TENDER SPECIFICATIONS FOR 175t/25t FLAMEPROOF EOT CRANE · TENDER SPECIFICATIONS FOR 175t/25t...
Transcript of TENDER SPECIFICATIONS FOR 175t/25t FLAMEPROOF EOT CRANE · TENDER SPECIFICATIONS FOR 175t/25t...
SATISH DHAWAN SPACE CENTRE SHAR
SOLID PROPELLANT PLANT
File No: SHAR/SPP/2015002267
TENDER SPECIFICATIONS FOR
175t/25t FLAMEPROOF EOT CRANE
Page 1 of 3
BID QUALIFICATION CRITERIA FOR SUPPLY OF 175t/25t EOT CRANE
Bidders who are qualifying/meeting following Technical and Financial capabilities are eligible to participate in the bid for supply of 175t/25t EOT crane. Bidder shall furnish all the requirements asked in this criteria with documentary proof and submit along with quotation. Bids of the parties which are not meeting the following criteria will not be considered for evaluation and will be rejected without seeking any further clarifications.
I. Technical Qualification Requirements:
The bidder should meet the following technical qualifying requirements and
shall submit relevant certificates to establish his credentials.
1. The Bidder should be an organization with experience in having executed contracts for design, engineering, manufacture, supply, erection, testing and commissioning of
Double girder EOT cranes & Hoists Package for last 25 years in India.
2. The firm should have successfully completed Design, Manufacture, Installation, Testing and Commissioning of at least 5nos. of double girder EOT cranes of capacity 200t and
above and Span equal to 20m and above during last 7 years ending 31.12.2014.
Bidders have to provide relevant certificates from the Owners (end users) along with
the submission of bid for consideration of bid document.
3. The firm should have successfully completed Design, Manufacture, and commissioning of EOT cranes with VVVF (VFD) drive & control systems at least 10 nos. of cranes
and at least one crane of capacity not less than 150t in last 10 years.
4. The firm should have successfully completed Design, manufacture and establishment of fail safe mechanisms & controls like Emergency disc brake on rope drum (actuated in
case of failure in power transmission line), wire rope spooling monitoring and
redundant (double) wire rope reeving system at least in 2nos. of EOT cranes in last
10years.
5. The firm should have experience and knowledge in the Design and manufacture of EOT crane with dual drive hoist (Twin load path). It is preferable to have completed
realization of such cranes.
6. The firm should have successfully completed Design, manufacture, and establishment
of at least 05 nos. of EOT cranes (not less than 100t capacity) with twin motor with
planetary gearbox system for Hoist mechanism for last 10 years.
7. The firm should have successfully completed Design, manufacture, and establishment
of at least 05 nos. of EOT cranes (not less than 100ton capacity) for ladle cranes (hot
metal handling cranes) for reputed steel mills for last 10 years.
8. The firm should have facility to full load test and over load testing of 200t EOT crane (hoist and cross travel) at their factory.
9. The firm should have successfully completed Design, manufacture and establishment
Page 2 of 3
of high capacity EOT cranes (100t and above) to the satisfaction of reputed third party
inspection agencies like M/s MECON and M/s M.N.Dastur.
10. Bidder shall furnish the details of their factory like manpower, machinery, quality system etc., for department to access their capability. Bidder shall submit above
information in the format given in “Questionnaire” attached as Annexure to this BQR.
II. Financial Qualification Requirements:
The bidder should also meet the following financial qualification requirements:
2.1 The Bidder should have annual turn over of not less than a value of Rs. 10 crores per year last three financial years ending 31-03-2014.
2.2 Firm should have undertaken and successfully completed following value of works related EOT cranes at least in last 05 (Five) years :
Single work of EOT cranes not less than : Rs.10 Crores.
(or)
Two works of EOT cranes not less than : Rs.5 crores (each)
(or)
Three works of EOT Cranes not less than : Rs.4 crores (each)
2.3 Bidder should possess a current Solvency Certificate from Nationalized Bank for an amount of not less than 10 crores.
2.4 IT/ TDS certificate shall be submitted with Loss & Profit.
2.5 Bidder shall submit audited statement of financial status for last 03 years.
III. The following documents shall be submitted along with the application for
prequalification of Bid:
1. Firm establishment certificate and nature of work (for Sl no.1).
2. Detail of work of similar type completed during the last seven years ending 31.12.2014 ( for Sl. No.2).
3. Satisfactory work Completion certificates from the clients, with the work order copies (for S.Nos 2 & 3).
4. Performance Report of EOT cranes established (with years of service) from End users, with addresses and contact person with phone numbers.
5. Documentary evidence (Technical details & drawings) for fulfilling special technical conditions (Sl. no. 2, 3, 4 & 5).
6. Copy of audited Balance Sheets for last three years.
7. IT / TDS certificates for last three years.
8. Current Solvency Certificate.
9. List EOT crane projects ( for capacity 100t and above / Span 20m and above) completed for last 10 years with PO copies.
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10. List, value and work order copies of total projects under Execution with Purchaser name and address.
11. Duly filled “Questionnaire” with signature, name, phone no and company seal.
12. Structure and Organizational Chart
13. List of personnel with qualification & experience in the firm in the areas of design, production, quality, safety, administration etc.,
14. List of Machinery & Equipments to be used for the work.
15. Any other relevant information which add value to above.
IMPORTANT NOTES :
1. Bidder shall furnish all the above details fully and explicitly. 2. Please note that the “BID” without above mentioned the documents/information in
support of the eligibility criteria will be summarily rejected.
3. No further clarifications will be seeking in this regard.
IV. Bid Selection Procedure and Process of BID Qualification
Step - 1: Short listing based on documents submitted, satisfying the all eligibility criteria
given above by the firm or individual along with their Bid / application. (Non-
submission of any document as given in above list within stipulated time leads to
rejection of Bid)
Step - 2: Subsequently Bidder’s competency, their technical achievements and financial status will be evaluated suitable for his project. Feedbacks from Bidder`s clients will be verified.
Step – 3: Visit to sites/EOT Cranes by technical team (ISRO or Third party) where Bidder has
established above mentioned capacity EOT cranes. Step - 4: If required to visit will be made to their factory/ firm by technical team (ISRO or
third party) for accessing the capability of manufacturer. Step - 5: Mean while technical Bids will be opened and scrutinized for meeting all technical
specification and supply conditions.
ISRO - SHAR reserves right to verify the information / data furnished by Bidder. If the
same is found as fault or with any deviation the bid will be rejected.
Only those Bidders who are found suitable & meeting all the above qualification
Criteria/requirements will be finally qualify for opening the Price Bids for evaluation.
Annexure to Bid Qualification
QUESTIONNAIRE FOR DESIGN, MANUFACTURE, TESTING AND ERECTION & COMMISIONING OF HIGH CAPACITY EOT CRANES
(INFORMATION TO BE PROVIDED BY BIDDERS)
Name & Address of EOT Crane supplier:
Phone : Mobile : Fax : Email :
Sl. No.
Items/ Information
Specification/ details of items
Remarks
1. Type of Industry (SSU, Medium, Govt, etc.,)
2. Year of Establishment
3. Annual Turnover (in Rs. lakhs) for last three years year ending up to 31-03-14
3.1 Turn over – 2013-14
3.2 Turn over – 2012-13
3.3 Turn over – 2011-12
4.
Orders executed during last 03 years, capacity of EOT Cranes, references are is to be mentioned. (Separate sheet can attached for this)
a. 2013-14
b. 2012-13
c. 2011-12
5.
Quality Certification of company (ISO, TUV, etc.,)
Page 1 of 6
Annexure to Bid Qualification
6.
Nos. of EOT Cranes of capacity 200t and above and Span :20m and above manufactured during last 10 years ending 31.12.2014
7.
No of EOT Cranes of capacity not less than
100t with SIEMENS VVVF (VFD) drive &
control systems produced in last 10 years.
8.
No. of EOT Cranes of capacity not less than
100t supplied with Emergency Rope drum
caliper brake.
9.
No. of EOT cranes produced (not less than
100 ton capacity) with twin motor with
planetary gearbox system for Hoist
mechanism for last 10 years.
10.
No. of steel mill cranes ( not less than 100 ton
capacity) produced for molten metal ladle
handling in last 10 years.
11. Shop floor Area Covered
12.
No of Employees (Supplier shall mention contract personnel separately)
a. Engineers b. Supervisors c. Technicians d. Quality control engineers Administrative staff
13.
Raw Material Sourcing: a. Steel Plates b. Rolled sections, Flats c. Forged Rods, Blanks d. Round bars (for Axles) e. Seamless pipes
Page 2 of 6
Annexure to Bid Qualification
14.
Sources of Bought out components: a. Electric Motors b. Brakes Flameproof c. Gearboxes d. Couplings e. Limit switches f. Wire ropes
15.
Details regarding out sourcing, if any, of manufacturing and fabrication works.
16.
Handling facility available: a. Over head /Gantry crane details
(capacity, span, lift). b. Mobile cranes
17.
Load testing Facility Available: a. Maximum weight available. b. No. of weights c. Total test load available.
18.
Welding /Fabrication Workshop (Type/ capacity/ Quantity of machines shall be provided)
a. MMAW machines b. GMAW machines c. Gas cutting m/cs d. Plasma cutting m/cs e. Welding Fixtures
19.
Fixtures available for Welding of Girders of span more than 20m.
Page 3 of 6
Annexure to Bid Qualification
20.
Welding Professionals: a. No. of welders (MMAW)
Qualification details Qualified by
b. No. of welders (GMAW) Qualification details Qualified by
c. No. of welders (TIG) Qualification details Qualified by
21.
Details of Welding Inspection Equipment & welding inspector available with supplier ( LPT, UT, MPT, X-ray, etc) Any out sourcing can be mentioned.
22.
Forming Facilities available (with brief specification of each machine)
a. Shearing Machine b. Cutting machine c. Bending machine
23.
Machining Facilities available (with brief specification of each machine)
a. Turning Lathe (Conventional/CNC) b. Milling Machine (Conventional/CNC) c. Gear cutting/ hobbing machines. d. Gear Grinding machines e. Drilling Machine (Conventional/CNC) f. Cylindrical Grinding Machine
(Conventional/CNC) g. Any other machines
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Annexure to Bid Qualification
24.
Details of Inspection facilities / Instruments available (Brief description & specifications shall be provided)
25.
If third party inspection services are taken for manufacturing of EOT Cranes give details.
26.
Range of Capacity of EOT Cranes manufactured, till now (list with brief specs, & customers shall be provided)
27.
Maximum capacity of EOT Crane manufactured with dimensions, type, quantity, customer, and purpose of EOT Crane.
28.
Maximum dimensions of EOT Crane manufactured with capacity, Span, quantity, customer, and purpose of EOT Crane.
29.
Special purpose EOT Cranes manufactured, if any, capacity, dimensions, and customer
30.
Design facility available: a. Drafting & Modeling software
packages b. FEM software c. Other Softwares d. Design engineers (with qualification
& experience)
Page 5 of 6
Annexure to Bid Qualification
31.
Painting facility available a. Sand/ Abrasive blasting facility. b. Painting equipment c. Make of paints generally used.
32.
General stock level of Raw materials/brought out items in the factory:
1. Structural steel plates etc., 2. Alloy steel round bars 3. Bought out items 4. Paints, etc.,
33. Any awards or recognitions obtained through product excellence
34.
Collaborations with other reputed manufactures and OEMs with product details and Name of Principal supplier, country of origin etc.,
35. Any other relevant information in design, manufacture and testing of EOT Cranes
36. List of documents enclosed with this questionnaire
37. Any other information like to add (separate sheet can be attached)
Signature of competent person Name : Designation :
Date : Company seal :
Page 6 of 6
SATISH DHAWAN SPACE CENTRE SHAR SOLID PROPELLANT PLANT
Ref: SHAR/SPP/2015002267
TENDER SPECIFICATIONS OF 175t/25t EOT CRANE
Facility : Propellant Machining Facility - II
Sl.
No. Type of crane
Capacity
of crane
(ton)
Span
(m)
Height of Lift
(m)
Crane Travel
(m)
Duty
class of
crane
Quantity
( No)
1
Double Girder
Flameproof
EOT Crane
175t / 25t 21.0 MH – 22.50m AH – 24.50m
32.00
Class - II
of
IS 3177
01
175t/25t EOT crane shall be supplied, transported, erected and commissioned as per the Technical Specifications, Terms & Conditions given in following pages of this document.
Ref : SHAR/SPP/2015002267
CONTENTS OF BOOKLET
Sl. No
Contents
Page No.
1
Technical Specifications cum Compliance statement, Terms & conditions of supply including codes and standards.
1 to 44
2 Annexure – 1A to 1D : Figures, EOT Crane Clearance diagram, Location of VVVF room and dimensions.
45 to 48
3 Annexure – 2 : Schematic of Pendant Button operating station
49
4 Annexure – 3 : Quality Assurance, Inspection and Testing plan for EOT Cranes
50 to 60
5 Annexure – 4 : Price format for Spare parts for EOT crane.
61
TECHNICAL SPECIFICATIONS OF
175t/25t FLAMEPROOF EOT CRANE
SECTION – I
GENERAL SPECIFICATIONS
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:1 of 41
A
B
C
Contact Person :
FAX No :
Mobile No : Email :
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
1
DNAME & ADDRESS
OF THE Bidder :
Bidder shall submit complete information asked in Qualification Criteria and Questionaire for qualifying for
bid with all informations, certificates and earlier references of manufacture should be enclosed. The offer
meeting all the requirements & conditions in all respects will only be considered for further processing.
Bidder shall completely fill the following format of technical specifications & supply conditions with
mentioning required details. Bidder can add more information and details, if required, by attaching seperate
sheets, by giving point no. of this format. Inadequate /incomplete, ambiguous, or unsustainable information,
against any of the clauses of the specifications / requirements shall be treated as non-compliance to tender
and quotation will be rejected. Generalized statements like crane shall be manufactured "as per your
specifications" or "as per IS standards" or "as per enclosed specification" is not acceptable and Bidder shall
submit all the specifications by filling in the following FORMAT only, otherwise it is not valid.
Deviations with respect to specifications given below are not acceptable. However Bidder can submit /
suggest improvements, if any, seperately by indicating the clause no. in this specifications.
SCOPE OF SUPPLY
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
Supply & Erection of Bridge gantry rail along with its accessories for bay length
of around 32.0meter. (Gantry girder is in the scope of Department / Purchaser).
VVVF panels shall be erected in a separate room at ground level and cabling
must be done to the EOT crane at gantry girder height of 19m as per clerance
diagram enclosed.
Supply & erection of Drag chain power cable system for EOT crane as per the
specifications mentioned.
Design, detailed engineering, manufacture, inspection, shop testing, supply,
erection, commissioning & performance proving of Heavy duty 175T/25T
capacity, Flame proof, Top running, double girder EOT Crane as per following
specifications and IS 3177, IS 807 & relevant codes & standards.
The scope of work shall also include procurement of all materials including
importing of components (from other countries) required for completion of the
work, coordinated planning for manufacture, inspection, painting, load testing at
supplier works.
Packing, marking, loading on Trucks/ Trailers and safe transportation of EOT
crane & other parts / items / accessories from supplier site to SHAR site .
Main Hoist (175t) shall be provided with dual rope reeving system i.e., two
independent wire ropes shall be provided with balanced reeving system, wire
rope spooling & monitoring as per the specifications mentioned in this
document.
Erection, testing & commissioning of EOT crane shall be done as per the
Technical Specifications, conditions given below and also in accordance with
latest editions of IS: 3177, IS: 807 & relevant codes and standards.
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:2 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
2 Quantity of Crane : 01 No. (One)
Main hoist drive system shall be designed to provide assurance
that a failure of single component of hoist mechanism (Motor, Gearbox,
brake, coupling, wire rope) would not result in loss of load and uncontrolled
movement of the lifted load. This can be accomplished by the application of
dual hoist drive unit described below.
Dual Hoist Drive with two gearboxes and rope drum (Twin Load path) :
The dual-hoist drive shall have rope drum, two parallel shaft helical gear
trains ( on each side of drum), two drive motors (each gearbox driven by
motors) and at least two holding brakes located on input shaft of geartrain
and realted couplings. This shall ensure two independendant load paths for
main hoist drive and each of two independant load paths shall be capable of
driving & holding the rated load of 175t.
1.9
Supplier shall arrange "Third party inspection Agency " for design
verifications, approvals, inspection during manufacture, load teasting,
and certfying the EOT crane as per QAP.
Arranging the third party inspection is in the scope of supplier for the entire
scope of work as given above and as per QAP enclosed. Bidder shall engage
TPIA - Third Party Inspection Agencies like M/s Mecon,(or) M/s M.N.Dhastur
only. The finalization of third party agency shall be done on mutual agreement
between ISRO and Bidder.
1.10
3
3.1 Application
This Heavy duty EOT crane is used for handling of
hazardous / dangerous materials like rocket motors,
propellant containers, delicate flight hardware etc., for
positioning and assembly during process operations.
Failure of EOT crane & its components during handling
may result in loss of life and property. Hence Bidder
shall design, manufacture and erect the crane with
emphasis on quality, reliability and safety and shall
ensure smooth & reliable operation of crane with long
service life.
3.2Usage period &
desired life of crane
This heavy duty EOT crane will be put to use for 365
Days’ intermittent duty (Class II duty as per IS3177)
with CT, LT and Hoist movements. EOT Crane shall
be designed for minimum life of 30years.
4
4.1
4.2
5
Operating
Environment of
Crane / Weather
conditions
Operating environment is Indoor, near to sea (i.e.,
saline atmosphere), with ambient temperature of 50ºC
and with relative humidity of 95%. Weather conditions
are tropical. Bidder shall consider above while design
of EOT crane, electricals, painting of crane & related
parts.
Hazardous area conditions
VVVF panels shall be provided in a separate room at the ground level and
cabling must be done to the EOT crane which is at a height of ~19m. The
VVVF panels shall be suitable for normal atmospheric conditions.
The EOT crane shall be equipped with flame proof electrical systems suitable
for operating in hazardous area classified as Zone 1, Gas group IIA / IIB, T4 as
per relevant IS 5572 / IEC standards.
Usage of EOT crane
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:3 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
6
6.1 Type of CraneDouble girder, Flameproof, Indoor, Heavey duty EOT
Crane
Structures : Class-II duty as per IS 807
Mechanisms : Class -II duty as per IS3177
Main Hoist Gearboxes: Class IV duty of IS:4137-1985
6.3EOT Crane capacity (in
ton)
175t (Main Hoist)
25t (Auxiliary Hoist)
6.4 Span 21.00 meters
6.5
6.5.1 Main Hoist (meters)Above FFL - 17m , Below FFL - 5.50m,
Total : 22.50m
6.5.2 Auxilary Hoist (meters)Above FFL - 19.00m , Below FFL - 5.50m,
Total : 24.50m
6.6 Operation Speeds ( meters/minute)
6.2
Lift Height
Class & duty of EOT
Crane
MAIN PARAMETERS OF EOT CRANE
6.6.1
Main Hoist with dual
load path (four motors
& two gearboxes)
Main speed : 2.0 m/min & creep speed: 0.2m/min with
all motors running--Main speed :1m/min & creep speed
:0.1m/min when half the motors are running.
6.6.2 Auxilary Hoist 2.5 m/min in main speed, 0.25 m/min in creep speed.
6.6.3 Cross travel 6.0 m/min in main speed, 0.6 m/min in creep speed.
6.6.4 Long travel 6.0 m/min in main speed, 0.6 m/min in creep speed.
6.7
Side clearance
(Distance from centre
of gantry rail to nearest
obstruction)
400mm (minimum) on both sides.
6.8
Head room available
(Vertical distance from
top of gantry rail to
lowest overhead
obstruction)
6.00 meters (maximum) (Refer clearance diagram).
6.9Distance from floor to
top of gantry rail~ 19.00 meters
6.10 Bay length in meters ~ 32.00 meters
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:4 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
6.11
DSL side :
Main Hook : around 2.00m
Aux. Hook : around 3.50m
6.12Non-DSL Side Main Hook : around 3.20m
Aux. Hook : around 1.70m
6.13CT DSL side : not more than 4 m (LT forward side)
Non DSL side : not more than 4m (LT reverse side)
6.14 LT wheel base as per IS807 / shall not be less than 1/5th of span.
shall be as minimum as possible for having optimum
LT hook approaches for better utilization of crane &
building.
Max. Width of crane around 8.00m.
6.16
6.16.1
6.15
Main hoist drive system shall be designed to provide assurance
that a failure of a single component in hoist mechanism would not result
in loss of load and uncontrolled movement of the lifted load. This can be
accomplished by the application of dual hoist drive units. The wire rope
drum, hook, hooknut, and load block structure are exempted from this
Main Hoist Drive
Hook Approaches
(Refer Clearance
diagram) (supplier shall
optimise these values)
Width of Crane
drum, hook, hooknut, and load block structure are exempted from this
requirement. Supplier shall accomplish above failure proof design feature as
described below.
In case of any problem & failure in one load path, easy & safe switch over to
second/redundant load path shall be done smoothly without free fall and heavy
jerks. Proper arrangement shall be made for safe & reliable mechanical
decoupling of defective drive system.
Motors and gearboxes shall be rated such that each set of motor and Gearbox
will take full rated torque at rated speed i.e., 2m/min
Proper Electrical and drive interlocks shall be provided betwee motors and
brakes such that drive system is safe gaurded without damage, incase of failure
in one load path and to overloading of other load path.
6.16.2
Dual Hoist Drive with two planetary gearboxes, 4 drive motors and rope
drum (Twin drive Load Path) : The dual-hoist drive shall have rope drum,
two parallel shaft helical planetary gear trains (on each side of drum), four
drive motors (each gearbox driven by two motors) and at least two brakes
per motor located on input side of each gearbox and related couplings. This
shall ensure two independendant load paths for main hoist drive and each of
two independant load paths shall be capable of driving & holding the full rated
load. Each gear box train shall be sized for the total full-load drive
torque with appropriate service factor as per IS4137. All motors shall be driven
through two/four VVVF drives with syncronization with proper control &
interlocks. There shall be two independent wire ropes, each shall be capable of
holding the rated load. Refer Schematic arrangement given in Fig .1. Supplier
can suggest & design alternate configuration to meet above safety,
redundancy, and reliable Main Hoist system with optimum hook
approaches.
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:5 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
6.16.3
6.17
6.17.1
6.17.2
6.18
6.18.2
6.18.3
Service brakes shall be located on Input shaft of gearbox. 2nos. of Imported
flameproof brakes per motor shall be provided.
LT drive shall be provided with twin drive system at two corners of crane.
Horizontal foot mounted helical gearboxes, motors and thruster brakes shall be
used.
Each corner drive components shall be easily accessible and shall be designed
with inter changeable components.
Single motor with one Horizontal, foot mounted, parallel shaft Helical gearbox
of standard make mentioned in this specification.
LT Drive
Two service brakes (Imported, flameproof brakes ) must be provided on either
side of input shaft of gearbox.
Wherever applicable the driving pinions shall not interfere with the removal of
wheels.
6.18.1
Drive size shall be selected such that Crane can be moved by two motors
drives with one VFD.
Auxiliary Hoist Drive ( conventional hoist system)
6.18.4Number of wheels for
LT drive
8Nos or 16Nos. & Drive wheels : 50% of total wheels
based on design.
6.18.5Diameter of wheels for
LT driveNot less than 710 mm.
6.19
6.19.1
6.19.2
6.19.3
6.19.4Number of wheels for
CT drive
4Nos or 8nos.,and Drive wheels : 50% or 25% of total
wheels based on design
6.19.5Diameter of wheels for
CT driveNot less than 630 mm.
6.19.6Maintenance of CT
drives
Maintenance platform shall be provided for CT drives
covered with chequered plate.
6.20Type of bearings for
LT/CT wheels
Anti-friction, Heavy duty Double row Spherical Roller
Bearings
6.21Type of mounting of
LT/CT wheels"L" type brackets with fit bolts and locknuts.
CT Drive
CT drive shall be provided with sufficient no. of drive systems / central drive.
Helical parallel shaft gearbox, motor and imported thruster brakes shall be
used.
All the drive components shall be easily accessible and shall be designed with
interchangeable systems. (If twin drive is selected for CT)
Wherever applicable the driving pinions shall not interfere with the removal of
wheels.
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:6 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
6.22Total Weight of EOT
Crane (tons) Bidder to Specify
6.23 Weight of trolley (tons) Bidder to Specify
6.24Weight of each Bridge
Girder (tons) Bidder to Specify
6.25Weight of each End
Carriage (tons) Bidder to Specify
Weight of Electricals
on top of crane Bidder to Specify
Weight of electrical
Panels in room (tons) Bidder to Specify
6.27 LT wheel load (tons) Bidder to specify
6.28 CT wheel load (tons) Bidder to specify
6.29Size of Cross Travel
Bridge Girder RailCrane rails not less than CR-100 as per IS 3443
6.26
6.30
Size of Crane gantry
rails (for Long Travel) -
Scope of Crane Bidder
Crane rails not less than CR-100 as per IS 3443
TECHNICAL SPECIFICATIONS OF
175t/25t FLAMEPROOF EOT CRANE
SECTION – II
MECHANICAL DESIGN AND DETAILS
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:7 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
7
The design of components shall be done on the basis
of ultimate tensile strength, the value of stress factor
used shall be the product of the basic stress factor and
the duty factor for the appropriate mechanism class as
mentioned in IS:3177.
The design of all mechanical components shall be done
as per IS:3177 & as per this technical specifications
and also on the basis of minimum ultimate tensile
strength with factor of safety of not less than 5.
7.1.1
7.1.2
7.1.3
7.1
All mechanical components in Hoist (vertical load path), shall be designed for
infinite fatigue life. Fatigue analysis shall be based on the crane maximum rated
load.
Materials with less than 15% elongation shall not be used for any of
mechanical load bearing component except for electrical motors, panels and
MECHANICAL DESIGN AND ELEMENTS' DETAILS
The stresses in all components of hoist mechanism and gearboxes should not
exceed 66% of yield point (proof stress) of the material for the component
under break down conditions of motor i.e. pull out torque of motor.
Factor of Safety
7.1.3
7.1.4
7.1.5
7.2 Hoist hook type
Main Hoist : Ramshorn type hook with swiveling anti-
friction thrust bearing and safety latch as per IS:5749.
Aux. Hoist : Single Point hook with swiveling anti-
friction thrust bearing and safety latch as per IS 3815
& relevant standards.
7.2.1
7.3Number of falls for
Hoist
Main Hoist : ~ 16 (8 + 8).
Aux. Hoist : ~ 8
7.4
7.4.1
7.4.2
No cast iron part should be used as load bearing member on the crane except
for electrical equipment. Similarly wood or combustible material and Bush
bearing should not be used in any part of the crane.
Stress Concentration factors shall be considered in mechanical design for
calculating working stresses and also combination of stress concentration
factors shall be considered at required conditions.
mechanical load bearing component except for electrical motors, panels and
hydraulic components.
Rope drum diameter shall be minimum 40 times the diameter of wire rope.
ROPE DRUM
Rope Drum shall be of welded / fabricated type of IS:2062 steel with duly stress
relieved. Rope drum shall be designed as specified in IS:3177 in general.
Allowable stress in drum shall not be more than 1/5th of UTS.
The hooks shall be free to swivel on antifriction roller thrust bearing of
adequate capacity and so constructed as to exclude dirt and also shall
be provided with a means for lubrication.
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:8 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
7.4.3
7.4.4
7.4.5
7.4.6
7.5
7.5.1
7.5.2
The design of the rope reeving system shall be such that a single rope
failure will not result in the loss of the lifted load. A load balance
sytem shall be provided on each rope system.
Drum grooves shall be helical and machined with smooth surface finish. Drum
grooves shall be dimensioned as per IS3177.
Reeving system shall be divided into two separate load paths so that either
path will support the rated load and maintain vertical alignment in the event of
Fleet angle of wire rope from drum to sheave shall not be more than 2.5 deg
and drawings & calculations shall be provided in this regard.
Rope dead ends shall be clamped with minimum three clamping wedges with
two numbers of bolts on each clamp. The bolts shall be at the centre of
clamp and shall be wire locked.
MAIN HOIST WIRE ROPE - Double rope reeving system
Length of the drum shall be sufficient to accommodate the rope in one layer of
the rope requisite for the specified lift and in addition rope drum shall be
provided with not fewer than three dead turns at each anchored end and at
least one spare groove at the other end when hook is at full height of lift
condition. Grooves shall be finished smooth and shall be rounded at edges &
corners.
7.5.2
7.5.3
7.5.4
7.5.5
7.5.6
7.5.7
7.5.8
7.5.9
7.5.10
Minimum factor of safety of 10 shall be provided for wire rope of Main Hoist on
Minimum Breaking Strength (MBS) of rope with two ropes combined together.
With single rope the factor of safety shall be 5 on the MBS of main hoist rope.
The wireropes shall be of M/s USHA MARTIN make, Non-rotating type,
Galvanized, Powerform, 35x7 construction, core : IWRC, RH, Regular lay,
preformed, Minimum tensile strength / Grade : 1960MPa.
i). Sensing and automatic signaling of excessive rope load/displacement to
either side shall be provided.
ii). Provision, tooling and procedure shall be provided for adjustment of
wireropes to take equal load.
iii). The vertical displacement of the load, following a rope failure, shall be
minimized.
path will support the rated load and maintain vertical alignment in the event of
rope breakage or failure in one rope system.
Upper block assembly and lower load block assembly shall be designed
such that the sheaves will be contained & maintain vertical balance of load
in the event of failure of single wire rope.
No joints shall be used for wire ropes under this specification.
In the event of a hook over travel, where the lower block contacts the
crane trolley structure, the ropes shall not be cut or crushed.
During hoisting & lowering hook block shall not oscillate/ rotate without load or
with load.
Dual rope reeving system shall be designed such that the bottom load block &
hook shall follow a true vertical path ( true vertical lift) during hoisting and during
with No load & Full load conditions.
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
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Page:9 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
7.5.11
7.6
7.6.1
7.6.2
7.6.3
7.6.4
7.6.5
Auxillary hoist wire rope shall be single path & conventional reeving system
with true vertical lift as per IS3177. Wire rope shall have factor of safety of 6
on Minimum Breaking Strength (MBS). The make wirerope shall be of M/s
USHA MARTIN only. Wire rope shall be Non-rotating type, Hotdip Galvanized,
35x7 construction, Core : IWRC, RH, Regular lay, preformed, Minimum tensile
strength/Grade : 1960MPa.
Sheave diameters (at the bottom of groove) shall be minimum 29 times rope
diameter. Sheave fleet angle shall not be more than 2.5 degrees.
ROPE SHEAVES
All sheaves shall be mounted on special roller type sheave bearings.Grease
lubricated sheave bearings should be provided with individual grease
lubrication fittings and shall be easily accessible for maintenance.
Design of sheaves in general shall be as per IS:3177.
All sheaves shall be of forged steel only.
Equalizer sheave diameter (at the bottom of groove) shall be minimum 18 to
20 times the diameter of wirerope for Aux Hoist.
The equalizer sheave /Equalizer Bar shall be mounted above the trolley floor
7.6.6
7.6.7
7.6.8
7.6.9
7.6.10
7.7
A) Main Hoist (Twin
drive & Dual load path)
Hoist drive shall be provided with two parallel shaft
helical planetary gearboxes each driven by two
motors. Standard make, Crane duty, Horizontal foot
mounted, Parallel shaft, Helical Gearboxes shall be
used.
B) Aux. Hoist
Standard make, crane duty, parallel shaft, Helical,
horizontal foot mounted gearboxes shall be used for
Aux. hoist motion.
7.7.1
All the upper block sheaves shall be mounted above the trolley platform for
ease of maintenance and inspection.
GEARBOXES
All Sheaves shall have guards, which fit closed to the flange having a clearance
not more than 1/3rd rope diameter between sheave and inside of guard, to
prevent the wire rope from leaving the sheave grooves.
Sheave grooves shall be machined smooth and support wire rope uniformly at
least 136° angle of contact over its circumference.
The equalizer sheave /Equalizer Bar shall be mounted above the trolley floor
and shall be easily accessible for maintenance from the floor of the trolley.
Equalizer Bar / sheave shall be made in such a manner that it can
turn or swivel to align itself with the pull of the ropes.
Equalizer sheave /Bar shall be arranged such that reeving equalization
shall not be restricted under normal operating conditions. Adequate free
movement to compensate for operational block swing and/or normal rope
stretch shall be provided.
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:10 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
Helical parallel shaft, Crane duty, gearboxes, shall be
used for CT & LT drives. LT drive shall be of
horizontal foot mounted gearboxes.
Travel drive gearbox ratings for bending strength and
pitting resistance shall be based on 2 times rating of
AC motor.
7.7.3 Make of Gearboxes
Heavy duty, and crane duty gearboxes of Elecon /
Shanti/ GREAVES (Premium transmission) /
Flender/ DB-Radicon / Sumitomo / Renold only.
Other make & Own make gearboxes are not
acceptable. Bidder shall confirm the acceptance.
Tender will be rejected for not meeting this
requirement.
1) Gearboxes selection shall consider starting torque
of motor (i.e., 2 times the Full load torque) of selected
motors.
2) The gearing shall be designed for strength,
durability, and momentary high overloads which
includes the loads imposed during starting,
braking and failure of components.
7.7.2Gear Boxes for CT &
LT drives
3) Due consideration shall be given for braking torque
on input shaft of Gearboxes.
4) The stresses in all components of hoisting
machinery and gearboxes should not exceed 66% of
yield point of the material for the component under
break down conditions ( Pull Out Torque) of motor.
5) In design of gearboxes, due consideration shall be
given to creep speed and also ramping down of rated
speed (rpm) to zero speed through VVVF drives.
7.7.5
7.7.6
7.7.7
7.7.8
7.7.9
7.7.10
7.7.11
Torque & Power rating
of Gearboxes / Pinions
/ Gears / Shafts
All gear teeth shall be helical and with helix angle not less than 15°.
7.7.4
All pinions shall be integral with shafts.
Drawings and dimensional details of gear boxes, selection criteria, power rating
& torque rating calculations, bearing details, data sheets from gearbox
manufacturer shall be submitted for TPIA / Purchaser (SDSC SHAR) approvals
during design engineering phase.
Main hoist gearboxes shall be designed & manufactured as per class '4' duty
of IS:4137.
Gear teeth shall be cut in metric module system. All gear teeth shall be profile
ground to smooth with less error & for low noise while running.
Gearboxes with parallel shaft helical gearing shall be used for all motions.
All gears shall be of forged alloy steel preferably case hardeneing steels.
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
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Page:11 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
7.7.12
7.7.13
7.7.14
7.7.15
7.7.16
7.7.17
7.7.18
Gearboxes shall have fill and drain connections, BREATHERS, lubricant
level indicator, and shall have good accessesibility for checking, maintenance
and oil filling.
All gear boxes shall be totally enclosed and splash or forced lubrication system
shall be provided. Gearboxes shall have sufficient heat radiation area to
maintain lubricant at temperatures below maximum operating
temperature
The casings of gearboxes shall be made from structural steel (IS:2062) or cast
steel.
Vertical Gearboxes shall have an oil pump lubrication system when
vertical gearing exceeds of two reductions. Tubing/ Piping for gearbox
lubrication shall be provided with SS316/SS304 and must be properly clamped.
No hoses shall be used. Visual indicator for oil flow shall be provided in line.
Gearbox cover shall be split horizontally at each shaft centre line and fastened
and arranged so that the top half can be removed for inspection and repair
Fabricated gearbox housings shall be made of minimum 10 mm thick steel
plate. All fabricated gearboxes shall be duly stress relieved.
For all gearboxes lubrication shall be esured even at creep speed of motor and
from the intial start of motion (i.e. main or creep).
7.7.18
7.7.19
7.7.20
7.7.21
7.7.22
7.7.23
7.7.24
7.8
7.81
7.8.2
7.8.3
Drive Shafts (LT & CT)
Shafts shall be of 45C8 forged steel or alloy steel.
The noise level at gear box must not be more than 75-80 dBA measured at a
distance of 1m from the direct vicinity of the gear box. This is very important for
all the gearboxes, and any gearbox making more noise is liable to be rejected.
Torsional deflection of the shafts at torque corresponding to 1.33 motor rated
torque during acceleration shall not exceed 0.10deg./meter of shaft length.
Open gears should not be used in any drive / motion.
Sufficient clearance need to be maintained between gear of one stage to pinion
of next stage of non meshing sets to avoid interference.
Radial clearance between the gear box inner surface and the outside diameter
of the gears shall be at least 1 ¼ times the depth of the largest gear tooth
inside gear box or 20 mm whichever is higher.
and arranged so that the top half can be removed for inspection and repair
without disturbing the bottom half.
Realiable oil seal arrangement i.e., preferabley double stage oil sealing
arrangment shall be provided for shafts of gearboxes.
No oil leakage is allowed from gearboxes. Oil drip pans shall be provided
around the gearbox.
Shaft supports on plummer blocks of SKF / FAG / TIMKEN make only.
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:12 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
7.9
MAIN HOIST BRAKES
2 brakes per motor.
Aux. Hoist : 1 motor
and 2 brakes.
Torque rating of each thruster brake shall be minimum
2 times motor full load torque. Torque adjusting
Brake performance certificate, test certificate, and Exproof (ATEX) Certificate
shall be provided from original manufacturer of brakes.
7.9.1
Imported Flameproof thruster drum brakes shall be used for all drives / motions
in EOT crane. Make of brakes shall be M/s Pincsh Bubenzer-Germany, M/s
SIBRE-Germany, M/s Galvi-Italy, M/s Wittonkramer-UK , M/s SIME-GKN
Stromag-France. Thrusters for all brakes shall be Explosion proof (Ex d),
ATEX/ PTB Certified, Make of thrusters : EMG, Germany or Brook crompton,
UK. ATEX/ PTB/ Exproof Certificates for brakes & thrusters shall be submitted
for Approvals.
Two nos. of imported electro hydraulic flameproof
thruster drum brakes per motor with Manual release
and antiwear compenstor shall be provided (the second
brake is for redundancy). Minimum time lag shall be
provided between two brakes of main hoist and Aux.
Hoist as per standard.
Brakes
Brakes shall be mounted on the input pinion shaft of the gear boxes.
7.9.2
7.9.3 Brake Rating Hoist.
2 times motor full load torque. Torque adjusting
provision shall be available in the Brakes. Selected
Brake shall have sufficient margin with maximum
catalogue torque rating.
7.9.4Braking distance/brake
path for hoist
Hoist components and brake shall be selected such
that the braking distance for lowering motion shall be
as IS3177 with one brake at full rated speed.
Necessary calculations shall be submitted in this regard
during design phase.
7.9.5 Brakes for CT & LT
Imported, flameproof Electro hydraulic thruster drum
brakes of above make, as per clause no 7.9.1, shall be
provided.
7.9.6
7.9.7Brake rating for CT
and LT motions
Braking torque shall be checked so that it is capable of
arresting the motion within a distance in meters equal
to 10% of speed when travelling with rated load at
rated speed, provided there is no skidding.
7.9.8Manual release for
Brakes
Brake manual release mechanisms shall be
provided to permit drive movement during
power stoppage. Manual release shall be of self-
reset type and operative only when held manually in
the release position.
7.9.9
Brake drum size and thermal rating shall be selected such that with the duty
cycle mentioned, the surface temperature shall not exceed "T4" classification
of hazardous area.
No oil leakage is allowed from thruster brakes. Oil drip pans shall be provided
under thrusters.
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:13 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
shall be made from forged / cast steel / SG iron.
Drums shall be completely machined to smooth surface
and Statically & dynamically balanced.
Hardness of surface of finished drum shall be 38-43
Rc.
Width of the brake drum shall be 10mm more than the
width of the brake shoes.
7.11 Mounting of equipment
All the gearboxes, motors, brakes, bearing pedestals,
etc. shall be mounted on machined and levelled
surfaces.
7.12
7.12.1Couplings between
motors and gearbox
Flexible Full / half geared couplings. Make of
Couplings shall be of FENNER/ELECON/ Shanthi
Flexible Couplings
between gearbox and
rope drum for main
hoist ( For dual load
path/ twin drive)
Drum/ Barrel couplings of M/s Malmedie, Germany
shall be used for Main hoist . Selection criteria, service
factor (as per ISO-M8 class), Torque rating, drawing
shall be submitted for approval.
Brake drums
Couplings
7.10
path/ twin drive)shall be submitted for approval.
Flexible Couplings
between gearbox and
rope drum for Aux.
hoists
Drum/ Barrel couplings of M/s Malmedie, Germany
shall be used for Aux hoist . Selection criteria, service
factor (as per ISO-M8 class), Torque rating, drawing
shall be submitted for approval.
7.12.3
7.12.4
7.13
7.13.1
7.13.2
All crane wheels shall be made from forged steel C55Mn75 and minimum
surface hardness shall be 350 BHN for a case depth of 10mm. The wheels
shall be capable of taking up misalignments in span as specified.
All Couplings selection shall be based on the manufacturer's rating and
applicable service factors for heavy duty cranes compared to the applied
torque on the coupling and as per IS3177. Consideration shall be given to
motor starting torque, gear ratio, dynamic effects, brake torque etc.,
Track Wheels
All crane wheels shall be of double flanged with straight tread, with 12° taper
flanges, and accurately machined. Drive wheels shall be precision machined
and matched in pairs with minimum deviation.
Motor shafts shall be connected to gear extension shafts through flexible /
shock absorbing couplings. Geared couplings shall be used between gearbox
output shaft and intermediate shaft or end shaft and also for connecting
intermediate lengths of long travel and cross travel shafts. Between
intermediate shaft and end shaft and between end shaft and wheel axle, any
other special coupling which can give better and more reliable service may be
used after obtaining specific approval of the Purchaser (SDSC SHAR).
7.12.2
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:14 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
7.13.3
Galvanized, high tensile fasteners of tensile quality not
less than 8.8 shall be used in crane parts, except for Fit
bolts of Girder. Make of all fasters shall be of M/s TVS
/ M/s UNBRAKO
Maximum combined stresses induced in the fasteners
by normal operating loads (but not including
pretensioning loads) shall not exceed 20% of the
ultimate strength of the fasteners.
7.15
7.15.1
General design & sizing of wheels shall be as per IS:3177.Crane wheels of
minimum 630mm dia for cross travel and minimum 710mm for long travel shall
be used. Necessary sizing & contact stress calculations as per IS:3177 shall
be submitted.
Semi centralized lubrication system shall be provided for all mechanixms in
EOT crane with easy approach for all pedastal bearings, couplings, wheel
bearings, gearboxes etc.,
Wheel bearings shall be provided with suitable gearing points on both the sides
Lubrication of Crane
Fasteners7.14
7.15.2
7.15.3
7.15.4
7.15.5
7.15.6
All keys where ever used should be of parallel keys as
per IS:2048 (Couplings / gear boxes / motor shafts)
Material of keys shall be 45C8 or alloy steel.
Proper fits and tolerances shall be used between key
and key ways, such that key should not get loosened in
service life. Key end arrestors shall be provided.
Ball and roller antifriction bearings of approved make
SKF/ TIMKEN/ FAG/ INA only shall be used throughout
the drives except where specified otherwise.
Rated life of ball and roller bearings shall be not less
than total life (B10 or L10) in working hours not less
than 20,000 hrs .
Keys & Keyways
Wheel bearings shall be provided with suitable gearing points on both the sides
of wheel and shall be made approachable.
Suitable provision shall be provided for lubrication of hook and sheave
bearings.
Adequate provisions/arrangements shall be made to prevent lubricants
falling from the crane.
Trunion of wheel bogies shall be provided with suitable greasing points for both
the sides of the pins.
Hoisting ropes shall be lubricated with lubricant approved by rope manufacturer.
7.16
7.17 Bearings
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:15 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
Main hoist gearbox's bearings shall be selected based
on rated life given in class 4 duty of IS 4137.
Special consideration shall be given to bearings
which operate at low speeds. Certified
confirmation of the bearing's capacity at low
speeds must be obtained from the
manufacturer during design phase.
All bearings shall be provided with proper
lubrication or means of lubrication. Mounting fits,
tolerances and clearances shall be as recommended
by the bearing manufacturer.
Life of bearing shall be calculated in accordance with
bearing manufacturer’s recommendations.
7.17.1 Bearing Housings
All bearings housings shall be of STANDARD MAKE
(SKF/FAG/TIMKEN) and made of cast steel or wrought
steel or fabricated steel bolted to a rigid portion of
crane structure by at least 4 bolts. Housings shall be
split on the shaft centre line to permit removal of the
Bearings
(Continued from
previous page)
split on the shaft centre line to permit removal of the
shafts. The underside of the base of each bearing
pedestal shall be machined and shall bear upon a
machined surface. Standard make Bearing housings.
7.18
In Mian hoist motion of EOT Crane, wire rope spooling monitoring shall be
provided. The wire rope spooling monitor is an electro-mechanical assembly
that senses improper or mis spooling of wirerope from drum grooves. Improper
spooling is sensed prior to wire rope damage. Since, wire rope damage and
loss of the load can result, if improper wire rope spooling is detected, the wire
rope spooling monitor actuates the Failure Detection System (i.e., limit switches
) and stops main hoisting motion.
Hoist Drum Wire Rope mis-spooling monitoring in Main Hoist Motion of
EOT crane :
TECHNICAL SPECIFICATIONS OF
175t/25t FLAMEPROOF EOT CRANE
SECTION – III
STRUCTURAL DESIGN AND DETAILS
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:16 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
8.0
8.1Design of structural
work of Crane
The crane should be rigid, robust and of sturdy
construction. The design of all structures shall be Class
II as per IS:807 and as per this technical
specifications.
8.2
8.3
8.4
8.5
8.6 Material of structurals
All the structural plates used in fabrication of Girders,
Trolleys and End carriages, machine bases shall be of
minimum 10 mm thick of IS 2062 Gr. B.
8.6.1Covering chequered
plates
Trolley and platforms shall be covered with Chequered
plates of minimum of 6mm thick.
STRUCTURAL DETAILS OF EOT CRANE
Black bolts shall not be used in the main structures of the crane.
All the bolts, nuts, washers etc., shall be heavy duty galvanized and shall be
protected against corrosive environment.
Unless otherwise specified, only bolted or welded joints shall be used.
For welded construction such as that of bridge girders and carriages, trolley
frames, rope drums, gearboxes etec., all steel plates shall confirm to IS:2062 or
its equivalent.
plates plates of minimum of 6mm thick.
Shall be of double Girder Box Type construction having
Maximum rigidity.
For box plate girders in addition to the required full-
length diaphragms, short diaphragms shall be inserted
where required to transmit the trolley wheel load to the
web plates and to limit the maximum stress in the
trolley rail within safe permissible stress.
Girders shall be cambered and amount equal to the
deflection caused by the dead load plus one half of the
live load and the trolley.
8.8 Deflection of Girders
Deflection shall not be more than 1/1000 of span in
mm with safe working load, with trolley stationed at mid
span and excluding deflection due to dead load.
8.9 Girder Joints
No splice joint is permitted. Girder is to be of single
piece only. Number of weldable butt joints along the
total length of the girder should not exceed two.
8.10Ratio of span to depth
of Girder
For Box Girders Span to Depth ratio shall not exceed
18. Other ratios for construction of girder shall be
maintained accordingly as per standard.
8.11Local Buckling of top
flange
Local buckling of top flange and compression members
shall be considered and necessary calculations shall be
submitted for approval.
8.7 Girders
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:17 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
8.12 End Carriages
End carriage shall be fabricated as solid box section
made from rolled steel plates IS:2062, except for
essential openings which shall be reinforced.
8.12.1
8.12.2
8.12.3
8.12.4 Rail Sweeps.
A rail sweep shall be provided in front of
each outside wheel. The rail sweep shall
project below the top of the bridge runway
rail.
8.13
End ties shall be designed to accommodate up to 6mm difference in
A rigid frame analysis shall be used to determine the proportions of the
loads resisted by the end ties and by the girders.
End ties shall be designed to resist the loads due to crane
movement and the load combinations as per IS807 & IS3177.
Equalizer bridge trucks shall be incorporated into the end carriage
design to promote equal sharing of bridge wheel loads, and equalizer
pins shall be provided between the equalizer trucks and equalizer beam
and/or the rigid bridge frame structure.
End ties for cranes with more than four bridge wheels shall be of
rigid type. End ties shall be constructed of box sections in structural steel.
8.14
8.15
8.16
8.17
Structural bolted
Joints/ Girder to End
carriages
Fit Bolts ( as per IS:3640) with property class 5.6 and
reamed holes shall be used for all structural joints
between girder & end carriages, wheel L - bracket &
end carriages etc.,
8.18
8.18.1
8.18.2
8.18.3
8.18.4
8.19
Trolley
No parts shall be mounted under the trolley except for the gravity limit switch
weight. Top pulley block and all other pulleys, equalizer bars, fitments shall be
mounted on the top of trolley platform only.
Lubrication of Bogie joint pins shall be from a centralized or semicentralized
lubrication points.
Details of Bogie joint of End carriages shall be provided along with quotation.
End ties shall be designed to accommodate up to 6mm difference in
elevation of the bridge rail between any wheels or pair of wheels without
exceeding allowable stresses.
The trolley frame shall be built up of rolled sections and plates to form a rigid &
robust structure and shall be arranged to afford maximum accessibility to
mechanical and electrical parts placed on it.
The trolley frame shall be of rigid construction such that lifted loads do not
cause deflections that impair the proper operation of machinery.
Safe access for maintenance and removal of all mechanical and electrical parts
must be ensured without any additional scaffolding.
Trolley shall be designed such that at the highest position of hook there shall be
a clear distance of 700 mm between the lowest point of trolley obstruction and
the highest point of bottom block.
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:18 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
8.20
8.21
Full length chequered platform of width 750mm shall be
provided for both bridge girders in order to access for
LT drive and CT cable track for maintenance and with
hand rails of height 1000mm. The platforms shall be
jointed to Girders with fasteners.
Additional maintenance accesss platforms on four
inside corners of the girder shall be provided between
inside faces of girder for repair & maintenance inner LT
wheel bearings & mountings of End carriage. These
platforms must not hinder with the CT hook
approaches.
8.22.1Hand rails along girder Handrails of 1000mm height shall be provided along
8.22 Platforms
All electrical cables on trolley shall be so laid that they are not liable to be
damaged and can be easily inspected and maintained.
All parts requiring replacement or inspection or lubrication shall be easily
accessible without the need for dismantling of other equipments or structures.
8.22.1Hand rails along girder
platform
Handrails of 1000mm height shall be provided along
the length of the girder near to platform.
8.22.2Hand rails for around
trolley
Handrails of 1000mm height shall be provided on all
the four sides of the trolley.
8.23Maintenance of CT
drives
Maintenance platform shall be provided for CT drives
and shall be covered with chequered plate.
8.24Top chequered plate of
trolley
Chequered plate of 6mm shall be used all over trolley
except for openings required for the ropes for bottom
block etc., to pass. All the mechanical and electrical
equipment shall be placed above trolley top only .
8.25 CT rail wear plateFull length wearing plate of minimim 10mm should be
provided under the trolley rails.
8.25.1 Rails
All bridge and trolley rails required to transmit
vertical down and horizontal loads due to
operation, and shall conform to the IS3443.
8.26 CT rail welding
CT Rails shall be made continuous by welding standard
lengths. Welding shall be done as per standard
procedure approved by Third Party Inspection Agency
and Purchaser.
8.27 CT & LT rail clamping
CT & LT Crane rails shall be clamped to the girders
with double bolt clamping plates. The rail clamps shall
be spaced not more than 450mm apart. Rail clamps
shall be of Make : M/s GANTREX only.
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SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:19 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
8.28Rail stoppers /Wheel
ramps
CT & LT Rails shall be prevented from creeping in the
longitudinal direction by welded rail stops and Wheel
ramps.
8.29 Jacking pads
Suitable jacking pads should be provided on end
carriages and trolley for jacking up the crane & trolley
for changing track wheels & bearings .
8.30 Safety Pads
Safety pads shall be provided under the end carriages
and crab to prevent the crane/ trolley from falling more
than 25mm in the event of breakage of a track
wheel/axle or bogie pin.
8.31
8.31.1
8.31.2
8.32
Spring buffers are to be provided on four ends of the bridge and trolley.
Buffers shall be rigidly bolted in place preferably along the Centre line of crane
rail or trolley rail as the case may be, such that the bolts are not in direct shear.
End Buffers
Buffers shall be designed to absorb the kinetic energy released at 50% of the
full load rated travelling speed, the average rate of deceleration not exceeding
5.0 m/s² at 50% of the rated travelling speed.
8.33Metric Component
Systems
All components including fasteners should be in metric
system only
8.34 Locking of All fasteners
Bolts in rotating parts shall be locked with spring
washers & lock nuts. All couplings & brake drums shall
be provided with "Fit" type bolts.
8.35NDT of Butt joints of
girders
All butt joints shall be 100% radiographed or Ultrosonic
tested for both compression and tension joints.
8.36 Toe gaurds
Toe gaurds shall be provided for all openings, on trolley
and on bridge platforms with minimum height of
100mm.
8.37
Mounting of machinery
on machined bases on
trolley / LT
Parts of steel frames carrying machinery should be
provided with doubling plates (including stiffners) of
adequate thickness welded and machined to true
surface.
8.38
8.39
8.39.1
5.0 m/s² at 50% of the rated travelling speed.
Welded snugs shall be fitted against against the feet of all pedestals,
gearboxes, brakes etc., except motors. Motors shall be provided with alignment
screws for side alignment.
Ladders
Approach ladder shall be of staircase type. Ladders shall be provided from
catwalk to end carriage and to LT platforms in all four corners.
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SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:20 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
8.39.2
8.40Protection Gaurds for
rotating equipment
Guards: All the moving parts couplings, shaft should
be duly covered with guards as per safety norm. Proper
guard / cover / tray to prevent falling of bolts from
coupling etc should also be provided, wherever
required. The covers shall be strong enough to take
person weight ~ 100 kg.
8.41
Approach ladders to be provided for reaching the trolley at two locations along
the span of the girder.
Fasteners for pedestal blocks, motors, gear boxes etc., shall be easily
removable from the top of platform. Studs or body bound bolts shall not be used
as fasteners for mechanical items except for fixing covers.
TECHNICAL SPECIFICATIONS OF
175t/25t FLAMEPROOF EOT CRANE
SECTION – IV
ELECTRICAL DESIGN & DETAILS
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SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:21 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
9.0
All Electrical equipments shall be supplied for tropical
and humid climate (Temperature of 50°C & RH not
less than 95%) . De-rating of drive motors, power
cables etc., shall be done for ambient temperature of
50°C.
Flame proof electrical fittings and controls shall be
selected, assembled and tested as per relevant Indian/
IEC standards like IS:5571, IS:2148, and IS:5780.
However for control circuit, intrinsic safe modules of
make : M/s. P&F shall be used.
9.2 Power supply condition
The power available at 415 Volts, 3phase, 4 wire, 50
Hz near by the Crane panel. The power and control
equipment selected shall be suitable for operation on ±
10% variation in the voltage and ± 3% variation in
supply frequency. Power source available to tap for
protective panel (where main power source is located
ELECTRICAL DESIGN AND DETAILS
9.1
Electrical equipment
environment
The Electrical equipment shall conform to IS3177 and also to the latest Indian
electricity rules and regulations as regards safety requirements, earthing and
other essential provisions specified therein.
protective panel (where main power source is located
approximately 50m distance).
9.3Power Supply for
motors3 phase, 415 V, 50 Hz / A.C + 10%
9.4 Control voltage1 phase, 110 Volts AC, only for switchgears inside the
panel
9.5
For Push buttons,
Indication lamps, limit
switches in the field
(top of the crane) and
24V, Intrinsic Safe Package Supply, Make : M/s P&F
9.6Under slung HPMV
lights.
4nos of 400watts, well glass flame proof lights shall be
provided.
9.7 DSL for LT & CT All cables for LT and CT are to be routed through IGUS
chain (plastic) with guided cable tray only.
9.8
9.8.1
9.8.2
9.8.3
9.8.4
Panels: (Non FLP), Make: M/s Rittal only. (Located in separate room at ground
level, suitable air conditioned units shall be part of the VFD panel).
Individual panels (nos.) to be provided as follows:
Main Hoist panel - 2 or 4 Nos. (as per design).
Aux hoist panel – 1 No. (One)
Protective panel – 1 No. (One)
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SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:22 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
9.8.5
9.8.6
9.8.7
9.8.8
9.8.9
9.8.10
9.8.11
9.8.12
9.8.13
CT panel - 1 No. (One)
LT Panel - 2 Nos. (One)
Individual isolating switch (with SDF) to be provided for each panel.
Individual Power Contactors are to be provided for each motion for controlling.
Panel lighting shall be provided and it shall be CFL or LED lamps only.
All the Panels shall be provided with space heaters to avoid moisture
condensation.
Rubber mats of 2mx1m shall be provided before the all panels such that
persons stand on rubber mats during maintenance.
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.
A minimum clearance of 250mm shall be provided between the terminal strip
and the panel bottom cover to facilitate cabling.9.8.13
9.9
9.9.1
9.9.2
9.9.3
9.9.4
9.10Mounting of panels
and resistance boxes
Panels are to be mounted on the floor with required
anchored Bolts and nuts.
9.11 Switchgears Make: SIEMENS only
AC4 Duty
The contactors shall be able to withstand their rated
current for one second without welding / fusing of the
contacts
Manually operable
To be provided for all panels except protective panel.
All the power and control terminals are to be provided with suitable terminal
numbers.
Contactors
TPNSFU with Semi
conductor fuses
Power terminal blocks shall be separated from each by means of replaceable
insulated spacers.
All the power terminals are to be selected for connecting the ring type lugs (in
both panel and FLP junction boxes)
All the power terminals and live parts are to be covered with proper terminal
covers.
Group terminal markers to be used for the clear identification.
and the panel bottom cover to facilitate cabling.
9.12
9.13
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SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:23 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
9.14 Fuses
Hoist, Aux hoist, CT and LT power supply to VVVF
drives to be routed through Semi conductor fast acting
Fuses of adequate rating only. Semi conductor fuses
shall have a indicator for fusing.
Make: M/s Siemens
Qty: as per design 6 Nos. (shall be wired for individual
panel)
Input voltage – 110V / 230 V AC
Output voltage – 24 V DC
Current rating – as per the circuit load
9.16
9.16.1
9.16.2
9.16.3
Terminal blocks and labels
Terminal blocks shall be of 750 Volts grade of the stud type and shrouded.
Insulating barriers shall be provided between adjacent terminals.
9.15 SMPS
Provisions shall be made for label inscriptions for the easy identification of
terminal blocks.
9.16.4
9.16.5
9.16.6
9.17To be provided for the motor which is not powered viz.
VVVF drive. (ie., all thruster brakes).
9.17a
MPCB to be selected with 2 nos. of NO and NC points
as auxiliary contacts and preferably one no. of alarmn
contact.
between neutral and earth - 19 mm
Labels shall be of acrylic sheet with white engraving on black background /
computerized labels.
ON/OFF/TRIP inscriptions shall be clearly marked over the individual panel with
clear marking of direction of the operation of handle apart from the standard
marking provided by the switchgear manufacturer.
Safety in arrangements
Minimum clerance to be maintained as follows (IS 60947-1)
between phases - 25 mm
9.18between phases and neutral - 25 mm
between phase and earth - 25 mm
Enamel Danger plates / stickers of size and descriptions as recommended in
the relevant IS, shall be provided on the Panel inscribed in Hindi and English
languages. The same is to be indicated in panel G.A dwgs after PO and before
proceeding for fabrication.
Motor protection circuit
breaker (MPCB)
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SPECIFICATIONS CUM COMPLIANCE STATEMENT
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Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
All the live parts to be covered properly in order to avoid possibility of in advent
touching.
All the joints / tapping points of the terminal blocks / terminals shall be suitably
shrouded to prevent accidental contact.
All the switchgear and termincal blocks to be covered with suitable electrical
protective cover.
9.19
VVVF Drives
The power/current rating of VVVF drive shall be one step higher than the
selected rating of motor.
Main Hoist – as per design 2 or 4 nos.( Capacity of drive shall be suitable to
motor kW selected)
Aux Hoist – 1 No.
LT – 2 Nos.
CT – 1 No. Depending on drive motors.
Drive shall be supplied with 20 % additional DI / DOs for future usage.
VVVF Drives shall have PROFINET Communication facility.
9.18
cont.
Suitable input and output chokes are to be provided for
controlling the harmonics from VVVF drive to source for
all VVVF drives.
THD should not exceed 5 % and individual Harmonics
should not exceed 3 %.
It needs to be demonstrated at site during erection and
commissioning.
Both control and lighting transformers can be located
outside the panel with suitable enclosure for ventilation.
Transformer terminals are to be covered with hylum
sheet or acrylic sheet to prevent from inadvertant /
accidental contact.
9.22 DBU Suitable size and rating of DBU for all the above drives.
Make of VVVF drives : M/s. SIEMENS only.
For Hoist motions, Control shall sense sufficient motor torque (or current)
before releasing holding brakes (i.e., torque proving).
9.21Input and output
chokes
9.21a Transformer
The Control circuit shall be so designed as to ensure that brakes for all motions
are applied near about zero speed of rotation.
9.20
VVVF Drives shall have PROFINET Communication facility.
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SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:25 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
Dynamic braking resistors of suitable capacity/rating
shall be provided to all VVVF drives. For Hoist motions
DBRs shall be sized for a minimum of 150% of
motor full load torque and it shall not be less than the
torque limit setting of the VFD in the hoisting
direction.
Necessary forced cooling needs to be planned.
Controlling of the cooling fans needs to be linked with
control supply ON.
The DBR panels shall be designed such that during
maintenance activities the entire door has to be dis-
asssembled for enabling the better access to the
components inside the panel.
Each motion shall have its individual panel.
Each side of the LT platform 2 Nos. of 1 phase, 230
Volts AC FLP switch cum socket with plug top and 1
No. on the Crab.
2 Nos. of 230 V AC power sockets with ON / OFF
switch shall be provided inside for the all the panels
except protective panel.
9.23Dynamic braking
resistors
9.24 Power Sockets outlets
Separate control is required for the following:
Under Slung Lights (In pendent)
Socket outlets on the Crane platforms (In protective
panel)
Control circuits (In pendent)
9.25.1Training on Siemens
Drives
Training shall be offered for our engineers by M/s
Siemens about operation, maintenance and trouble
shooting of VVVF drives during commissioning of
Crane.
9.26
9.25 Isolating Switches
MOTORS
Crane duty Motors suitable for Inverter Operations shall be as per IS3177.
Flameproof (Zone 1, Gas group IIA/IIB, T4).
Squirrel cage induction motors kW rating as per IS3177
Temperature classification - T4.
Class of insulation - Class F
For accepting the input from VVVF drives, 60% CDF, min of with 300 starts per
hours, IP55, and Pull out torque of not less than 2.75 times of nominal value
and specifically designed for crane duty application .
All the motors shall be housed with inbuilt thermistor and it is to be linked with
VVVF drive for necessary protection like switch OFF the motor in case of
increase in surface temperature more than T4 classification of hazardous area.
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SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:26 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
Hoist and Aux hoist motors shall be 8 pole with ~750
rpm speed.
Long Travel and cross travel motors shall be 8 poles
with ~ 750 rpm.
Bidder shall provide following details of motors like:
No. of motors
In cases where sufficient clearance is not possible in front of terminal box for
facilitating maintenance / cable connections, terminal box shall be provided on
the top of the stator frame.
9.27 Speed rating of Motors
The Motors shall have preferably ZZ type bearings.
No of motors required
Main Hoist Motion - 4 Nos. (as per design, required power/torque capacity )
Aux Hoist Motor -1 No.
Long travel - 4 Nos. (as per design)
Cross travel - 1 or 2 Nos. (as per design)
The Motors shall have both side extended shaft
Power of motor
Frame size
make
duty : Crane Inverter duty,
no. of starts/hr (300 starts/hr)
CDF : 60%
No. of poles :8
amb.temp : not less than 50 deg C
9.29Current drawn by
motors
Maximum Current drawn by all motors with full load
should not exceed 80% of the full load rated current.
9.30Torque Rating of
motors
Motor full load torque rating shall be min. 120% of
calculated rating on full load.
Imported Electro Hydraulic flame proof Thruster Drum
Brakes for
Main Hoist motion - 2nos. Per motor
Aux. Hoist Motor - 2 nos.
CT Motors - each one no. per motor.
LT motors - each one no. per motor.
Rating, duration and frequency of operation shall be
mentioned in quotation.
9.28
Details to be provided
related to motor
selection and
calculations
9.31 Brakes
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SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:27 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
Main Hoist motors - one no. per motor
Aux Hoist Motor -1 No.
Shall have FLP / Intrinsic safe hollow shaft
incremental encoder for better dynamic performance.
The same to be used to achieve vector control mode of
operation.
All Encoders shall be of Flameproof / Intrinsic safe in
nature.
Encoders' signal shall be of intrisic safe only. Screened
cable as per manufacturer recommendations shall be
used for all encoders.
9.33
9.32 Encoders for motors
Pendant Push button station
Floor operated pendant (Push Button Station) shall be provided with 3-way
Selector Switch for selecting the hoist motors.
PBS shall be provided with push buttons for controlling crane motions:
Main Hoist motion UP / DOWN - Main speed & Creep speed
Selector switches shall be of semi flush mounted type.
Only the front plate and operating handle projecting.
Cross Travel motion Right / Left - Main speed & Creep speed (with 5Hz)
Long Travel motion Fwd / Rev - Main speed & Creep speed
Main Hoist motion UP / DOWN - Main speed & Creep speed
Aux. Hoist motion UP / DOWN - Main speed & Creep speed
Number and arrangment of push buttons and indication lamps in Pendant
shall be as per the Annexure - 2A
9.34 Selector switches
Pendent Shall be provided with Key way switch Lockable at OFF (for Control
ON command),
Emergency OFF (Lockable) ( One more emergency OFF shall be planned in
Bridge platform).
Crane ON indication Lamp – Powered through Intrinsic Safe circuit.
PBS shall also provide with 2-way Switch for Under Bridge Lights.
At least 30 % Spare Core shall be provided in PBS.
All push buttons at Push button station are to be powered through Intrinsic safe
module only apart from other control elements like limit switch, over speed
switch, etc..,
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SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:28 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
Interlocking is to be carried out for selection of
command for all the motions.
Pendent level: Hard wired interlocks are to be
provided at push button station. For example when
Main Hoist UP motion push button is pressed Hoist
Creep / Hoist Down (Main and Creep) motions should
not be activated even if pressed and Vice versa.
Auxiliary contactor level: Hard wired interlocks are to
be provided such that when Aux.contactor operates
with respect to the motion selected, remaining Aux.
contactors with respect to other Aux. hoist motions
should not be operated.
In the VVVF Drive: It is to be programmed such a way
only one motion has to be selected for operation at a
time in the VVVF drive.
1. Selection of Hoist motor / each load path.
2. Rotary limit switches i.e hoist and lower, Gravity limit
switch
9.35 Interlocks
switch
3. Wire rope mis-spool limit operation
4. Auxilary Hoist operation
6. Thruster Brakes' MPCB condition.
7. Provision shall be made for two extra interlocks for
future usage.
1. Rotary limit switches i.e. Aux hoist and lower
operation limit.
2. Gravity limit switch
3. Main Hoist operation
4. Thruster Brakes' MPCB condition.
5. Provision shall be made for two extra interlocks for
future usage.
1. Right and Left limit switches for respective motion
of the drive.
2. Brakes' MPCB condition.
3. Provision shall be made for two extra interlocks for
future usage.
9.37
Auxiliary Hoist VVVF
drive ON command is
to be interlocked with
the following.
9.36
Main Hoist VVVF drive
ON command is to be
interlocked with the
following.
9.38
Cross Travel VVVF
drive ON command is
to be interlocked with
the following.
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Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
1. Forward / Reverse limit switches for respective
motion of the drive
2. Brakes' MPCB condition.
3. Provision shall be made for two extra interlocks for
future usage.
Indication lamps shall be provided for all 3 phases for
the protective panel.
Control ON / OFF (based on the pendent push button
control) indication lamps shall be provided on the
protective panel.
Indicating lamps shall be of Cluster LED type only,
provided with translucent lamp covers.
Lamps and lenses shall be easily replaceable from the
front.
Cluster LED module shall be suitable for direct
operation on 230 V, 50 Hz AC in general except the
indication lamps planned in push button station.
Long Travel VVVF
drive ON command is
to be interlocked with
the following.
9.40 (a) Indication lamps
9.39
Indication lamps in push button station to be powered
viz. Intrinsic safe relays only.
All wiring for power, control, lighting etc., (which is not
running in the IGUS cable drag chain) shall be carried
out with 1.1.K.V grade XLPE Armored copper
conductor cables.
All wiring for power, control, lighting etc., (which is
running in the IGUS cable drag chain) shall be carried
out with 1.1.K.V grade flexible copper conductor
cables.
Minimum size 4 mm sq. in power circuit and 2.5 mm sq
in control circuit.
All wiring to be done neatly through perforated trays
from the protective panel / VVVF panel to the top
junction boxes fixed in suitable places.
Wiring shall be neatly bunched, adequately supported
and properly routed to allow easy access and
maintenance.
Wires shall be identified by numbered ferrules at each
end.
The ferrules shall be of the ring type and of non-
deteriorating material.
Cable tags to be provided for cable connections as per
circuit diagram.
9.41Power and Control
Cables
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Page:30 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
9.42 Earthing
The crane rails, structures, motor/brake frames, metal
enclosures of all electrical equipment, conduit and trays
shall be effectively grounded with double earthing and
shall be connected to building earth through gantry
rails. The laying of Earth strip from Gantry rail to Earth
pit ( which is around 10meter away from the crane
bay) outside the building is in the scope of EOT
Crane's supplier.
Labels of permanent nature to be specified.
All power and control cables, etc are to be tagged at
both the ends.
FLP junctions Boxes are to be planned for inter facing
the connections between field connections and panel
connections. Sufficient space to must be available for
the maintenance.
The probable locations of the JBs are
Crane LT Girder
Crane Platform
9.43
9.44 Junction Boxes (FLP)
Identification of Circuit
& Cables
Crane Platform
Crane Trolley / crab
Rotary Limit Switch – 1 No. To be linked with the hoist
motors and linked to the control circuit according to the
operational requirement) (For hoist and lower limit).
Gravity Limit Switch – 1 No.
Rotary Limit Switch – 1 No. (For hoist and lower limit)
Gravity Limit Switch – 1 No.
9.47Limit Switches for CT
& LTLever type - 2 Nos. for CT & 2 Nos. for LT
9.46Limit Switches for Aux
Hoist
9.45Limit Switches for Main
Hoist
SECTION – V
OTHER SPECIFICATIONS AND TERMS &
CONDITIONS OF SUPPLY OF
175t/25t FLAMEPROOF EOT CRANE
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Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
10
10.1 Surface Cleaning
The entire surface of fabricated materials, girders,
frames, platforms, trolley, end carriage, wheels etc.,
are to be sand / grit / abrasive blasted to white metal
finish (SA 2½ quality) and cleaned properly off rust,
grease & dirt.
10.2
Painting with Epoxy
Primer (Total thickness
of 80 microns)
Two coat of epoxy primer (Apcodur CP 680 of M/s
Asian Paints or equivalent) shall be applied to a Dry
Film Thickness (DFT) of 80 microns.
10.3
Painting Epoxy Paint
(Total thickness of 120
microns)
Two coats of epoxy paint of Golden Yellow color
(Apcodur CF 693 of M/s Asian Paints or equivalent)
shall be applied to a Dry Film Thickness (DFT) of 80
micron and 40 micron for first and second coats with
proper drying in between coats. Final touching shall
be done after erection & commissioning at site.
Painting quality shall ensure austhetic looking of crane.
Total paint thicknessNot less than 200 microns. This will be tested during
PAINTING OF CRANE : Total painting thickness, DFT, shall be 200
microns. (DFT shall be measured at the time of final inspection)
10.4Total paint thickness
including primer
Not less than 200 microns. This will be tested during
stage inpsections and final inspection at supplier
works.
10.5
10.6
11
11.1
11.2
11.3
11.4
11.5
INFORMATION/DOCUMENTS TO BE SUBMITTED ALONG WITH
QUOTATION (offer will be rejected unless these information / documents
are submitted)
Bid Qualification Record (BQR) with duly funnished information, as given
"Appendix" along with this Specifications
The bidder shall quote separately for erection and commissioning of Crane.
Interior of all gear box housings shall be sand blasted and painted with two
coats of oil resisting durable paint.
Questionnarie, attached with BQR, duly filled by Vendor given along with the
"Appendix" of this specifications.
Technical Specifications with Point-wise Specifications to all points as given in
this "Specification cum Compliance Statement" (given in this FORMAT).
Deviations, if any shall be mentioned clearly in a separate sheet. (See. II in
page 1).
GA drawing showing full details of crane, with dimensions, span, height of lift,
end clearances, head room, overhead clearance, hook approach limits,
weights, wheel loads, major components and general arrangement of main
Hoist Drive etc..
In addition if any intermediate cleaning required between successive coats of
paint are to be carried out as per the recommendation of paint manufacturers
and as per the instruction of the Purchaser (SDSC SHAR).
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:32 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
12.1
12.2
12.3
At the same time, Supplier shall be responsible for proper submisssion of
following drawings & calculations along with technical specifications to Third
party Inspection Agency (TPIA) and obtain design Approvals from them.
If the drawings and other particulars are returned by the Purchaser (SDSC
SHAR), because they are incomplete or faulty, the Bidder shall make the
necessary correction / modifications and resubmit the drawings and
calculations within a reasonable time, but in any case, should not exceed two
[ Note : It is the responsibility of the supplier to get the drawings /
documents approved from Third Party Inspection Agency (TPIA) ]
Bidder shall submit following list of Three sets (03 sets) of drawings/
calculations / documents (in 03 -three sets) for approval before manufacture of
crane within 4 weeks after placement of purchase order. (12.5 to 12.40).
Note: It is the responsibility of the supplier to get the drawings/ documents
approved from TPIA/ Purchaser (SDSC SHAR).
DRAWINGS /DOCUMENTS (EACH 3 COPIES) TO BE SUBMITTED AFTER
PLACEMENT OF ORDER FOR APPROVALS.12
DESIGN APPROVALS:
12.3
12.4
12.5
12.6
12.7
12.8
12.9
12.10
12.11
12.12
12.13
Design of load bearing structures shall be as per IS 807 and drive mechanisms
as per IS 3177 and Main Hoist Gearboxes as per IS4137 and also as per
technical specifications in to consideration.
Sub-assembly drawings for rope drum assembly, wheel assemblies, hook
blocks etc.,
General Arrangement drawing of Dual wire rope reeving with dimensions and
rope equlizer assembly.
Bridge Girder CT rail arrangement drawing to scale with BOM.
GA Drawing of individual drive mechanisms for Main Hoist, Aux. Hoist, CT and
LT. G.A drawing of Main Hoist drive shall be submitted.
calculations within a reasonable time, but in any case, should not exceed two
weeks from the date of receipt of purchaser’s / third party inspection agency's
comments.
LT rail arrangement (on Gantry Girders) drawing to scale with Bill of Materials
(BOM).
GA drawings, details and selection criteria, design calculations for gear boxes
with manufaturer's data sheets as per this specifications and conditions.
General Arrangement (GA) drawing of crane to scale with dimensions, Bill of
materails, Boughtout items, makes, weight breakups and wheel loads.
GA Assembly Drawing of Trolley with all components.
Design & Constructional Drawings of Girder, end carriage, and trolley their
connections with bill of materials.
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:33 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
12.14
12.15
12.16
12.17
12.18
12.19
12.20
12.21
12.22
12.23
Delivery schedule of EOT crane in the form of Bar chart indicating different
stages.
Selection of bearings for EOT Crane.
Selection of sheaves & sheave pin with calculations.
Calculations for selection of CT & LT rails.
Calculation for bridge girder with deflection & camber, trolley frame, end
carriage, with weight breakup.
Quality Assurance Plan for total crane manufacture, erection & testing as given
in Annexure - 3.
Calculations for selection of wheels & wheel bearings.
Sizing calculations for selection of Machine elements like wire rope, hook
blocks, cross head, sheave pins, rope drum, couplings, wire rope pulleys,
shafts, bearings etc.,
Calculations for drive shafts and plummer block bearings.
Selection of keys, key ways & couplings
12.24
12.25
12.26
12.27
12.28
12.29
12.30
12.31
12.32
12.33
12.34
12.35
Lubrication arrangement of EOT crane with points indicated in drawing.
Total weight of structural, mechanical and electrical components separately
Weight of each end carriage as assembled and ready for erection.
Bidder shall give the break-up weights of crane as mentioned below
during final design :
Weight of each bridge girder as assembled and ready for erection, with and
without mechanical and electrical components.
Calculations for selection of wheel bogie connecting pins.
All the componets of crane which are lifted for erection shall be design
checked for erection / lifting loads and necessary Calculations shall be
submitted.
GA drawings of Protective Panel and other panel and inside components
arrangements
Calculation for selection of motors, brakes, drives, cables and switch gear with
manufacturer datasheets & Exproof certificates. All Motors' torque and speed
curves shall be submitted for approval.
Electrical circuit diagrams of EOT crane with individual drive circuits, control
circuit, and with interlocks' circuits.
Wire rope spooling monitoring G.A drawing and electrical circuit.
Weight and name of individual heaviest mechanical components.
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:34 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
12.36
12.37
12.38
13
13.1
13.2
13.3
13.4
Total weight of trolley including electrical equipment.
2 sets of spare parts manuals
Total weight of crane including electrical equipment.
Test certificates of all items like raw materials, hooks, wire ropes, motors etc
and for all crane parts certified by "Competent person of third party agency"
as per QAP & standards.
Weight of trolley structure ready for erection shall be provided.
List of Manuals / drawings/ documents/ certificates to be submitted at the
time of inspection of crane at supplier's works and also at the time of
commissioning at ISRO, SHAR
4 sets of Crane operation & maintenance manuals
QAP/shop Inspection report document showing Third party design approvals,
manufacturer test certificates., all stage & final inspection reports, load test
reports as per QAP and TPIA report on final inspection at works & TPIA
clearance report.
13.5
13.6
13.7
13.8
13.9
13.10
13.11
14
14.1 Span over LT wheels + 4mm maximum
14.2 Diagonal on wheels ± 5mm maximum
14.3 Parallelism of Girders< 1/1000 of wheel gauge (measured at every 1m
interval)
4 sets of all as built Drawings of all systems of crane as mentioned above
aprroval drawings that have been finally approved by TPIA / Purchaser (SDSC
SHAR).
Final as built drawings of crane and machinery, Maintenance & spare part
Manuals, test certificates shall be supplied in soft form in the forms of DVDs
and Memory stick in the latest software format.
Trouble Shooting Chart for Main and all Sub-Systems.
2 sets of Gearbox spare parts and service manuals shall be provided.
Manufacturer installation & maintenance manuals, test certificates and
Warranty / Guarantee Cards for all Bought-Out-Items.
Lubrication schedule, diagram with details of lubrications.
Final test certificate of EOT crane from TPIA with inspection report
Bidder shall ensure that the crane shall be manufactured as per the
tolerances specified below. Final inpection reports shall be submitted in
drawing format.
Tolerances on Crane dimensions and manufacturing :
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:35 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
14.4 Verticality of Girders < 2mm (measured at every 1m interval)
14.5Verticality of End
Carriages< 1mm (measured at every 1m interval)
14.6 Trolley wheel gauge ± 2mm (measured at every 1m interval)
14.7 LT wheel alignment ± 1mm (maximum)
14.8Difference in height
between trolley rails<1/1000 of wheel gauge maximum at 1m interval
14.9CT Rail alignment w.r.t
Girder centre±1 mm (measured at every 1m interval)
14.10Tilt of wheels ( both
horizontal & vertical)< D/ 1000mm where D = diameter Of wheels
14.11CT/LT wheel
displacement<2mm (measured at all wheels) Wheel alignment
14.12CT / LT wheel
diameter variationless than 0.1 mm in diameter of wheel
14.13Squareness of Girders
to End carriageswithin 1.60mm ( for wheel base of ~4000mm)
14.14 Hoisting speed +10% -5% of specified speed.
14.15 Lowering speed +20% -5% of specified speed
14.16 Travelling speed +10% -5% of specified speed.
15
15.1
DESIGN / DRAWINGS
APPROVALS &
CERTIFICATE from
TPIA before crane
manufacture.
Supplier shall obtain all design/ drawings approvals
from third party inspector (TPIA) before starting
crane's production. Crane & components shall be
manufactured & inspected as per the approved
drawings only. All inspection/test repots shall be made
with respect to approved drawing with ref. no.
INSPECTION & TESTING DURING MANUFACTURE & SHOP TESTING OF
CRANE
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:36 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
15.2QAP & Third party
agency
INSPECTION and testing shall be carried out as per
QAP enclosed here with in Annexure-3. Supplier shall
hold the manufacturing at specified "HOLD" places and
call for inspection. The Schedule of Inspections shall
be strictly adhered to and shall be witnessed by THRID
PARTY and/or ISRO. All the critical inspections and
load testing shall be done in the presence of Third
Party and /or ISRO.
15.3
Raw materials
identification &
stamping
Raw material identification for structures, wheels, hoist
mechanisms, Gears, load pins etc., shall be done by
Third party inspectorate and/or department. Raw
material test certificates, traceability of materials with
identification marks shall be made available during
identification.
15.4Welding inspection &
Testing
All Butt Welded Joints (both compression & tension
flanges / web joints) shall be subjected to 100% X-Ray
Testing and X-Ray Films to be produced for TPIA
and/or ISRO/SHAR for evaluation and shall form part of
the quality (QA) documentation submitted to purchaser.
15.5Inspection major parts
and records
Inspection of Bridges, End Carriages, trolley, rails
gauge, Wheels and Measurement of Camber,
mechanical assemblies checking as per QAP. Reports
shall be made in drawing format.
15.6
Dimensional inspection
& alignment checking
& records
Inspection of Span & Diagonal Dimensions (Minimum
~10Kg pull should be applied while checking),
Checking bridge & end carriages' squareness,
Checking of Wheel Alignments, Mechanical drive
Assemblies alignment and Pulley blocks alignment.
Reports shall be made in drawing format.
15.7
15.8 Load testsNo load test, Full load tests and Deflection
measurement as per as per QAP and as per IS: 3177.
15.9 Load tests
Test at OVER-LOAD (125% SWL) capability Check
and Permanent Set Measurement as per QAP and as
per IS 3177.
15.10 Clearance for despatch
The equipment shall be despatched only after
satisfactory performance testing/ inspection at
supplier's works and on written clearance from ISRO &
TPIA.
15.11Testing the extra safety features in EOT crane i.e. performance & interlock
checking of twin hoist system.
The crane hook should be tested and certified by the dock labor board / govt.
Approved test house for twice its SWL and test certificate should be provided.
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:37 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
16
16.1 At ISRO- SHAR worksFully in the supplier's scope. Inspection and testing
during/after erection shall be as per QAP.
16.2Erection Plan &
Procedure
Before erection, supplier shall submit detailed erection
plan and procedure along with erection loads on
building & also on parts being lifted shall be submitted
for approval.
16.3 Erection Supervision
Supplier shall depute adequate qualified personnel i.e.,
Two Engineers/supervisor/ foreman, (one for
mechanical and one for electrical), fitters, riggers, and
electricians and helpers for carrying out quality
erection work at our site within schedule.
16.4
16.5
Material (lifting
equipment, lifting
tackles, etc) required
during erection.
Fully in the supplier's scope. All lifting machines /
tackles used shall be tested & certified as per
standards before their usage for lifting crane.
ERECTION & COMMISSIONING OF EOT CRANE
Initial unloading of EOT crane parts shall be done by supplier. Equipment
support ( with available equipments if any) will be spared for unloading like
Mobile crane / Forklift / Pick & carry mobile crane (Hydra).
16.6
16.7
16.8
Performance Proving &
Smooth running of
EOT crane
No Load test, Full load test and overload test (for
125%SWL) shall be done as per QAP and as per
IS3177. Proving out for the Crane’s Capacity and
Smooth Functioning of the Crane at Full load (SWL)
and Over load (125%SWL) shall be the responsibility of
the supplier.
16.9Test/Clearance
certificates for crane
To be inspected and certified by "Competent Person of
Third party Inspection Agency " as per Industrial Laws
and shall provide Certification from Third Party
Inspection Agency for final clearance & regular usage
of EOT crane .
17
17.1GEAR BOXES and
Geared Motors
Elecon /Shanti /GREAVES(Premium transmission) /DB-
Radicon/ Renold/ Sumitomo/ Flender.
MAKE OF THE BOUGHT-OUT ITEMS
Department shall provide suitable hooks on the roof in the facility for lifting of
crane components. Supplier can use these hooks for lifting of crane
components during erection of Crane. The capacity & location of erection
hooks shall be given by manufacture during detail engineering. However the
lifting machinery ( power winch, pulley blocks, wire ropes, lifting gear, etc.,) and
accessories are in the scope of supplier. All lifting machines/tackles' Test
certificates shall be furnished.
Initial filling of lubricants and spare parts required for commissioning at site
shall be provided by the supplier.
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:38 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
17.2
Structural Steel
Materials Plates, rolled
sections
All the structural raw materials (plates, angles, beams)
shall be NEW and of reputed make of M/s SAIL / M/s
JINDAL/ M/s ESSAR/ M/s TATA STEEL / VIZAG-RINL
17.3
Forged steel materials
wheels, shafts, keys,
gears
SAIL / JINDAL / TATA STEEL / ESSAR / VIZAG-RINL
/ SUNFLAG STEEL / TIMKEN / Mahindra Ugine Steel
(MUSCO) / BHARTH FORGE
17.4 Wire Ropes M/s. Usha Martin only.
17.5 Bearings SKF / FAG / TIMKEN / INA
17.6Imported flameproof
Thruster Brakes
Pintsch BUBENZER / SIBRE / WITTON KRAMER /
GALVI/ Sime GKN Stromag
17.7 Hooks EEK / Hercules/IRZAR/ Shilpa Udyog
FENNER / Elecon / Shanti / Renold
Drum/Barrel coupling - Malmedie, Germany
17.9 RailsSAIL / IISCO / JINDAL / ACCELOR / TATA STEEL /
ESSAR
17.8 Couplings
17.9 RailsESSAR
17.10 Paints Asian Paints / Berger
17.11All Electrical Switch
gearM/s Siemens
17.12 Flame Proof Motors M/s. Siemens / Bharat Bijilee / Crompton Greaves
17.13 VVVF Drives M/s. Siemens only.
17.14 Pushbutton switches M/s Siemens
17.15 Limit switches M/s. Sterling controls / Speed-O-Control / Electromag.
17.16LT power & control
cablesM/s. Lapp / Universal / Nicco / Finolex / RPG / Uniflex.
17.17 Panels M/s. Rittal
17.18 Terminal Blocks M/s. Elmex / M/s. Connectwell
17.19 EncodersM/s. Hubner / P&F (Flame Proof / Intrinsic safe)
Hollow shaft type Encoder can be planned.
17.20 Junction Boxes (FLP) M/s. FCEG / BALIGA
17.21Junction Boxes (Non-
FLP)M/s. Rittal
17.22 Intrinsic Safe realys M/s P&F only
17.23 UB lights M/s Baliga
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:39 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
17.24
18
18.1
18.2
18.3
18.4
In the design of Crane, all Indian standards, all safety regulations as applicable
under provision of factory Act, Indian Electricity rules etc. as prevailing in the
country / State of Andhra Pradesh (site of installation) shall be taken into
consideration.
Arrangements shall be made by the supplier for the inspection and testing of
the crane during different stages of its manufacture starting form the raw
materials till the completion of the crane by the SDSC,SHAR and/or Third Party
Agency at the suppliers site as per the QAP schedule.
Dimensions of all parts used on crane shall conform to metric standards.
Assembly at site is to be kept as minimum as possible to enable early
No cast iron part should be used on the crane except for electrical equipment.
Similarly wood or combustible material and Bush bearing should not be used in
any part of the crane. Open gears should not be used in any drive / motion.
General TERMS & CONDITIONS during Supply and Installation :
Other reputed and reliable makes of bought out items will be conisdered during
detail engineering with submission of technical details, references and
credentials. However about other makes final decision is of SDSC SHAR.
18.5
18.6
18.7
18.8
18.10
18.11
The supplier should satisfy himself about the site condition beforehand to avoid
any difficulty during erection and commissioning of the crane
Supplier shall submit complete erection plan with details of erection loads &
pattern of wheel loads that will act on building civil structure, erection
procedure, material handling procedure etc.
A toolbox containing all necessary tools as given in Page no. 40 required for the
maintenance of the crane should be from part of supply along with the Crane.
Free electricity and water will be provided by the purchaser for the erection,
testing and commissioning of the crane at the site.
During the erection, testing and commissioning of the crane at site in
Sriharikota, the supplier has to make his own arrangements for boarding,
lodging, transportation of his men and materials. However, hostel
accommodation may be provided by the purchaser (SDSC SHAR) on
chargeable basis, if available.
Assembly at site is to be kept as minimum as possible to enable early
commissioning of the crane. Welding of crane at site is to be avoided as far as
possible.
For unloading the crane parts at site (in respective building) material handling
support like Forklifts (~12 ton cap.) and mobile crane (~20 ton/50ton cap.) will
be provided by department at free of cost.
Supplier shall make his own arrangements for welding and gas-cutting works if
any, that are required for erection and commissioning of Cranes.
18.9
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:40 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
18.12
18.13
19
19.1
19.2 Supply Prices shall be F.O.R Sriharikota.
COMMERCIAL TERMS & CONDITIONS :
Delivery Schedule : 12 months for total work. The crane shall supply the
crane within 10 months from date of Order and shall be erected &
commissioned with in 2 months from date of supply.
SDSC, SHAR / Third Party Inspection Agency (TPIA) shall have the right of
inspection and supervision of the manufacturing process adopted by the
supplier for the manufacture of equipment at various stages through their
authorized representatives. In case the manufacturing process adopted is not
found suitable and commensurate with the desired quality of the equipment, the
Supplier will be advised to adopt the correct manufacturing process which will
be binding on the supplier. SDSC, SHAR’s decision regarding the quality of
work and its acceptability shall be final and binding on the Supplier.
Bidder should quote separately for spares as considered necessary
for two years of normal operation of crane as given in Annexure-4. Bidder
can suggest any extra spare parts with cost in this regard. However, purchaser
may use his discretion in selecting/removal of spares at the stage of
ordering.
19.2
19.3
19.4.1
19.4.2
19.5
19.6
19.7
Guarantee period shall be for a period of 12 calendar months, commencing
from the date of acceptance & taken over by the purchaser at our site. During
this period any defect noticed on design, materials, workmanship shall be
replaced/rectified by the supplier at free of any cost.
Excise duty (ED) exemption Certificate will be issued by the Department for the
final product. (Hence, ED shall be NIL). Also Octroai exemption will be provided
by department on request from supplier. ED exemption will not be provided for
input materials.
Liquidates Damages (LD): In case of delay in fabrication, supply, testing and
commissioning beyond the stipulated delivery period LD will be levied at 0.5%
per week or part thereof subject to a maximum of 10% of total order value.
Supply Prices shall be F.O.R Sriharikota.
All Taxes (like sales tax, VAT, service tax etc.,) and duties applicable shall be
indicated clearly in quotation.
Customs duty (CD) exemption certificate shall be issued by the purchaser for
the imported components used for this EOT crane. Hence, details of items, qty
and cost of the imported items shall be mentioned in the quotation. Bidder shall
provide necessary details accordingly for availing CDEC.
Performance Bank guarantee (PBG) for 10% of total cost of the crane shall
be provided by the Vendor for a period of 12 months from the date of
commissioning and acceptance of the crane at purchaser’s site at Sriharikota.
SDSC SHAR
SPP
175t / 25t FLAMEPROOF EOT CRANE
SPECIFICATIONS CUM COMPLIANCE STATEMENT
Page:41 of 41
Sl.No. DESCRIPTION ISRO SPECIFICATION Bidder OFFER /
ACCEPTANCE
19.8
19.8.1Advance along with
Order30% of supply value against Bank guarantee
19.8.2Payment after crane
receipt at site60% of Supply value along with taxes & duties.
19.8.3
Balance Payment after
completion of erection
& commissioning &
acceptance
10% of Supply value + 100% TPIA charges + 100%
erection & commissioning charges against submission
of Performance Bank Guarantee as per clause 19.7.
19.9
Date : Signature & Office Seal of the bidder
Validity of Offer shall be minimum period of 120 days from the tender due
date.
Payment Terms in three stages. Vendor shall comply with following
payment terms only :
Date : Signature & Office Seal of the bidder
42
List of Tools to be supplied along with the crane (Ref : 18.14)
Sl. No.
Description of Item Units Required Qty
1 Double end Spanners from 10-11 to 36-41 (set of 13nos.) of make : M/s Snap On / Taparia)
Set 01
2 Ring Spanners from 10-11 to 36-41 (set of 13nos.) Set 01
3
Heavy duty socket spanner set with T-handle, Ratchet and Extension rod with ¾” drive or 1” drive from 20mm to 55mm. (1 set – 10 nos.)
Set 01
4 Heavy duty single end spanners of size 55 Nos. 01
5
Screw driver set a) Flat – 300mm long b) Star – 300mm long
No No
01 01
6 Adjustable spanner of 12” or 300mm length No 01
7 Cutting plier ( Size ~10” length) No 01
8 Locking / Grip plier ( Size ~10” length) No 01
9 Circlip plier
a) External Circlip plier ( Size ~10”) b) Internal Circlip plier ( Size ~ 8”)
No No
02 02
10 Special tool driver kit suitable for SIEMENS Drives
Nos. 01
11 Nut driver kit suitable for selected terminal blocks inside the panel
Nos. 01
12 Calibrated steel tape of 30m length of reputed make.
Nos. 02
13 Suitable hydraulic jack capacity 50t. Nos. 02
43
CODES AND STANDARDS FOR 175t / 25t FLAME PROOF EOT CRANE
The design, manufacture and testing of the crane shall conform to the latest editions of the following codes and standards wherever applicable:
IS:807 Code of Practice for Design, Manufacture, Erection and Testing (Structural Portion) of Cranes and Hoists.
IS:3177 Code of Practice for Design of Overhead Traveling Cranes and Gantry Cranes other than Steel Works Cranes.
IS:4137 Code of practice for Heavy duty electric overhead traveling cranes including special service machines for use in steel works
IS:2062 Steel for general structural purpose.
ANSI/AWS D14.1 Code of welding practice for Industrial cranes, Mill cranes and other material handling equipment
IS:800 Code of practice for use of structural steel in general building construction.
IS:3681 Gears tooth form and modules.
IS 7403 : 1974 Code of Practice for Selection of Standard Worm and Helical Gear Boxes
IS 4460 : Parts 1 to 3 : 1995
Gears - Spur and Helical Gears - Calculation of Load Capacity
IS:1835 Steel Wires for Ropes
IS:6594 Technical supply conditions for steel wire ropes and strands.
IS:2266 Steel Wire Ropes for General Engineering Purposes.
IS:2363 Glossary of terms relating to wire ropes.
IS:3973 Selection, installation, maintenance and technical supply conditions of wire ropes.
IS:3443 Crane Rail Sections
IS:5749 Forged Ramshorn Hooks
IS:3815 Point Hook with Shanks for General Engineering purpose
IS:816 Code of Practice for Use of Metal Arc Welding for general Construction in Mild Steel.
IS:823 Code of Practice for Use of Metal Arc Welding of Mild Steel.
IS:1181 Qualifying Tests for Metal Arc Welders (Engaged in Welding Structures other than pipes).
IS:1323 Code of Practice for Oxy-Acetylene Welding for Structural Work in Mild steel.
IS:325 Three Phase induction Motors.
IS:4029 Guide for Testing Three Phase induction Motor.
ANSI/ASME B30.2 Safety Codes for overhead and Gantry Cranes.
IS:2147 Degrees of protection provided by enclosures for low voltage switch gear and control gear.
IS:5571 Guide for selection of electrical equipment for hazardous areas
IS:5572 Classification of Hazardous Areas (Other than Mines) for electrical installations.
IS 2148 : 1981 Flameproof enclosures for electrical apparatus
IS 2206 : Specification for Flameproof Electric Lighting Fittings
IS 5780 : 1980 Specification for Intrinsically Safe Electrical Apparatus and Circuits.
IS:8239 Classification of maximum surface temperature of electrical equipments for use in explosive atmosphere.
IS:1554 PVC Insulated (Heavy Duty) electric cables.
IS:2208 HRC cartridge fuse links up to 650V.
IS:2959 Contactors for voltage not exceeding 1000V AC or 1200V DC
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.
IS:4237 General requirements of switch gears and control gears for voltages not exceeding 1000V AC.
IS 8623 : 1993 / IEC Pub 439-1 : 1985
Specification for Low-Voltage Switchgear and Control gear Assemblies - Part 1 to Part 3
IS 13947 : Part 4 : Sec 1 : 1993 / IEC Pub 947-4-1 : 1990
Specification for Low-Voltage Switchgear and Control gear - Part 1 to Part 5 : Suppliers and Motor-Starters - Section 1 : Electromechanical Contactors and Motor Starters
IS 10118 : 1982 Code of Practice for Selection, Installation and Maintenance of Switchgear and Control gear
Part I : General
Part II : Selection
Part III : Installation
Part IV : Maintenance
IS 1024 : 1999 Use of Welding in Bridges and Structures Subject to Dynamic Loading - Code of Practice
44
SECTION – VI
ANNEXURES
Annexure – 1A
Rope drum
Top pulley block
Brake 2Brake 1
Planetary gear box 1
Motor 1
Motor 2
Brake 3 Brake 4
Encoder 1
Encoder 2
Motor 3
Motor 4
Encoder 3
Encoder 4
Planetary gear box 2
Brake 6Brake 5
Brake 7 Brake 8
Overspeed sensor
Rotary limit switch
Pedestal bearing
Drum / barrel coupling
Overspeed sensor
Rotary limit switch
Pedestal bearing
Fig 1 : 175t Main Hoist Configuration, Dual drive and Twin load path. 45
48
EOT CRANE CLEARANCE DIMENSIONS – 175t / 25t FLAMEPROOF EOT Crane
(Top running, Double Girder, Flameproof EOT crane)
Refer Annexure – 1A (Fig) for details All Dimensions are in meters
Sl.No Facility Name
Rated SWL
In tons
Span (S)
A B C D F G H P N M X Y
01 Propellant Machining – II
MH– 175t AH – 25t
21.0 m 6.0m 2.20m 1.70m 2.0m 0.1m 0.4m 0.3m 19.00m ~ 6.0 m Not more
than 8.0m
~ 3.0m ~ 3.0m
Height of Lift (m)
Main Hoist Auxiliary Hoist
I J K L
17.0m 5.50m 19.00m 5.50m
Note :
1. The above dimensions are indicative only. EOT crane supplier shall work out the exact dimensions by keeping the view to minimize the end hook approaches and head room and shall provide the same in Cranes GA, drawing along with quotation.
2. EOT Crane span & lift are subjected minor changes which shall be accommodated by supplier during detail engineering.
49
Annexure – 2
SCHEMATIC OF PENDANT PUSH BUTTON OPERATING STATION
Crane Motion / Requirement Selector Switch
No. of push
button
Indication lamps
Selection of Hoist Motor
1 & 2 3-way Selector
switch - - 1
2
Hoist
Main UP
-
1
- Main DOWN 1
Creep UP 1
Creep DOWN 1
Aux. Hoist
Main UP
-
1
- Main DOWN 1
Creep UP 1
Creep DOWN 1
Cross Travel
Main Right
-
1
- Main Left 1
Creep Right 1
Creep Left 1
Long Travel
Main Forward
-
1
- Main Reverse 1
Creep Forward 1
Creep Reverse 1
Emergency Stop with Lockable Key - 1 -
Control ON - 1 -
Control OFF - 1 -
Control ON Indication lamp - 1
Push Button for Bell (Flameproof bell) - 1 -
UB lights Two way
selector switch - -
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend
1 Third Party Inspection Agency
2 Vendor (Suppliers)
3 Sub Vendor / Item Supplier
(TPIA) Place:
Date:
Signature of Crane Vendor
with Designation
Annexure - 3
50
Sl.
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Operations
Characteristic to
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Category
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Method of
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Extent
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check
Ref.
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Acceptance
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A B C D E F G H I J K
i)
H
Identification of Raw
materials structural
plates, forged steel
material, Alloy steel etc.,
All raw materials shall be offered with test certificates for identification for Crane manufacture
before start of fabrication. Stamping shall be done for verification at later date.
Component
Specs./ IS 2062/
IS1570/ En steels
Stamping on
parts &
Identification
record
1
-
_
All materials shall be Identified by
Third
Party Agency . (HOLD)
1 STRUCTURAL WORKS : BRIDGE GIRDERS, END CARRIAGES, CRAB FRAME, DRIVE BASES & PLATFORMS ETC.
1.1
Materials -
Plates/rolled sections
Chemical composition/
Mechanical Properties Major T.C. Correlation
(if not available
then test)
One per
heat Approved
drawings/
Specs./ IS 2062
Approved
drawings / Tech.
Specs./ IS 2062
Material T. C. /
Supplier's Test
Report
3,2
-
1
Reports / TC review by TPIA .
1.1.1 Lamination /Internal
defects Major Ultrasonic
Testing 100% ASTM A-435 ASTM A-435 Supplier IR
3,2
-
1
For a l l plates of thickness > 20mm,
UT qualification ( volumetric test)
1.2 Welding Welding procedure &
Welders qualification. Critical Test piece visual
& physical test.
One for
each
position
ASME Sec.IX ASME Sec.IX WPS/ PQR
format
2
-
1
1.2.1
Load Bearing Butt
welds (both tensile and
compression)
a) Welding quality &
Surface defects
Critical Visual &
D.P. Test
100% IS:3658 &
AWS D14.1 IS:3658 &
AWS D14.1
Supplier’s IR
2
-
1 Visual inspection & Use weld
gauges for measurement of weld
size
b) Sub surface defects
Critical
Radiography
100 %
ASME Sec.VIII
Div I
ASME Sec.VIII
DivI
Supplier’s IR
2
1
-
Review of radiography films by I.A.
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend
1 Third Party Inspection Agency
2 Vendor (Suppliers)
3 Sub Vendor / Item Supplier
(TPIA) Place:
Date:
Signature of Crane Vendor
with Designation
Annexure - 3
51
Sl.
No
Components/
Operations
Characteristic
to be checked
Category
Type /
Method of
check
Extent
of
check
Ref. Document
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A B C D E F G H I J K
1.2.2 Other than load
Bearing Butt welds &
fillet welds
Surface defects & Size Major Visual & DPT 100%
Visual
check &
DP test
10%
random
IS:3658
IS:3658
Supplier’s IR
2
-
1
Use weld gauges for
measurement of weld size
1.2.3
H
Bridge Girder & End
Carriage inspection
before closing the box
Visual, & Welding
Measurement Major Visual &
welding quality Visual
100% DPT-
random of
10%
Component
drawing AWS
D14.1
Component
drawing/ AWS
D14.1
Supplier’s IR
2
1
-
Use weld gauges for
measurement of weld size
(HOLD)
1.2.4 Final Welding
Inspection Visual Inspection Major Inspection of
Welding quality 100% Specification/
AWS D14.1 AWS D14.1 Supplier’s IR
2
-
1 Visual final welding inspection by
TPIA
1.2.5 Final Inspection of
fabricated components
Girders, End carriages,
Trolley, LT drive frame,
etc..,
Dimensional , Camber ,
straightness, level,
Parallelism, verticality,
etc.,
Major Measurement
tolerances as
per
specifications
100% Tech.
Specification/
Component
drawing/IS
807
Tech.
Specification/
Component
drawing/IS 807
Supplier’s IR
2
-
1
Measured Dimensions shall be
marked on component drawing.
Review of reports at next stage by
TPIA. (HOLD)
2.0 ROPE DRUM Fabricated/
Heavy duty Seamless pipe
Material composition/
Mechanical Properties
UTS, YS, % elongation
Major T.C. Correlation
(if not available
then test)
One per
heat Spec/drawing/
ASTSM A106/
IS 2062
Spec/drawing/
ASTSM A106/
IS 2062
Material T. C. /
Supplier’s Test
Report
3,2
-
2, 1
Reports / TC / pressure test
reports review by TPIA
2.1 ROPE DRUM joint
Welding / Seamless pipe
Welding Joint quality &
Weldment defects Critical Visual/DP
Test/RT/ UT 100% Component
drawing ASME Sec.VIII
Div I Supplier’s IR
3/2
2`
1
Measured Dimensions shall be
marked
on component drawing.
Examination of RT films by TPIA. Stress relieving Major Verification 100% Mfg’s std. Stress relieving
chart Supplier’s IR
3/2
2
1
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend
1 Third Party Inspection Agency
2 Vendor (Suppliers)
3 Sub Vendor / Item Supplier
(TPIA) Place:
Date:
Signature of Crane Vendor
with Designation
Annexure - 3
52
Sl.
No
Components/
Operations
Characteristic
to be checked
Category
Type /
Method of
check
Extent
of
check
Ref. Document
Acceptance
Norm
Format of
record
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A B C D E F G H I J K
3.0
Gear box Housings
Fabricated
Material composition/
Mechanical Properties
UTS, YS, % elongation
Major T.C. Correlation
(if not available
then test)
One per
heat Spec/drawing/
IS 2062 Spec/drawing/
IS 2062 Material T. C. /
Supplier’s Test
Report
3,2
-
2, 1
Reports / TC to be
review by TPIA
3.1 Stress relieving Major Verification 100% Mfg's std. Stress relieving
chart Supplier's IR
2
-
1 SR chart will be reviewed by TPIA.
3.2 Surface defects &
dimensional check Major Visual/DP Test/
Measurement DPT 10%
random &
100%
visual
IS:3658/
Component
drawing
IS:3658/AWS
D14.1 Supplier's IR
2
-
1
Measured Dimensions shall be marked
on component drawing
4.0 a) Platform
b) LT Frame
c) Hand Rails
d) chequered Plates
Dimensional
Conformity/
Visual checking /
Mfr’s TC
Minor Measurement 100%
Critical
dimension
s / others
at random
Component
drawing/ Mfr’s
TC/ Industrial
standards
Component
drawing/ Mfr’s
TC/ Industrial
standards
Supplier's IR
2
-
1
5 MECHANICAL COMPONENTS – GEAR BOXES
5.1 MH, AH , CT & LT Input
shafts, Gears , Pinions,
keys, spacers
Material composition/
Mechanical properties
Hardness value / UT /
MPT/ DPT of materials
Major Correlation with
Mfr’s TC ( if not
test materials)
100% Specification
IS:1570 / BS 970
/ IS:2048
Component
drawing/ IS2048
Specification/
IS:1570 / BS 970
Mfr's TC/
Supplier's IR
3,2
-
1
1) UT volumetric test for wrought or
forged materials as per ASTME
114 and A388.
2) DPT or MPT shall be performed as
per ASTM A 275, E709
5.1.1
Machined components
for Gear boxes like input
shafts, gears, pinions,
keys, spacers etc.,
Dimensional conformity
Hardness of gear teeth/
Bearing s/ Oil seals/ keys
and key ways.
Major Measurement/
Visual
examination for
finishing
100% Component
drawing/
IS4460/
AGMA/DIN
IS:2048
Component
drawing/ IS4460/
AGMA/DIN/ Heat
treatment chart
Supplier's IR
2
-
1
Key ways shall be inspected by TPIA
before assembly of gearboxes.
Measured Dimensions shall be marked
on component drawings.
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend
1 Third Party Inspection Agency
2 Vendor (Suppliers)
3 Sub Vendor / Item Supplier
(TPIA) Place:
Date:
Signature of Crane Vendor
with Designation
Annexure - 3
53
Sl.
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Components/
Operations
Characteristic
to be checked
Category
Type /
Method of
check
Extent
of
check
Ref. Document
Acceptance
Norm
Format of
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A B C D E F G H I J K
5.1.2
H Gear box Assembly Dimensional
conformity/ Inspection
of machined surfaces
like gearbox base,
bearing mounts etc.,.
Major Measurement/
Visual check of
Internal
painting
100% Gearbox GA
drawing Gearbox GA
Drawing. Supplier's IR
2
-
1
Measured Dimensions shall be marked
on Gearbox GA drawings with
allowed dimensional variations.
(HOLD)
5.1.3
Gear box assembly
testing (No load run test for
minimum of 4 hours )
Contact ratio of
surfaces/ Backlash/
Noise level & Bearing
temperature/ Breather/
Oil level gauge
Major Measurement &
no load running 100% Gearbox GA
drawing /
IS4460/ AGMA
/ Specification
Gearbox GA
drawing / IS4460/
Specification /
Noise level of
gear box ≤ 80dBA
Supplier's IR
2
1
-
No Load Test shall be witnessed
by TPIA. Noise level of gearboxes
shall be ≤ 80dBA. Temperature rise
shall be as per gearbox manufacture
standards.
5.2 MECHANICAL COMPONENTS – LT AND CT DRIVE SHAFTS
5.2.1 Materials of LT & CT
Shafts, and Keyways &
Keys
Material composition/
Mechanical properties
Hardness of material /
UT / DPT
Major Correlation with
Mfr’s TC ( if not
test materials)
100% Approved
drawing/ IS2048/
Specification
IS:1570/BS970/
Approved
drawing/ IS2048
Specification/
IS:1570 / BS 970
Mfr's TC/ Test
reports/
Supplier's IR
3, 2
-
1
UT of wrought and forged materials as
per ASTM
5.2.2 Machining of LT & CT
Shafts, and Keyways &
Keys ( Dimensional
measurement)
Straightness &
Dimensional conformity
Checks & Inspection of
Key way milling
Major Dimensional
Measurement/
Visual
examination
100% Approved
drawing/
Specification
IS:1570 /
BS 970/IS2048
Approved
drawing/ IS2048
Specification/
IS:1570 / BS 970
/IS 2048
Supplier's IR
2
-
1
Keys & keyways shall be inspected
by
TPIA before assembly.
5.3 COUPLINGS
a) Materials
b) Torque capacity
c) Key ways
Coupling s Size/
Material composition/
Mechanical properties /
Hardness value / UT /
DPT
Major Correlation with
Mfr’s TC 100% Approved
drawing/
Specification
IS:1570 / BS 970
Approved
drawing/ IS2048
Specification/
IS:1570 / BS 970
Mfr's TC/
Supplier's IR
3, 2
-
1
Keys & keyways shall be inspected by
TPIA before assembly.
UT of wrought and forged materials
as per ASTM
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend
1 Third Party Inspection Agency
2 Vendor (Suppliers)
3 Sub Vendor / Item Supplier
(TPIA) Place:
Date:
Signature of Crane Vendor
with Designation
Annexure - 3
54
Sl.
No
Components/
Operations
Characteristic
to be checked
Category
Type /
Method of
check
Extent
of
check
Ref. Document
Acceptance
Norm
Format of
record
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A B C D E F G H I J K
5.4 Plummer blocks &
bases PB & bearing sizes/
Material composition/
Mechanical properties
Major Correlation with
Mfr’s TC 100% Approved
drawing/
Specification
Approved
drawing/
Specification/
Mfr's TC/
Supplier's IR
2
-
1
Review of Test certificates by TPIA and
issue Compliance certificate.
Measured Dimensions shall be marked
on Component drawings with allowed
dimensional variations.
5.5 LT & CT Wheels
5.5.1
a) Material Forged steel
C55Mn75
Material composition/
Mechanical properties
Hardness of material /
Major Correlation with
Mfr’s TC 100% Approved
drawing / Tech.
Specification
IS:1570/BS970
Approved
drawing / Tech.
Specification
IS:1570/BS970
Mfr's TC/ Test
reports/
Supplier's IR
3, 2
-
1
Review of Test certificates by TPIA and
issue Compliance certificate.
UT of forged blanks Major UT checking 100% ASTM A-388 ASM A-388 Mfr's TC
Supplier's IR
3, 2
-
1 Review of Test certificates by TPIA and
issue Compliance certificate.
5.5.2 b) Wheels after
machining with Keys &
key ways
Dimensional Conformity
for Bore, wheel tread,
taper of flange /
Hardness/depth
Major Measurement 100% Approved
Component
drawing
Approved
Component
drawing
Supplier's IR
2
-
1
Measured Dimensions shall be marked
on each Component drawings with
allowed dimensional variations.
5.6 WHEEL AXLES with key
ways & keys Material composition/
Mechanical properties
Dimensional inspection
UT & DPT /MPT
Major Correlation with
Mfr’s TC /
Measurement
100% Approved
drawing / Tech.
Specification
IS:1570/BS970
Approved
drawing / Tech.
Specification
IS:1570/BS970
Mfr's TC/ Test
reports/
Supplier's IR
3,2
-
1
Measured Dimensions shall be marked
on each Component drawings with
allowed dimensional variations.
5.7 Pulleys with Roller Bearings
5.7.1 a) Material (Forged Steel )
Material composition/
Mechanical properties
Hardness of material /
UT & DPT / MPT
Major Correlation with
Mfr’s TC 100% Approved
drawing / Tech.
Specification
IS:1570/BS970
Approved
drawing / Tech.
Specification
IS:1570/BS970
Mfr's TC/ Test
reports/
Supplier's IR
3, 2
-
1
Review of Test certificates by TPIA and
issue Compliance certificate.
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend
1 Third Party Inspection Agency
2 Vendor (Suppliers)
3 Sub Vendor / Item Supplier
(TPIA) Place:
Date:
Signature of Crane Vendor
with Designation
Annexure - 3
55
Sl.
No
Components/
Operations
Characteristic
to be checked
Category
Type /
Method of
check
Extent
of
check
Ref. Document
Acceptance
Norm
Format of
record
Agency
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A B C D E F G H I J K
5.7.2 b) Visual Inspection
c) Dimensional Inspection Overall visual inspection
/ All dimensions as per
drawing like bore,
width, groove,
etc.,/hardness of
Major Measurement
with vernier /
Micrometer
100% Component
drawing /
Specification
Component
drawing /
Specification
Noise level of
gear box < 80db
Mfr's TC
3
-
1,2
Measured Dimensions shall be marked
on each Component drawings with
allowed dimensional variations.
5.8 Snatch block Cross
head
Material composition/
Mechanical properties
Dimensional
inspection, 100% UT &
MPT
Major Correlation with
Mfr’s TC /
Measurement
100% Approved
drawing / Tech.
Specification
IS:1570/BS970
Approved
drawing / Tech.
Specification
IS:1570/BS970
Mfr's TC/ Test
reports/
Supplier's IR
3,
2
-
1
Measured Dimensions shall be marked
on each Component drawings with
allowed dimensional variations.
5.9 Snatch block assembly Dimensional Conformity Major Measurement 100% Approved
Assembly dwg . Assembly
Drawing Supplier's IR
2
-
1 Review of reports by TPIA
5.10
Hook
Material composition/
Mechanical properties/
and 100% UT& DPT /
MPT
Major Correlation
with TC. 100% Component
drawing / IS1875 Component
drawing /IS 1875 Mfr's TC
3
-
2, 1 Proof load test from Govt. approved
test house.
Proof Load Test Major Testing 100% IS5749/IS3815 IS5749/IS3815 Mfr's TC
3
-
2, 1
Stress relieving Major Verification 100% Component
drawing/ IS3815 Component
drawing /IS3815 Vendor TC
3
-
2,1
5.11
Brake Drums with key
and Key ways
Material composition/
Mechanical properties Major Correlation with
Mfr’s TC /
100% Approved comp.
drawing / Tech.
Specification
IS:1570/IS1030
Approved comp.
drawing / Tech.
Specification
IS:1570/IS1030
Mfr's TC/ Test
reports/
Supplier's IR
3,
2
-
1
Measured Dimensions shall be marked
on each Component drawings with
allowed dimensional variations.
5.12
Dimensions/ Dynamic
balancing/ Key way and
key inspection.
Major Balancing test/
Measurement
with
100% Component
drawing /
Specification
Component
drawing /
Specification
Mfr's TC
2
-
1
1. Dynamic balance report shall be
reviewed by TPIA.
2. Measured Dimensions shall be
marked on each Component drawings
with allowed dimensional variations.
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend
1 Third Party Inspection Agency
2 Vendor (Suppliers)
3 Sub Vendor / Item Supplier
(TPIA) Place:
Date:
Signature of Crane Vendor
with Designation
Annexure - 3
56
Sl.
No
Components/
Operations
Characteristic
to be checked
Category
Type /
Method of
check
Extent
of
check
Ref. Document
Acceptance
Norm
Format of
record
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A B C D E F G H I J K
6 BOUGHT-OUT & Other items
6.1
Wire Rope
Dimensional, Genuine
of make, Lay, core and
stands, Tensile grade
Major Mfr's TC 100% Component
drawing/ BOOM Component
drawing / BOOM Mfr's TC
3,2
-
1
Review of Mfr's TC by TPIA.
Visual examination of wire rope for any
defects by 2 & 1.
Breaking Load test Major Mfr's TC 100% IS2266 IS2266 Mfr's TC 3 - 1
6.2 Bearings Bearing No./ Genuine
Major Mfr's TC/
Invoice 100% Approved make
and type SKF/FAG/TIMKEN Mfg TC/
Supplier IR
2
-
1
6.3 Machined Fit Bolts &
Nuts
Material composition/
Mechanical properties /
Measure dimensions
Major Correlation with
Mfr’s TC /
Measurement
100% Approved comp.
drawing / Tech.
Specification /IS
Approved comp.
drawing / Tech.
Specification
IS:1570/IS1030
Mfr's TC/ Test
reports/
Supplier's IR
3,
2
-
1
Measured Dimensions shall be marked
on each Component drawings with
allowed dimensional variations.
6.4 FASTENERS (Bolts, nuts,
washers, lock nuts)
Type / Genuine make
conformity Major Mfr's TC/
Invoice 100% Approved make
and type TVS/UNBRAKO Mfg TC/
Supplier IR
2
-
1
7 ELECTRICAL EQUIPMENT
7.1 Electrical Control
Panels ( VVVF drive
panels)
Dimensional, Visual
Sequence / Functional
and high voltage Test
Major Electrical test 100% Electrical Circuit
diagram/
Approved
drawing/
Specifications
Approved
drawing/
Specification.
Supplier's IR
3
1
Review of test certificates of all bought
out items by IA
7.2 Motor Visual/ Name Plate Major Name Plate 100% IS 325/ Spec IS 325/spec Mfr's TC
2
-
1
7.2.1 Routine / No load test Major Elec. test 100% IS 325 IS 325 Mfr's TC
3
-
2, 1 Review of TC & Flameproof
certificates by TPIA 7.2.2 Flameproof test cert. Major Gap measure 100% IS2148/ CMRI IS2148/ CMRI Type test cert.
3
-
2,1
make conformity
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend
1 Third Party Inspection Agency
2 Vendor (Suppliers)
3 Sub Vendor / Item Supplier
(TPIA) Place:
Date:
Signature of Crane Vendor
with Designation
Annexure - 3
57
Sl.
No
Components/
Operations
Characteristic
to be checked
Category
Type /
Method of
check
Extent
of
check
Ref. Document
Acceptance
Norm
Format of
record
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A B C D E F G H I J K
7.3 Brakes and
Thrusters,
Brake Coil
Visual/ Name plate/
Make Torque & Thrust /
Material TC verify / Test
certificate/ Ex proof
certificate
Accessibility of parts.
Major Name plate
details, make
Verification of
TC
Verification of
Ex-proof TC
100% Approved
Drawing/ Make/
BOM/Spec
Approved
Drawing/ Make/
BOM/Spec/
ATEX- PTB/
IS2148 -CMRI
Mfr's TC/ Type
test cert for
Flameproof /
Supplier IR
3
-
1
Review of TC & Ex-proof certificates
by
TPIA
7.4 Resistance box Megger test, Resistance
value Major Electrical test 100% BOM/ drawing
/ Specifications. BOM/ drawing /
Specifications. Mfr's TC
3
-
1 Review by TPIA.
7.5 Master controller /
Limit switches / Switch
Gear
Sequence, Number
of cams, Idle
operational test
Major Visual 100% BOM/ drawing /
Specifications. BOM/ drawing /
Specifications. Mfr's TC
3
-
1
Review of TC by I.A.
7.6 Cables Routine test Major Test One per BOM/spec. BOM/spec. Mfr's TC
3
-
1 Review of TC by I.A.
8 H ASSEMBLY OF CRANE (Before assembly of EOT crane all parts shall be inspected by TPIA/Purchaser. Supplier shall inform readiness of all parts) (HOLD)
8.1 Bridge Girder &
End carriage
assembly.
Overall Dimension s
Structural Alignment &
LT Wheel alignment.
Span measurement
Diagonal Checks
Major Measurement/
visual
inspection
100% Approved
General
Arrangement
drawing /
Specifications
Approved
General
Arrangement
drawing /
Specifications
Supplier's IR
2
1
-
Measured Dimensions /
alignment values shall be
marked on GA
/component drawings with allowed
dimensional variations.
8.2 Crab assembly with Main Hoist & CT machinery
Dimensional & CT
Wheel alignment
Couplings’ alignment
Major Measurement 100% Approved
drawing /
Specifications
Approved
drawing /
Specifications
Supplier's IR
2
1
-
Measured Dimensions /
alignment values shall be
marked on GA
/component drawings with
allowed dimensional variations.
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend
1 Third Party Inspection Agency
2 Vendor (Suppliers)
3 Sub Vendor / Item Supplier
(TPIA) Place:
Date:
Signature of Crane Vendor
with Designation
Annexure - 3
58
Sl.
No
Components/
Operations
Characteristic
to be checked
Category
Type /
Method of
check
Extent
of
check
Ref. Document
Acceptance
Norm
Format of
record
Agency
Remark
s
Pe
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rme
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Wit
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A B C D E F G H I J K
9 H LOAD TESTING AT WORKS (HOLD)
9.1 NO LOAD TEST
(MH ,AH , CT & LT
mechanisms)
NO Load test/
Performance & Safety
systems verification
speed, Current etc.,
Major NO Load test/
Measurement
of parameters
100% Approved dwg /
IS807/ IS 3177
/Specification
Approved dwg /
IS807/ IS 3177
/Specification
Supplier's IR &
Load test
Format
2
1
-
Measure Gear Box Noise. (Noise
Level should be <80dBA).
9.2 FULL LOAD (SWL) TEST AT WORKS FOR HOIST & CT MOTIONS
9.2.1 DEFLECTION TEST
With Safe Working Load Deflection Major Measurement
as per approved
procedure.
100% Specifications/
IS807/ IS 3177 Specifications/
IS807/ IS 3177 Supplier's IR &
Load test
Format
2
1
-
Deflection < Span/1000 . Record
procedure of test & measurement
with sketch.
9.2.2 Main Hoist and Auxiliary
Hoist With Safe Working
Load
Performance, duty cycle,
Speeds, Current, , Safety
systems etc.,
Major Full Load test/
Measurement
of parameters
100% Approved dwg /
IS807/ IS 3177
/Specification
Approved dwg /
IS807/ IS 3177
/Specification
Load test
report
/Supplier's IR
2
1
-
Measure Gear Box Noise. (Noise
Level should be <85dBA) .
9.2.3 CT Mechanism With Safe
Working Load Performance, duty cycle,
Speeds, Current, , Safety
systems etc.,
Major Full Load test/
Measurement
of parameters
100% Approved dwg /
IS807/ IS 3177
/Specification
Approved dwg /
IS807/ IS 3177
/Specification
Load test
report
/Supplier's IR
2
1
-
Measure Gear Box Noise. (Noise
Level should be <85dBA) .
9.2.4
OVER LOAD (125% SWL)
TEST
(MH, AH & CT)
Static test/ Capability of
all motions/ Permanent
set
Major Capability of CT
&Hoist motion/
Measurement
100% Approved dwg /
IS807/ IS 3177
/Specification
Approved dwg /
IS807/ IS 3177
/Specification
Supplier's IR &
Load test
report
2
1
-
Record procedure followed for test
& measurement with sketch. After
testing check for any damage,
cracks/paint flaking in load bearing
members. 10 PAINTING
10.1 Sand/ Grit Blasting &
Surface Cleaning Surface Cleanliness/
texture visual inspection
Major Visual Random Specification /
SSPC SA2 1/2 Specification /
SSPC SA2 1/2 Supplier's IR
2
-
1
10.2
Primer Coat Painting DFT Thickness/ visual
inspection Major Measurement
in µm / Visual Random Specification /
DFT ≥75µm Specification /
DFT ≥75 µm Supplier's IR
2
-
1 Paint thickness shall be measured
with paint thickness gauge/
elcometer.
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend
1 Third Party Inspection Agency
2 Vendor (Suppliers)
3 Sub Vendor / Item Supplier
(TPIA) Place:
Date:
Signature of Crane Vendor
with Designation
Annexure - 3
59
Sl.
No
Components/
Operations
Characteristic
to be checked
Category
Type /
Method of
check
Extent
of
check
Ref. Document
Acceptance
Norm
Format of
record
Agency
Remarks
Pe
rfo
rme
d
Wit
ne
sse
d
Ve
rifi
ed
A B C D E F G H I J K
10.3 Epoxy paint Painting
(Two coats of 80 µm &
40 µm)
DFT Thickness/ visual
inspection Major Measurement/
Visual Random Specification /
DFT ≥195 µm Specification /
DFT ≥195 µm Supplier's IR
2
-
1
Paint thickness shall be measured with
paint thickness gauge/ elcometer . Final
DFT measured in presence of TPIA.
11 ERECTION AT SITE
11.1 GANTRY GIRDER RAIL
ALIGNMENT
Gantry rail Span, Level,
straightness, rail Joints
and Rail clamp distance.
Major Measurement
of parameters 100% Approved
drawing / IS 807
Specification /
IS3177
Approved
drawing / IS 807
Specification /
IS3177
Supplier's IR
2
-
1
Tolerances:
Rail span : ±5mm; Slope of rail : 1/1000
at 2m interval; Height diff : ±10mm
between LH & RH rails; Rail Gap :2mm;
Straightness of rails: ±5mm
12 LOAD TESTING AFTER ERECTION AT SITE.
12.1 NO LOAD TEST
(MH ,AH , CT & LT
mechanisms)
NO Load test/
Performance & Safety
systems verification
speed, Current etc.,
Major NO Load test/
Measurement
of parameters
100% Approved dwg /
IS807/ IS 3177
/Specification
Approved dwg /
IS807/ IS 3177
/Specification
Supplier's IR &
Load test
Format
2
1
-
Measure Gear Box Noise. (Noise Level
should be <80dBA).
12.2 DEFLECTION TEST
With Safe Working Load Deflection Major Measurement
as per approved
procedure.
100% Specifications/
IS807/ IS 3177 Specifications/
IS807/ IS 3177 Supplier's IR &
Load test
Format
2
1
-
Deflection < Span/1000 . Record
procedure of test & measurement with
sketch.
12.3 Main Hoist and Auxiliary
Hoist With Safe Working
Load
Performance, duty cycle,
Speeds, Current, , Safety
systems etc.,
Major Full Load test/
Measurement
of parameters
100% Approved dwg /
IS807/ IS 3177
/Specification
Approved dwg /
IS807/ IS 3177
/Specification
Load test
report
/Supplier's IR
2
1
-
Measure Gear Box Noise. (Noise Level
should be <85dBA) .
12.4 CT Mechanism With Safe
Working Load Performance, duty cycle,
Speeds, Current, , Safety
systems etc.,
Major Full Load test/
Measurement
of parameters
100% Approved dwg /
IS807/ IS 3177
/Specification
Approved dwg /
IS807/ IS 3177
/Specification
Load test
report
/Supplier's IR
2
1
-
Measure Gear Box Noise. (Noise Level
should be <85dBA) .
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Legend
1 Third Party Inspection Agency
2 Vendor (Suppliers)
3 Sub Vendor / Item Supplier
(TPIA) Place:
Date:
Signature of Crane Vendor
with Designation
Annexure - 3
60
Sl.
No
Components/
Operations
Characteristic
to be checked
Category
Type /
Method of
check
Extent
of
check
Ref. Document
Acceptance
Norm
Format of
record
Agency
Remarks
Pe
rfo
rme
d
Wit
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sse
d
Ve
rifi
ed
A B C D E F G H I J K
12.5 LT Mechanism With
Safe Working Load Performance, duty cycle,
Speeds, Current, , Safety
systems etc.,
Major Full Load test/
Measurement
of parameters
100% Approved dwg /
IS807/ IS 3177
/Specification
Approved dwg /
IS807/ IS 3177
/Specification
Load test
report
/Supplier's IR
2
1
-
Measure Gear Box Noise. (Noise Level
should be <85dBA) .
12.6 Brake Path Test/
Brakes Effectiveness
testing for all motions
Each Brake holding
Brake path / Delay
between two brakes
Major Measurement
of path &
Brake currents
100% Specifications/
Brake path
≤17mm for Hoist
Specifications/
Brake path
≤17mm for Hoist
Load test
report
/Supplier's IR
2
1
-
12.7
OVER LOAD (125%
SWL)
TEST (MH, AH , CT and
LT motions)
Static test/ Capability of
all motions/ Permanent
set
Major Capability of CT
&Hoist motion/
Measurement
100% Approved dwg /
IS807/ IS 3177
/Specification
Approved dwg /
IS807/ IS 3177
/Specification
Supplier's IR &
Load test
report
2
1
-
Record procedure followed for test &
measurement with sketch. After testing
check for any damage, cracks/paint
flaking in load bearing members.
13.
Final Painting & touch up
Aesthetic look of crane/
DFT measurement
Major
Thickness
measurement
Random
Tech .
Specifications.
Tech .
Specifications.
Supplier's IR
2
1
-
Final DFT measured in presence of
TPIA.
14
Safety features like limit
switches, overload relays,
buffers, stoppers etc.,
Performance, interlocks
Minor
Performance
100%
Tech .
Specifications./
IS3177
Tech .
Specifications./
IS3177
Supplier’s IR
2
1
-
15
Spool limit switch
Performance
Major
No Load test
100%
As per
Specifications
As per
Specifications Load test
report
/Supplier's IR
2
1
-
16 Decoupling of main
hoist output shaft
coupling to rope drum
Ensuring the
decoupling of drive
system
Major Ensuring the
removal and
fixing of drive
system
100% As per
specifications As per
specifications Load test
report
/Supplier's IR
2
1
-
61
Annexure - 4
LIST OF OPTIONAL SPARE PARTS (LUMPSUM PRICE)
S.No Item Description Unit Qty
I Electrical
1 Main Hoist - CUVC card No 1
2 Semi conductor fuse (for each type) Nos. 3
3 Indication lamps Red, Yellow, Blue (Each) Nos. 2
4 Push buttons Nos. 6
5 Emergency push button with lock and key Nos. 1
6 Encoder for main hoist No. 1
II Mechanical
7 Brake liner for main hoist Set 2
8 Thruster assembly for Imported Main hoist Brake (flame proof) No. 1
9 Bearings for input shaft of MH gearbox. Nos. 2
10 Bearings for CT Wheel. Nos. 2
11 Bearings for LT wheel. Nos. 2
12 Oil seals for input shaft of MH gearbox. Nos. 2
13 Oil seals for input shaft of AH gearbox. Nos. 2
14 Sealing rings for geared coupling (each type - 1no.) Set 2
15 Main hoist thruster brake springs Nos. 2
16 LT rail clamps Sets 5
17 CT rail clamps Sets 5
18 Special grease nipples of different sizes (Each) No 10
TOTAL COST OF SPARE PARTS OPTIONAL TO BE MENTIONED IN THE PRICE BID (Rs.)