in the height of 1600mm from FFL or as

agreed during detailed engineering.

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27.0Fuses

All the power supply to VVVF drives shall be routed through

Semiconductor fast acting Fuses or as per the Drive

manufacturer’s recommendation of adequate rating. Fuses

shall have an indicator for fusing.

28.0MCB

(a) Voltage input to the Multifunction meter shall be routed

through 3-pole MCB

(b) Individual components control shall be planned by a

dedicated MCB control.

(c) All the MCBs shall have the provision for ON, OFF and

Alarm contact provisions. The same shall be wired for the

control logics (wherever required).

29.0Contactor

29.1Power Contactor

(a) Duty: AC-3

(b) The contactors shall be able to withstand their rated current

for one second without welding / fusing of the contacts

(c) Individual Power Contactors shall be provided for each

motion for controlling.

(d) All the power contactors shall be powered viz. auxiliary or

interposing contactors / relays with suitable rating along with

surge suppressor.

(e) Any multiplication of NO, NC points – auxiliary contactor

shall be utilized.

(f) NO add-on blocks shall be allowed for power contactors.

29.2Auxiliary Contactor

(a) Shall be used as intermediate contactors to the power

contactors.

(b) All the field interlocks shall be wired to the auxiliary

contactor level.

(c) Suitable surge suppressor shall be supplied along with

auxiliary contactor.

(d) It shall be utilized for contact multiplication instead of add-on

NO, NC contacts for power and auxiliary contactor.

86


30.0Motor Protection Circuit

Breaker (MPCB)

(a) Rating shall be selected as per the type-2 co-ordination chart

with respect to fuse-less feeder.

(b) All the brakes shall be powered with suitable rated motor

protection circuit breaker.

(c) Shall be provided for the each motor where the output of

single VVVF drive is driving two or more nos. of motors.

(d) Trip status shall be wired as one no. of Digital Input to control

unit to create logic as per the user requirement.

(e) ON/OFF status also shall be wired as one no. of Digital Input

to control unit to create logic as per the user requirement.

31.0Intrinsic Safe Relay

Input Relay:

(a) All the field signals like pendant push button, limit

switches (motion & status) shall be wired to this relay.

(b) The above signals may be used for status monitoring in the

control unit of respective VVVF drive only.

(c) This relay shall be located in safe area (inside the panel) only.

Make: M/s P&F

(d) All this relay shall be selected to suitable for operating with

110V AC supply.

Output Relay:

(a) These relay shall be used for powering indication lamps in

the hazardous location.

(b) This relay shall be located in safe area (inside the panel) only.

Make: M/s P&F

(c) All this relay shall be selected to suitable for operating with

110V AC supply.

Interlock:

(a) All the output commands from control unit shall be directly

given to the digital input of this relay.

(b) All the interlock wiring (if required) as per the logic shall be

carried out in this relay itself.

(c) No relay board shall be used for creating any interlock inside

the panel.

Make: P&F only (both input and output relays)

87


32.0Thermistor Relay

(a) Individual thermistors shall be wired to the individual and

identified thermistor relay.

(b) This thermistor relay shall have a provision to indicate about

this tripping to PLC system in addition to the point which is

tripping the VVVF drive.

(c) This relay shall have an indication lamp for alarm and trip

conditions of respective thermistor.

(d) This relay shall be capable of resetting from the PLC

command via a separate relay or auxiliary contactor.

Make: SIEMENS only

33.0Panel

33.1

Individual panels (without patrician between panel) to be planned for all motions towards

effective utilization of panel AC. Make: M/s Rittal/ M/s President (both panel and AC)

33.2Protective panel shall be provided with mushroom head emergency switch to disable power

supply during maintenance

33.3Design & Construction

(a) Enclosure – Indoor, Floor mounting, Front operated free

standing

(b) Frame, Mounting plates, Doors & Covers – 2.0 mm Thickness

CRCA

(c) Lifting arrangements - Suitable Lifting Arrangement shall be

provided for each panel on the Top on all four sides

(d) Base frame – ISMC 100 x 50 with Matt black

(e) Glass door – shall be provided in the overall control panel

(where control unit, communicating systems, IS barriers,

contactors, etc is arranged)

(f) Degree of protection – IP 54.

(g) Shrouding – shall be as per standard (to be provided inside the

panel, in front of power components and power terminals).

(h) Cable entry (power and control) shall be from bottom.

(i) The panels shall be provided with panel A/C along with water

drain hose of sufficient length (min. 2 mtrs)

(j) The panels shall be provided with panel lamps (LED) along

with door limit switches

33.4Painting

(a) Paint shade : RAL 7032 / 7035.

(b) Base frame : Matt black.

(c) Mounting plate : Orange.

88


33.5Wiring

(a) Power circuit: Minimum size shall be 4 Sq.mm.

(b) Control circuit: Minimum size shall be 2.5 Sq.mm.

(c) Signal wire (for Control Unit and Encoder module):

Maximum size shall be 0.5 Sq.mm.

33.6Wire colour codes

(a) 110 V AC Phase: Grey without sleeve.

(b) 240 V AC Phase: Grey with RED sleeve.

(c) 110 V &240 V AC Neutral: Grey with BLACK sleeve.

(d) 415 V AC: Black with RED, YELLOW, BLUE and /

BLACK.

(e) 24 V DC Positive: Red. (If used in circuit)

(f) 24 V DC Negative: Blue.(If used in circuit)

(g) 8.9 V DC: Orange.

(h) Signal cable: As per the standard of LAPP / IGUS cable.

(i) Earth cable: Green & Yellow.

33.7Indication Lamps

(a) It shall be of cluster LED provided with translucent lamp

covers

(b) Cluster LED module shall be suitable for direct operation on

230 V / 110 V, 50 Hz AC or 24 V DC.

(c) Panel shall have the 3-phase indication lamps in the metering

cubicle controlled by 3-pole MCB.

(d) Indication lamps for drive Healthy, TRIP, Selected drives /

control unit etc. shall be considered.

33.8Name Plate(a) Material: Transparent acrylic.

(b) Colour of letter : White letter in black background.

33.9Earth bus bar

(a) Size : Minimum '30 X 10 Cu' with nuts, bolts & washers at

each end shall be provided per panel

(b) Necessary earth strip shall be supplied for the following

(i) To link panel to rail at the gantry girder.

(ii) To link rail and all the electrical elements on the EOT

Crane.

(iii)To link the panel to the earth strip.

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33.10Terminal blocks

(a) Terminal blocks shall be of 750 Volts grade of the stud

type and shrouded.

(b) Insulating barriers shall be provided between adjacent

terminals.

(c) All the terminal blocks are grouped with respect to the

following:

(i) 24 V Power distribution (separately for positive and

negative).

(ii) 110 V Power distribution (separately for phase and

neutral).

(iii)230 V Power distribution (separately for phase and neutral).

(iv)415 V Power distribution if any

(v) Motor and brake power distribution

(d) Short linked Terminal blocks shall be used for terminal

multiplication. More than one wires need to be avoided in one

terminal block.

(e) All future interlocks shall be provided with permanent

shorting link

(f) Interlocking between the panels shall be routed through

respective panel terminal blocks only. Direct wiring between

the components of two different panels to be avoided.

(g) Power & Control circuit: Ring type end termination of

suitable size

(h) All the terminals shall be provided with group markers

(i) 25% Spare Terminals Shall be provided for both Power and

Control in each Panel

(j) Make: Connectwell / Wago / Elmex

33.11Multifunction meter

(a) Panel shall be provided with Multifunction meter

(b) Along with Add-on DI / DO modules

(c) Communication: PROFINET modules

(d) Make: M/s SIEMENS; Model: PAC 4200

33.12SMPS (If required)

(a) 24 V DC power supply shall be provided (2 Nos.)

(b) Shall be used as common supply to all the motion including

protective panel.

(c) O Ring diode shall be supplied.

(d) The DC power supply failure shall be noticed via. Digital

inputs.

(e) If either the SMPS or O Ring diode fails a 24 V DC missing

indication lamp shall be provided.

(f) Quantity: 2 Nos.

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33.13Panel Space Heater

(a) Panel Space heater shall be mounted in such a way that, Power

& Control Cables must not run in close vicinity of it.

(b) All the Panels shall be provided with space heaters to avoid

moisture condensation.

(c) Necessary thermostat shall be supplied along with the space

heaters.

(d) ON / OFF Control of space heaters shall be interlocked with

main contactor. i.e., whenever main contactor is in OFF condition,

33.14Rubber mats

(a) Rubber mats to be supplied and provided in-front of all the

panels (supplied along with this system as per the designed

length of panels including Transformer and DBR panels.

(b) The length shall be supplied: minimum of 30 m.

(c) Class ‘A’, 3.3 kV ac (rms), 2.0mm ± 10% thickness as per IS

15652/2006

(d) Width: 1 m (maximum)

33.15Layout details

(a) The bottom most row of equipment mounted inside the panel

excepting terminal strip shall be at least 350mm above the

panel bottom cover to facilitate inspection and repairs

(b) Selector switches, indication lamps and operator panel shall

be provided on the panel door

(c) Routing of Signal & Power/Control cables shall be done

separately wherever possible

(d) All Communication cables shall be routed through wire

channel

(e) Shield of all Signal Cables shall be properly clamped to Body

of the Device/structure.

34.0Documents to be submitted during Detail Design Review and clearance:

34.1Motors

(a) Number of motors, Power rating of motors, Frame size,

make, duty, number of starts per hour, type and Number of

poles, Insulation, Ambient temperature, applicable IS for

construction, bearing, accessories, terminal position from

drive end, drawing nos. used for FLP certification, etc.

(b) Torque and speed curves, thermal withstand time curve,

efficiency and power factor with respect to loading of the

motor, speed and time with respect to current and complete

G.A of motor, terminal box / boxes by mentioning the

approved drawing reference and nos.

91


34.2Test Reports

(a) Flame proof electrical fittings / equipment test reports along

with approved drawings (Either by CIMFR / ERTL (E)) with

respect to all the annexure and amendment if available need

to be submitted for review and acceptance of all FLP items.

(b) Space heaters and its thermostat.

(c) Transformers.

(d) VVVF Drives and its components.

(e) Certificate for obsolesce for all the major electrical items with

not less than 15 years from the date of acceptance of the

crane.

34.3Sizing Calculation

(a) Control Transformer (with considering closed VA).

(b) Lighting Transformer.

(c) SMPS with and without loading.

(d) Power Cables.

(e) Control Cables with respect to no. of cores.

(f) Heat loss calculation towards panel AC selection.

34.4Technical Catalogue /

data sheets

(a)VVVF Drives.

(b) Switchgear components.

(c) Power and Control Cables.

(d) Encoder.

(e) Cable Drag chain and its cables.

(f) Limit switches.

(g) Intrinsic safe relays.

(h) Panel.

35.0To be considered during Detailed Engineering:

35.1Panel

(a) All the panels are to be maintained the uniform height.

Height of the panel not less than 2000 mm excluding the base

frame of 100 mm. Overall height of the panel not less than

2100 mm.

(b) Width of all the panels is to be maintained uniformly. Door

opening and rear access will be decided based on the

requirement during detailed engineering.

(c) All the panel line up shall be taken care like a bureau opening

type.

(d) Enamel Danger plates shall be provided on the Panel inscribed

in Hindi, Telugu and English languages as directed by

department.

(e) Drawing pocket shall be considered.

(f) Comfort handles with key shall be considered.

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35.2Cable

(a) Incomer cables rating shall be considered for maximum of

three different motions along with EOT Crane lights and

other transformers loads.

(b) Selected / approved motor electrical kW and rated current

shall be selected for the voltage drop calculation.

(c) Maximum 3% of Voltage drop only will be accepted in the

selected cables.

(d) Out of used cores, 30% of core shall be kept as spare with

respect to each size of the cables.

(e) Wires shall be identified by numbered ferrules at each end.

(f) The ferrules shall be of the ring type and of non-deteriorating

material.

(g) Cable tags indicating the source and destination shall be

provided for cable connections as per circuit diagram.

35.3Interlock Scheme

(a) Auxiliary Contactor level:

(i) Hard wired interlocks are shall be provided based on

push button command.

(ii) When Aux. contactor operates with respect to the motion

selected, remaining Aux. contactors with respect to other

motions should not be operated. Aux. contactor shall be

operated only when main power contactor is in ON

condition.

(b) In VVVF Drive Logic control:

(i) It is to be programmed such a way only one motion (either

UP / DOWN or LEFT/RIGHT, etc) has to be selected for

operation at a time in the VVVF drive.

(c) Wherever two motors are powered:

(i)Drive should control both the motor with a single drive.

(ii)If anyone motor or its power chain failed. Drive should not

be operated, unless changing the selection from two motors to

one motor control.

(d)Wherever one motor is powered

(i)The current setting in the drive also to be changed as per

the motor selection. i.e., if one motor is running

corresponding current setting should be selected and for two

motors, etc.

35.4Health Status

(a)All the VVVF Drive healthiness status shall be wired as one

number of DI to PLC in addition to the communication status.

(b)Main contactor of each motion as one DI to PLC.

(c) Brake TRIP and execution command as one DI to PLC.

(d)Brake current and its healthiness to be communicated to PLC

via PROFINET of intelligent module (SIMOCODE).

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35.5ON Interlock for Z

Travel motion

(a)Rotary limit switches i.e hoist and lower limit switches.

(b)Thruster Brakes' MPCB condition.

(c)Brake Close limit switch condition.

(d)Provision shall be made for two extra interlocks for future

usage.

35.6ON Interlock for X

Travel motion

(a) Rotary limit switches i.e hoist and lower limit switches.

(b) Thruster Brakes' MPCB condition.

(c) Brake Close limit switch condition.

(d) Provision shall be made for two extra interlocks for future

usage.

35.7ON Interlock for Y

Travel motion

(a) Right and Left limit switches for respective motion of the

drive.

(b) Thruster Brakes' MPCB condition.

(c) Brake Close limit switch condition.

(d) Provision shall be made for two extra interlocks for future

usage.

36.0To be considered for the supply:

36.1Spares

(a) One complete set of switchgears used for the each system (X,

Y, Film Lift & Boom Lift of FPS as well as Y & Z of ESS)

control.

(b) Two Complete set of professional maintenance tools required

for normal maintenance of equipment.

(c) Two sets of Digital clamp meter (Make: FLUKE) to be

supplied.

(d) Range for the Digital clamp meter is: (a) Capable of

measuring motors current, (b) Capable of measuring brake

currents.

(e) Supplied clamp meter shall have a provision to measure

resistance of the DBR Units, resistance of the motor windings,

voltages to all the systems, etc.

37.0Codes and Standards

a)IS 5571 Guide for selection and installation of electrical equipment in

hazardous areas (Other than Mines)

b)IS 5572 Classification of Hazardous Areas (Other than Mines) having

flammable gases and vapours for electrical installations

c)IS 8239 Classification of maximum surface temperature of electrical

equipment for use in explosive atmosphere.

d)IS 60079-1 (IS 2148) Equipment protection by Flameproof enclosures “d”

94


e)IS 2206 Specification for Flameproof Electric Lighting Fittings

f)IS 7820 Electrical apparatus for Explosive Gas Atmospheres – method of

test for ignition temperature

g)IS 9735

Electrical apparatus for Explosive Gas Atmospheres – Flameproof

enclosures “d” - method of test for Ascertainment of maximum

experimental safe gap

h)IS 15880 Three phase cage induction motors when fed from IGBT

converters

i)IS 15881 Three phase cage induction motors specifically designed for IGBT

converters supply

j)IS 4029 Guide for testing three phase induction motors

k)IS 12065 Permissible limits of Noise levels for rotating electrical machines

l)IS 14122 Built-in thermal protection for electric motors rated up to 690 V ac

– Specifications.

m)IS 60079-11 (IS 5780) Equipment protection by Intrinsic Safety “i”

n)IEC 60529-2 Degrees of protection provided by enclosures (IP Code)

o)IS 2147 Degrees of protection provided by enclosures for low voltage

switch gear and control gear.

p)IS 8130 Conductors for insulated electric cables and flexible cords –

specifications.

q)IS 7098 Specification for Cross-linked Polyethylene insulated PVC

sheathed cables.

r)IS 1554 (Part – 1) Specification for PVC Insulated (Heavy Duty) electric cables.

s)IS 2208 HRC cartridge fuse links up to 650V

t)IS 2959 Contactors for voltage not exceeding 1000V AC or 1200V DC

u)IS 4064

Air-break switches, Air-break dis-connector, Air-break switch dis-

connector and fuse combination for voltages not exceeding 1000V

AC or 1200VDC

v)IS 4237 General requirements of switch gears and control gears for

voltages not exceeding 1000V AC

w)IS 13947

Specification for Low-Voltage Switchgear and Control gear - Part

1 to Part 5 : Suppliers and Motor-Starters - Section 1 :

Electromechanical Contactors and Motor Starters

x)IS 10118 Code of Practice for Selection, Installation and Maintenance of

Switchgear and Control gear

95


38.0Air compressor

(Optional)

(a) Displacement : 1229 lpm

(b) Max Working pressure : 9 ksc

(c) Compressor type : Reciprocating type

(d) Electric motor power rating : 10 HP

(e) Electric motor current rating : 14.5 A

(f) Electric motor RPM : 1445

(g)Unit rpm : 920 rpm

38.1Air receiver (Optional)

(a) Capacity : 420 L

(b) Maximum working pressure : 12 ksc,

(c)Test pressure : 19.8 ksc

(d)Drain valve : Auto drain valve

96


Annexure - 1

Sl. No. Description Specifications

1 Manufacturer Fujitsu, Sony, HP

2 Processor Intel i7 processor -4 core or latest

3 Hard disk capacity 2 TB Solid State Drive

4 Drive controller Integrated or add – on SATA controller.

5 Motherboard Intel original (Suitable for the configuration)

6 DDR RAM (DDR4) 8 GB

7 Network cards Ethernet card: 2 Nos. (100 Mbps / 1 Gpbs)

8 Optical Drive DVD RW (Multi layer)

9 Power Supply Suitable 230 V AC Adapter with Indian Pin

10 Operating System

Licensed version of Windows 7 (32 / 64 bit)

ultimate or latest (Compatible with Master

drive, Micro-master, SINAMICS, Power

manager, SIMOCODE ES, ABB drive

software, etc)

11 Software to be supplied and

loaded on system

1. Licensed and latest version of SINAMICS

drive along with DCC software.

2. MS Visio Professional

3. MS Office 2016 Professional or latest

4. Licensed and latest version of ‘adobe

acrobat’ read & write software.

12 Monitor Screen 14”, supported resolution 1280 x 1024 and

above.

13 Optical Mouse (additional) Wireless mouse.

14 CD’s for software & drivers Required

15 Converter for communication (2

Nos. each)

1. USB to RS-485

2. USB to RS-232

3. USB to SINAMICS drive communication

4. USB to SIEMENS PLC communication

16 Quantity 1 No.

97


SECTION III: SPECIFICATIONS OF INSTRUMENTATION &

CONTROL SYSTEMS (Optional)

1.1 LOCAL OPERATING STATION

(a) HMI based touch screen local operating stations shall be provided individually for Film

positioning and End support systems.

(b) System power status, start, stop & emergency buttons.

(c) All subsystems current positions and positional set points.

(d) Types of Radiography and selection of speeds for all subsystems.

(e) Health status of all drive, encoder & other network notes.

1.2 FILM POSITIONING SYSTEM (FPS)

1.2.1 FPS X TRAVEL MOTION

(a) FPS X-Travel shall involve four proximity sensors to be mounted at the four corners of the

FPS X-Table. Among these, two sensors will be used as redundancy measure for sensing

the extreme position and two other sensors for sensing the parking or home position with

similar redundancy (Proximity sensors: 4 numbers-Digital Input).

(b) The X-Table assembly of FPS shall have provision to monitor and control its motion along

the X-axis (i.e., along the length of the Exposure hall). In this respect two ex-proof absolute

encoders (as a redundancy measure) with intrinsic safe profibus Communication shall be

mounted suitably.

(c) All the Digital Input and Output signals from the X-Table assembly shall be terminated at a

separate junction box with crimping type terminations.

(d) Since the area of operation (Exposure hall) is hazardous (Zone 1, gas group IIA, IIB, T4

class), all Proximity sensors, push buttons, LED lamps, etc., shall be intrinsically safe, the

absolute encoders shall be flame proof as per relevant standards. The supplier shall furnish

necessary certificates in this respect.

(e) Appropriate number of flame proof junction boxes with terminal blocks for control cables of

length 160 m (approx.) shall be provided.

(f) All controls / proximity sensors / push button signals shall be powered through intrinsic safe

circuits with IS isolators of P&F make.

(g) Each IS isolator shall be with one input/ two outputs for all intrinsic safe circuits.

98


(h) Suitable Control cables each of length around 160 m shall be provided for all motions and

proximity sensors.

(i) Suitable Control cables, each of length around 160 m shall be provided for interfacing with

VFDs and PLC with PROFIBUS communication.

(j) Encoders shall be connected through Profibus communication with redundant intrinsic safe

profibus cable to be provided along with connectors.

(k) Motor brake release feedback shall be acquired from motor’s brake with suitable terminal

block adjacent to Brakes.

(l) Motor brake release feedback shall be provided as Digital Inputs from both Motor’s brake &

respective motor’s drive.

1.2.2 FPS Y-TRAVEL

(a) FPS Y-Travel on the rails (mounted on the FPS X-Table) shall involve four proximity

sensors to be mounted at the four corners of the FPS Y-Table. Among these, two sensors

will be used as redundancy measure for sensing the extreme position and two other sensors

for sensing the parking or home position with similar redundancy (Proximity sensors: 4

numbers-Digital Input).

(b) The FPS Y-Table assembly shall have provision to monitor and control its motion along the

Y-axis (i.e., along the breadth of the Exposure hall) on the FPS X-Table. In this respect an

ex-proof absolute encoder with intrinsic safe profibus Communication shall be mounted

suitably.

(m)All the Digital Input and Output signals from the FPS Y-Table assembly shall be terminated

at a separate junction box with crimping type terminations.

(n) Since the area of operation (Exposure hall) is hazardous (Zone 1, gas group IIA, IIB, T4

class), all Proximity sensors, push buttons, LED lamps, etc shall be intrinsically safe, the



(o) Appropriate number of flame proof junction boxes with terminal blocks for control cables of

length 160 m (approx.) shall be provided.

(p) All controls / proximity sensors / push button signals shall be powered through intrinsic safe

circuits with IS isolators of P&F make.

(q) Each IS isolator shall be with one input/ two outputs for all intrinsic safe circuits.

99


(r) Suitable Control cables each of length around 160 m shall be provided for all motions and

proximity sensors.

(s) Suitable Control cables, each of length around 160 m shall be provided for interfacing with


(t) Encoders shall be connected through Profibus communication with redundant intrinsic safe


(u) Motor brake release feedback shall be acquired from motor’s brake with suitable terminal


(v) Motor brake release feedback shall be provided as Digital Inputs from both Motor’s brake &

respective motor’s drive.

(o) Limit switches shall be provided to locate the positions of the Y-Table assembly accurately

for the propellant and Tangential Radiography Positions. (Limit Switches: 2 numbers for

Digital Inputs).

1.2.3 FPS C-SLIDE

(a) FPS C-Slide Travel on the FPS boom along its length shall involve four proximity sensors.

Two sensors (with redundancy) shall be provided for sensing the extreme position and two

sensors for parking position (Proximity sensors: 4 numbers-Digital inputs).

(b) The FPS C-Slide shall have provision to monitor and control its motion along the length of

the boom. In this respect two ex-proof absolute encoders (as redundancy measure) with

intrinsic safe profibus communication shall be mounted suitably.

(c) All the digital input and output signals from the C-Slide shall be terminated at a separate

junction box with crimping type terminations.





(e) Appropriate number of flame proof junction boxes with terminal blocks for control cables

of length 160 m (approx.) shall be provided.

(f) All controls / proximity sensors / push button signals shall be powered through intrinsic

safe circuits with IS isolators of P&F make.


100



proximity sensors.







(m) Motor brake release feedback shall be provided as Digital Inputs from both Motor’s brake

& respective motor’s drive.

1.2.4 LOADER & UN-LOADER CABINET SYSTEM

(a) Loader and Unloader cabinet system motion shall involve four proximity sensors. Two

sensors (with redundancy) shall be provided for sensing the extreme position and two

sensors for parking position (Proximity sensors: 4 numbers-Digital Inputs).

(b) The Loader & Un-loader cabinet system shall have provision to monitor and control its

motion along the length of the Vertical Column. In this respect two ex-proof absolute

encoders (as redundancy measure) with intrinsic safe profibus communication shall be

mounted suitably.

(c) All the Digital Input and Output signals from the Loader & Unloader cabinet system shall

be terminated at a separate junction box with crimping type terminations.











proximity sensors.

101










(n) Limit switches shall be provided to acquire the mechanical locking status at the stopping

positions of Film Lift carrying the Loader and Un-loader cabinets for propellant and

tangential radiography. (Limit Switches: 2 numbers- Digital Inputs).

(o) Limit switches (With Redundancy) shall also be provided to acquire the positional status of

Film Lift for propellant and Tangential radiography. (Limit Switches: 4 numbers-Digital

Inputs).

1.2.5 FPS BOOM

(a) FPS boom Travel shall involve four proximity sensors. Two sensors (with redundancy)

shall be provided at extreme position and two sensors for parking position (Proximity

sensors: 4 numbers-Digital Inputs).

(b) The FPS boom shall have provision to monitor and control its motion along the length of

the Vertical Column assembly. In this respect two ex-proof absolute encoders (as

redundancy measure) with intrinsic safe profibus communication shall be mounted suitably.

(c) All the Digital Input and Output signals from the Boom Slide shall be terminated at a











102



proximity sensors.










positions of FPS boom for propellant and tangential radiography. (Limit Switches: 2

numbers- Digital Inputs).


FPS Boom for propellant and Tangential radiography. (Limit Switches: 4 numbers-Digital

Inputs).

1.2.6 OTHER INSTRUMENTS

(a) Suitable pneumatic pressure sensors / transducers shall be provided for the measurement

of pneumatic line pressure in connection with film loading & unloading operations.

(b) Suitable numbers of solenoid valves (Reputed make and with redundancy) shall be

provided for activation of loading and unloading of the cassette holders frames (Digital

outputs).

(c) Linac Heat exchanger to be provided by the purchaser shall be linked and operable with

suitable interlocks both from SCADA and Local control station.

(d) Chiller systems of the Linac X-Ray machine to be provided by the purchaser shall be

linked and operable with suitable interlocks from SCADA and Local control station.

(e) Linac Heat exchanger and chiller parameters such as water temperature, pressure, etc.,

shall be acquired for monitoring and control.

(f) RH instruments to be installed in the bay shall be interfaced to PLC for data

logging.

1.3 END SUPPORT SYSTEM (ESS)

1.3.1 ESS Y-TRAVEL

103


(a) ESS Y-Travel shall involve four proximity sensors to be mounted at the four corners of the

ESS Y-Table. Among these, two sensors will be used as redundancy measure for sensing

the extreme position and two other sensors for sensing the parking or home position with

similar redundancy (Proximity sensors: 4 numbers-Digital Input).

(b) The ESS Y-Table assembly shall have provision to monitor and control its motion along the

X-axis (i.e., along the length of the Exposure hall). In this respect an ex-proof absolute

encoder with intrinsic safe profibus Communication shall be mounted suitably.

(c) All the Digital Input and Output signals from the ESS Y-Table assembly shall be

terminated at a separate junction box with crimping type terminations.











proximity sensors.







(l) Motor brake release feedback shall be provided as Digital Inputs from both Motor’s brake


1.3.2 ESS Z-SLIDE

(a) ESS Z-Slide Travel shall involve 4 proximity sensors. Two sensors (with redundancy) for

sensing the extreme position and two sensors for sensing the parking position of the Z-Slide

(Proximity sensors: 4 numbers-Digital inputs).

104


(b) The ESS Z-Slide shall have provision to monitor and control its motion along the length of

the vertical column. In this respect an ex-proof absolute encoder with intrinsic safe profibus

communication shall be mounted suitably.

(c) All the Digital Input and Output signals from the ESS Z-Slide shall be terminated at a












proximity sensors.










positions of ESS Z-Slide for propellant and tangential radiography. (Limit Switches: 2

numbers- Digital Inputs).


ESS Z-Slide for propellant and Tangential radiography. (Limit Switches: 4 numbers-Digital

Inputs).

2.0 SPECIFICATIONS OF I & C ITEMS

2.1 PLC

105


S. No. ITEM SPECIFICATION

1

CPU The PLC incorporated shall be CPU 315T (Technology)-

3PN/DP or latest meant for motion control applications

with micro memory card of minimum capacity 8GB or

higher.

2

I/O cards Minimum 20% Extra spare channels shall be available.

DI Card Model No: 321-1BP00- 0AA0 (Make: Siemens).

DO card Model No: 322-1BP00- 0AA0 (Make: Siemens).

3

Software 1) Simatic step 7 V5.5 or latest software with floating

license in a dongle to be supplied with a laptop with i7 (or

higher) processor. A laptop adaptor for PROFIBUS

(embedded in laptop) also to be provided.

2) Technology licensed software for technology CPU.

4 PLC Programming

& Documentation

PLC programming shall be under supplier’s scope.

5

PLC Panels (a) DACS Panel: PLC and associate modules shall be

mounted.

(b) CJB Panel: Isolators and relays to be mounted (Make:

Rittal).

2.2 SCADA & HMI REQUIREMENTS

2.3 POWER SUPPLY ITEMS

(a) DC power supply with redundant configuration shall be provided for the PLC processor

modules.

(ii) DC power supply with redundant configuration shall be provided for the PLC input and

output modules.

S.No. ITEM SPECIFICATIONS

1 SOFTWARE Licensed latest SCADA software WIN CC C having

client- server configuration with Web Server with 3 clients

having with Unlimited Tags.

2 MMI PC 27” Desk top PC type console with latest processor

supporting mentioned server-client configuration.

3 MMI console Modular desk type console for placing above MMI PC

with place to work for six operators and space to expand

upto four PCs with revolving operator chair.

4 HMI console TP 1200 or latest for both FPS & ESS as Local operating

station.

5 SCADA

Development

SCADA development & software documentation shall be

under Supplier’s scope.

106


(iii) AC power supply shall be provided to all the operating stations and PLC accessories

through UPS (Uninterrupted Power Supply) with parallel configuration along with servo

systems. The rating of the UPS to be supplied by the supplier shall be selected such that it

does not load more than 80% of the rating. UPS, Servo and batter bank status, voltage &

current monitoring to be acquired by PLC.

2.4 FIELD INSTRUMENTS

2.4.1 Ex-proof Absolute Encoders

(a) Model no. : PSM78E

(b) Resolution : 14 bit (for Multi-turn encoder)

(c) Interface with PLC : Profibus

(d) Operating Voltage : 10 to 30 VDC

(e) Make : P& F

2.4.2 Proximity sensors

(a) Switching element function : NAMUR, NC,

(b) Rated operating distance : 30 mm

(c) Model no. : NCN30+U1+NO

(d) Make : P& F

2.4.3 Digital Input Isolator: (with 1-input, 2- output)

(a) Model no. : KFD2-SR2-Ex1.W.LB

(b) Rated voltage : 20-30 V DC

(c) Rated current : less than 50 mA

(d) Make : P& F

2.4.4 Digital output Isolator

(a) Model no. : KFD0-SD2-Ex1.1045

(b) Input rated voltage : 20 to 35V DC

(c) Open loop voltage : more than 22.7 V

(d) Make : P& F

107


3.0 EX-PROOF CAMERAS AND CCTV SYSTEMS

(a) Three numbers of Ex-proof Camera shall be provided for the surveillance of Exposure Hall

and the make shall be Infinova. These cameras shall be mounted at the user selected

locations on the concrete walls of the Exposure hall.

(b) One number of Ex-proof Camera shall provided at the top of FPS system for surveillance of

Loading of fresh Cassette holder frames from Loader cabinet into the C-Slide and

Unloading of exposed Cassette holder frames from C-Slide into the Un-Loader cabinet. The

make shall be Infinova.

(c) Two numbers of latest 51"Monitors with two numbers of Smart DVR of suitable memory

size and two numbers of smart keyboards shall be provided.

4.0 OVERALL CONTROL SYSTEM

The PLC system shall be of standalone configuration interface with SCADA for

operation of FPS and ESS and other items as mentioned above. The over all configuration of

Instrumentation and Control system is as given below

CPU 315T

3PN/DP

RS 485

IS

Couple

SWITCH

SERVER

CLIENT-1

CLIENT-2

FPS X

FPS Y

FPS Z

FPS CS

FPS CS

FPS-

Z

FPS-

X

FPS-

Y FPS-

FL

FPS-

CS

ESS-

Y ESS-

Z Profi Bus

Profi Bus

Profi Bus

Ethernet

RS 485

IS

Coupler

108


5. 0 SPARES TO BE SUPPLIED

S. No ITEMS Quantity

1 Proximity Switches 5

2 Selector Switch (Local/ remote selection) 1

3 Selector Switch (Speed selection) 1

4 Ex-proof Absolute Encoders 2

5 DI isolators 30

6 DO isolators 20

7 DO Relays 20

8 DI Relays 25

CLIENT-3

ESS Y

ESS Z

BAY AREA

CONTROL

ROOM

TP1200

TP1200ESS HMI

FPS HMI

109


SECTION –D

ANNEXURES

110


Annexure -I

SCHEDULE OF PRICES

Table-1

S. No Description Unit

Cost

(in Rs/foreign

currency as

applicable.)

1.

Design, preparation of detailed drawings,

manufacture, testing, inspection at manufacturer’s

works, packing, forwarding, transportation to site,

unloading, installation, testing, carrying out process

trials and commissioning of Film Positioning

System and End support system as per the scope of

work, specifications and terms & conditions

detailed in section A, B & C of the document

(without optional).

Lump

sum

2 GST on item in S.No.1 %

3. Transportation Charges for S.No.1 Lump

sum

4. GST on item in S.No.3 %

5.

Installation, Testing and Commissioning charges

for S.No.1

Lump

sum

6. GST on S.No. 5 %

Total Cost (Sum of S. Nos. 1 + 2 + 3 + 4 + 5 + 6)

Table-2 (Optional)

1. Instrumentation & Control system for FPS & ESS

Per /

Year

2. GST on Item in S. No.1 %

3.

Air Compressor and its relating piping as mentioned

in Section C, Point No. 5.0 (K) & (l)

Lump

sum


5. Transportation Charges for S.No.1 Lump

sum


111


7.

Installation, Testing and Commissioning charges

for S.No.1

Lump

sum

8. GST on S.No. 7 %

9.

Annual Maintenance Contract for PLC based Film

Positioning System for S139 Bay for 5 years

(Starting from first year after warranty period)

(Non-comprehensive)

10. GST on Item in S. No.3 %

Total Cost (Sum of S. Nos. 1+2+3+4+5+6+7+8) Per/

Year

The cost of AMC & optional items will be considered for evaluation of price bid. However, the

party may quote for optional items.

(SIGNATURE OF SUPPLIER)

112


Annexure-II

EXCEPTIONS AND DEVIATIONS

In line with Proposal Document, supplier may stipulate Exceptions and deviations to the

Proposal conditions if considered unavoidable.

SL.

NO Reference in

Specification

Dept.

Specification

Offered

Spécification DEVIATION

PAGE

NO

CLAUSE

NO

NOTE :

(a) Only deviations are to be written in this Annexure-II

(b) Any deviations taken by the Bidder to the stipulations of the Proposal document shall be

brought out strictly as per this format and enclosed along with the bid.

(c) Any deviations not brought out as per this Proforma (Annexure-II) and written elsewhere in

the Proposal document shall not be recognized and the same is treated as null and void.

(d) Any willful attempt by the Tenderer to camouflage the deviations by giving them in the

covering letter or in any other documents that are enclosed may render the Bid itself non-

responsive.

(SIGNATURE OF SUPPLIER)

113


Annexure -III CHECK LIST

S. No Description Response by

Supplier

1. The detailed scope of work and technical specifications are

under stood and price was quoted accordingly

Yes / No

2. All the general conditions of the contract as per the section-A

are acceptable.

Yes / No

3. In case of some general conditions of the contract as per the

section-A are not acceptable, deviation statement is to be

enclosed as per Annexure-II

Yes / No

4. The supplier evaluation format as enclosed along the proposal

document is filled-in and necessary supporting documents are

enclosed.

Yes / No

5. Un-priced copy of schedule of prices, payment schedule is

enclosed in the techno-commercial bid.

Yes / No

6. Taxes are quoted in the price bid Yes / No

7. Cost of AMC has been quoted Yes / No

8. Delivery schedule is acceptable. If not, the deviation is brought-

out in the deviation statement (Annexure-II)

Yes / No

9. Terms of payment are acceptable. If not, the deviation is

brought-out in the deviation statement (Annexure-II)

Yes / No

10. Liquidate damages clause is acceptable. If not, the deviation is

brought-out in the deviation statement (Annexure-II)

Yes / No

Signature of Supplier with Seal

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PLC BASED FILM POSITIONING SYSTEM · sdsc shar, sriharikota request for proposal for design,...

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