Specifications for segment rotators-edited · The starter shall be wall mountable for 8 T capacity...

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SPECIFICATIONS FOR SEGMENT ROTATORS

1.0 SCOPE OF WORK

The scope of supply includes design, procurement of materials, supply, commissioning and

load testing of following segment rotators:

1) 10 (ten) sets of flame proof having capacity 8 T (each set includes one drive unit and one

idler unit mounted on independent frames)

2) 10 (ten) sets of non-flame proof having capacity 5 T (each set includes one drive unit

and one idler unit mounted on independent frames)

3) Spares for the above:

4 (four) nos. of spare roller wheels to facilitate easy replacement of the rollers (either

for drive unit or idler unit) in case of sudden requirement.

The following are the major specifications and conditions.

2.0 SPECIFICATIONS

2.1 Capacity 1) 8,000 kg – flame proof rotator (for a set of two units,

i.e., one drive and one idler)

2) 5,000 kg – non-flame proof rotator (for a set of two

units, i.e., one drive and one idler)

2.2 Load per unit 1) 4,000 kg – for flame proof rotator

2) 2,500 kg – for non-flame proof rotator

2.3 Diameter of the

specimen to be rotated

1300 mm (nominal)

2.4 Mounting of units Driver and idler units shall be mounted on individual

structures and firmly secured to them using suitable

fasteners.

2.5 Roller size 350 mm diameter and 250 mm width

2.6 Centre to centre

distance within each

unit (drive / idler)

The roller wheels are to be positioned in such a way that

the specimen of overall diameter 1300 mm will be

supported at a choke angle of 60 degrees (nominal).

2.7 Total height (Ground

level to the top of the

roller)

630 mm (Nominal)

2.8 Total width of each unit

(drive / idler)

750 mm (approximately)

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2.9 Length, width & height

of the mounting

structure alone

To be specified by the party

2.10 Direction of rotation Both clockwise and anti-clockwise

2.11 Roller material Shall be steel wheels moulded with neoprene rubber.

Hardness of neoprene rubber shall be 70 shore A.

2.12 Speed of the roller

wheel

Shall be between 1 rpm

2.13 Drive arrangement One wheel shall be driven in the driving unit. Other wheel

should be idle and to be movable to adjust the distance

between the rollers.

� Longitudinal movement arrestors should be provided on both sides of the segment

rotators. Arrestors are to be provided with rollers (steel wheels moulded with neoprene

rubber). Suitable provisions to be incorporated to handle segments of length varying for

4000 mm to 6000 mm.

� Suitable provision shall be made for manual rotation also. For this purpose, a rotating

handle should also be supplied for each rotator. Care should be taken to ensure that in

no case, the driving effort required for manual rotation shall be more than 5kgf.

� All electric motors & starters shall be selected to meet the following conditions:

• Ambient Conditions:

Temperature : 18 °C to 50 °C

Relative Humidity : 40 % to 98 %

Saline atmosphere

• ELECTRIC MOTOR:

Voltage : 415 V ± 6 %, 3 Phase

Frequency : 50 Hz ± 3 %

Type of Motor : Flame proof (for 8 T rotators) Crane Duty Squirrel cage

induction motor conforming to IS 325

Gas group : Gas Group-II A, II B, Zone I as per IS 2148

Winding Insulation : Class ‘F’ with temperature rise limited to Class ‘B’

Duty : S4

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Winding Configuration : Delta

Temp. Classification : T4 (135 °C)

Enclosure Protection : IP 65

The motor selected shall be such that when it drives 8 T / 5 T load (supported at a

choke angle of 60°°°°), it should draw only 90% of its rated current.

• STARTER:

The starter and its associates shall be with flame proof enclosures (8 T rotators)

suitable for Group – II A, II B, Zone I as per IS-2148 with IP 55 protection and of

following specifications:

Type of starter : Direct On Line (DOL), push button

Control : Main TPNSFU. Forward and reverse starter suitable for

the motor selected.

Protection : Fuses, overload protection suitable for the motor

Selected.

� The contactors selected shall be twice the capacity of motor rated current.

� All the cable terminations shall be with double compression type flame proof glands

(only for 8 T rotators) suitable to hazardous zone indicated above.

� The number of cable entries and suitable number of glands shall be decided based on

the requirement. The cables used shall be of flexible armoured type.

� The starter shall be wall mountable for 8 T capacity rotators.

� For 5 T capacity rotators, the starter unit shall be permanently fixed on the drive unit

itself at convenient height of operation.

� Each drive unit for 5 T capacity rotators shall be provided with a male socket with

flexible armoured cable. Also, wall mountable female sockets suitable for the male

sockets shall be provided. Supply shall be as indicated below:

� 3 phase, 415 V, male sockets (4 pin) with flexible armoured cable of 3 m length – 10

nos.

� 3 phase, 415 V, wall mountable female sockets (4 pin) – 10 Nos.

� The flexible armoured cable of 3m length shall be provided for each 8 T rotators also.

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3.0 PAINTING

3.1 Sand / steel grit blasting conforming to SA 2 ½ shall be done for cleaning the surface of

all steel structural members.

3.2 After sand / steel grit blasting, all the surfaces have to be cleaned free from dust,

moisture, oil, etc.

3.3 Zinc rich epoxy primer shall be applied to a dry film thickness (DFT) of 75 microns

minimum.

3.4 Two coats of polyurethane enamel paint (colour: apple green) to a dry film thickness of

40 microns minimum each (total 80 microns for two coats) shall be applied.

3.5 The supplier shall measure the thickness of paint in the presence of the representative

of the purchaser at random locations selected by the representative. The supplier shall

use his own paint thickness measuring instrument.

3.6 Wherever box sections are provided, the inside surface shall be cleaned and brush

painted with zinc rich epoxy to a thickness of 65 microns (DRT) prior to closing the

section.

DESIGN DRAWINGS

3.7 In the event of placement of order, party shall submit GA drawings, giving overall

dimensions, etc., for approval by RPP, VSSC within two weeks of receipt of Purchase

Order. This shall be confirmed in your quotation.

3.8 Power and torque ratings of motor gearboxes, shafting details, size of rollers, thickness

of rubber, etc. shall also be included in the GA drawing.

3.9 The design calculations shall also be submitted to the purchaser along with GA

drawings. Any change in the design pointed out by the department shall be

incorporated without any extra cost. The fabrication shall start only after clearance of

the GA drawings by the department.

3.10 While the design calculations are sought for perusal by the Department, it shall be

the sole responsibility of the supplier to ensure that the item so designed shall meet

all the functional criteria as required by the users.

3.11 Process details of securing neoprene on the metal wheels are also to be mentioned for

information.

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3.12 The frame structure shall be suitably designed for L/900 deflection criteria.

3.13 All fasteners used shall be electro-galvanized.

3.14 All welding shall be DP tested after final weld. All welds shall be free from cracks or

any other defects.

3.15 Four lifting brackets shall be welded on the frame of each unit for balanced horizontal

lifting of the unit.

3.16 All drive systems should be provided with proper coverings as a safety measure

against interference with persons and other systems. Open gearing is not acceptable.

3.17 Specimen will be supported at 1000 mm (approx.) from ends on both units, i.e.,

specimen will be projecting for about 1000 mm from both idler as well as driver units.

Hence no drive system or any other part should interfere with the free rotation of the

specimen placed on the segment rotators. The specimen overall diameter is 1300 mm

at the support points resting on rotators and in the remaining portions (including

overhang portions) the overall diameter of the specimen is 1400 mm. Hence suitable

clearance should be available between the drive system and the specimen. A minimum

clearance of 200 mm may be provided between the roller wheel top to any other

member / system of the segment rotator.

3.18 Provision for handling the idler and drive units by using a forklift should also be

provided.

4.0 INSPECTION

4.1 In the event of placement of order, the representative of the purchaser shall have

access and right to inspect the work at all times, during the course of fabrication. Any

work, which is proved faulty, shall be corrected by the supplier without delay.

4.2 The purchaser has no obligation to discover defects in the work performed and it shall

be the sole responsibility of the supplier to ensure such completed work is defect free

and meets the technical specifications / requirements.

4.3 During intermediate and final stages of fabrication, the items shall be offered for

inspection to the representatives of the Centre Level Inspection team of the

Department at your site.

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5.0 DELIVERY SCHEDULE:

5.1 The item shall be delivered to VSSC within six months of receipt of Purchase Order

followed by a period of one month for erection, commissioning and load testing at our

site.

6.0 BOUGHT OUT ITEMS

The bought out items should be of the following make only.

6.1 FASTENERS : TVS, GKW, UNBRAKO

6.2 BEARINGS : SKF, FAG (SEALED FOR LIFE TYPE)

6.3 GEAR BOXES : ELECON, RADICON, SHANTI GEARS

6.4 ELECTRIC MOTORS : CROMPTON GREAVES, BHARAT BHIJLEE,

KIRLOSKAR, NGEF, SIEMENS

6.5 STARTER COMPONENTS : SIEMENS, L & T, BCH

6.6 PLUMMER BOXES : FYH, NTN

6.7 COUPLINGS : FENNER, ELECON, RADICON, SHANTHI, NEWTECH,

ALL-FLEX, HI-CLIFF

6.8 PUSH BUTTON : SIEMENS, BHC, L & T

6.9 LIMIT SWITCHES : STERLING CONTROLS, ELECTROMAG

6.10 PAINTS : ASIAN PAINTS, BOMBAY PAINTS, BERGER PAINTS,

NEROLAC

6.11 FLAME PROOF

PLUG & SOCKETS : M/s BALIGA LIGHTING EQPTS. PVT. LTD. & FCG

No other makes are acceptable. If for any reason, the supplier is planning to use difference

make, he has to get prior approval for the same from the purchaser. However, purchaser

reserves the right to reject such proposal.

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7.0 QUALITY ASSURANCE PLAN

7.1 The supplier has to check and produce certificates, at various stages during progress of

work as mentioned below:

� Before Fabrication:

� The fabrication shall start only after the clearance of the fabrication drawings

by the purchaser.

� Test certificates from Government approved test houses for chemical

composition of the raw materials to be used for fabrication should be

produced to the Department.

� During Fabrication:

� All the weldments shall be DP tested after final weld. All the welds shall be

free from cracks or any other defect.

� The thickness of the paint shall be measured after final painting by the

supplier in the presence of the representatives of the purchaser and shall

meet the specification.

� Repair works, if any, shall be carried out only after approval from the

purchaser.

� After Fabrication:

� The supplier has to produce a quality report incorporating all the certificates

/ documents as mentioned above.

� Before dispatch, the supplier has to assemble the items and show the

satisfactory performance of the system at the time of inspection (by the

representative of the purchaser) at supplier’s site.

� The supplier has to do final assembly and show the satisfactory performance

of the performance of the items with load as per the following conditions at

the time of commissioning at site in RPP, VSSC. (Necessary test loads will be

provided by the purchaser).

� The segment rotators shall be run at no load.

� The current drawn by the motor shall be within rated values.

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� The operation should be smooth.

� The rotators will then be loaded with 8 T (rated load).

� The current drawn by the motor should be within 90% of rated current of

the motor when driving 8 T load.

� The operation should be smooth.

� The RPM of the roller wheel will be measured and it should be as per

specification, i.e., 1 rpm.

� The maximum deflection observed in the stand should be below the

L/900 value.

� Rotators have to be tested for overload (125% of SWL, i.e., about 10 T)

� After load test, the rubber should not debond from the metal.

7.2 The QAP given above is only indicative. The supplier has to give the detailed quality

assurance plan before taking up the work, so as to identity the stages for clearance.

8.0 DESPATCH

8.1 In the event of placement of order, the items are to be dispatched to VSSC,

Trivandrum only after inspection & clearance for dispatch by the representatives of the

Centre Level Inspection team of the purchaser.

8.2 Any damages during transportation are to be rectified free of cost by the party.

9.0 GUARANTEE

9.1 Guarantee period shall be for a period of 12 (twelve) months from the date of

commissioning, acceptance & taking over by the purchaser. During the guarantee

period any defect noticed in the design, materials, workmanship shall be rectified by the

supplier, free of cost.

Specifications for segment rotators-edited · The starter shall be wall mountable for 8 T capacity...

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