अतिरक्ष िवभाग सतीश धवन अंतिरक्ष ... · 2019-05-13 · TECHNICAL SPECIFICATIONS OF DOUBLE GIRDER EOT CRANES Sl. No Type of crane

2

भारत सरकार Government of India

अ तिरक्ष िवभाग Department of Space

सतीश धवन अंतिरक्ष के द्र Satish Dhawan Space Centre शार SHAR

ीहिरकोटा डा.घ.524124 आ.ंप्र. भारत SRIHARIKOTA P.O. 524124, AP, INDIA टेिलफोन:+91 8623 225023 Telephone: +91 8623 225023 फेक्स: +91 8623 225170 Fax: +91 8623 225170

GOVERNMENT OF INDIA :: DEPARTMENT OF SPACE

SATISH DHAWAN SPACE CENTER SHAR :: SRIHARIKOTA – 524 124 SRI POTTI SREERAMULU.NELLORE DISTRICT (A.P)

TENDER NOTICE NO. SDSC SHAR/Sr.HPS/PT/05/2019-2020

On behalf of President of India, Sr. Head Purchase and Stores, SDSC SHAR, SRIHARIKOTA invites on line quotations for the following.

Sl No

Ref. No. Description Qty.

01 SHAR SPP 2019 0 10967 e-procurement [Two Part basis]

Procurement of Raw Materials, Supply, Site Fabrications, Inspection, erection, Levelling & Commissioning of Steel Structures.

1 Lot


Design, Manufacture, Inspection, Transportation, Testing, supply and Commissioning of 15t and 8t trailer.

1 Lot


Supply, erection, commissioning and Third Party inspection of Double Girder, EOT cranes 80t, 50t & 40t.

1 Lot

Last Date for downloading of tender documents : 11.06.2019 at 16:00 hrs. Due Date for submission of bids online : 11.06.2019 at 16:00 hrs. Due Date for Bid Sealing on : 11.06.2019 at 16:01 hrs. to 11.06.2019 at 17.30 hrs. Due Date for Open Authorization : 11.06.2019 at 17.31 hrs. to 13.06.2019 at 17:00 hrs. Due Date for opening of tenders : 14.06.2019 at 14:30 hrs.

Instructions to Tenderers:

No tender fee shall be applicable for tenders submitted through EGPS

01. For full details/scope of work and terms and conditions etc., please see the enclosed annexures.

02. Interested tenderers can download the e-tender from ISRO e-procurement website https://eprocure.isro.gov.in and submit the offer on line in the e-procurement portal. Offers sent physically by post/courier/in person will not be considered.

03. Tender documents are also available on ISRO website www.isro.gov.in ISRO e-procurement website https://eprocure.isro.gov.in and SDSC SHAR, Sriharikota website www.shar.gov.in. The same can be down loaded and offer submitted on line in the e-procurement portal.

04. Quotations received after the due date/time will not be considered.

05. The tender documents are available for download upto 11.06.2019 at 1600 hrs. and last date for submission of tenders on line 11.06.2019 at 1600 hrs. and Tender Opening on 14.06.2019 at 14:30 hrs.

06. Sr. Head, Purchase and Stores, SDSC-SHAR, Sriharikota reserves the right to accept or reject any/or all the quotations. DT: 09.05.2019 Sr. HEAD, PURCHASE AND STORES

SATISH DHAWAN SPACE CENTRE SHAR

SOLID PROPELLANT PLANT

Indent Ref: SHAR/ SPP/2019010952

TECHNICAL SPECIFICATIONS OF DOUBLE GIRDER EOT CRANES

Sl.

No

Type of

crane

Capacity

of crane

(ton)

Span

(m)

Height of

Lift (m)

Crane

Travel

(m)

Duty

class of

crane

Quantity

( Nos)

Facility

1

Flameproof

Double Girder,

EOT Cranes

80t 11.80m 13.0m ~27m

Class - II

of

IS:3177

02 (HVM) Mixer

Room, SPP

2

Flameproof

Double Girder,

EOT Cranes

50t 17.20m 8.0m ~58m 02 Premix Storage -

2, SPP

3

Flameproof

Double Girder,

EOT Cranes

50t 21.20m 9.0m ~66m 02 Bowl Cleaning-2,

SPP

4

Safe area

Double Girder,

EOT Crane

40t

(Non FLP) 19.20m 15.0m ~75m 01 HIL - 3, SPP

Note :

1. S.No. 2 cranes (02nos.) are running in the same building on the same rail and level. Hence, LT rails of 1 set for a

bay length of ~58m shall be provided and quotation must be submitted considering the LT rails of one bay length

only. The two cranes shall be of different colors.

2. S.No. 3 cranes (02nos.) are running in the same building on the same rail and level. Hence, LT rails of 1 set for a

bay length of ~58m shall be provided and quotation must be submitted considering the LT rails of one bay length

only. The two cranes shall be of different colors.

3. S.No. 4 crane is Non flame proof EOT crane.

The above EOT cranes shall be supplied, transported, erected and commissioned as per the Technical

Specifications, Terms & Conditions given in following pages of this document.

Ref : SHAR/SPP/2019010952

CONTENTS OF BOOKLET

Sl. No

Contents

Page No.

1 Bid Qualification Criteria for supply of Double Girder EOT Cranes Page i & Page ii

2 Technical Specifications cum Compliance statement, Terms &

conditions of supply including codes and standards & dimensions.

2.1 Mechanical Specifications M1 to M13

2.2 Electrical Specifications E1 to E16

2.3 Painting P – 1

2.4 Terms & conditions T 1 – T 9

2.5 Tools Tools - 1

2.6 Bought out items BOM - 1

2.7 IS codes Codes -1 – Codes 2

2.8 EOT crane clearance diagram CD - 1

2.9 EOT crane clearance dimensions CCD - 1

2.10 Schematic of Push Button operating station PBS - 1

3 Quality Assurance, Inspection and Testing plan for EOT Cranes QAP – 1 to QAP - 11

4 List of spares Spares - 1

Page i

BID QUALIFICATION CRITERIA FOR SUPPLY OF EOT CRANES (07Nos.)

Bidders who are qualifying/meeting following Technical and Financial capabilities are eligible to

participate in the bid for supply of 7nos. of EOT cranes. 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.

Bidder shall print, sign and stamp each page of proposal as token of acceptance & submit scanned

copy of the same along with the offer.

S.No Description of terms Bidders confirmation

1 Technical Qualification Requirements:

The bidder should meet the following technical qualifying

requirements a nd shall submit relevant certificates to establish his

credentials.

1.1 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 for

last 10 years in India. Necessary firm establishment certificate shall be

provided.

1.2 The firm should have successfully completed Design, Manufacture,

Installation, Testing and Commissioning of at least 1no. of double

girder EOT cranes during last 10years ending on 31.12.2018 of

capacity not less than 60 tons with a span of 12 m and above.

Bidder shall provide PO copies, relevant completion certificates

from the owners (end users) along with the submission of bid for

consideration of bid document.

1.3 The firm should have successfully completed Design, Manufacture,

and commissioning of EOT cranes with VVVF (VFD) drive, control

systems and fail safe mechanisms, hoist mechanism using

drum/barrel coupling of at least one no. of crane of capacity not less

than 60t in last 10 years. Bidder shall provide relevant certificates

and PO copies.

1.4 The firm should have facility to full load test and over load testing of

80t EOT crane (hoist and cross travel) at their factory.

1.5 The firm should have successfully completed Design, manufacture and

establishment of high capacity EOT cranes (60t and above) to the

satisfaction of reputed third party inspection agencies like M/s

MECON/ M.N.Dastur/Lloyds Register/ BV and DNV during last 10

years. Bidders shall provide relevant proof with certificates.

1.6 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 BQC.

2 Financial Qualification Requirements:

The bidder should also meet the following financial qualification

requirements:

2.1 The Bidder should have an annual turnover of not less than a value of

Rs.3crores per year on average for the last three financial years

ending 31-03-2018. Copy of audited Balance Sheets for last three

years have to be submitted.

Page ii

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.2.5 crores.

(or)

Two works of EOT cranes not less than: Rs.1.8crores (each)

Copies of PO`s shall be attached.

2.3 Bidder should possess a current Solvency Certificate from

Nationalized Bank for an amount of not less than Rs.1 crore.

2.4 IT/ TDS certificate shall be submitted with Loss & Profit for last

three years ending 31-03-2018. Copy of audited Balance Sheets for

last three years shall be provided.

2.5 Bidder shall submit audited statement of financial status for last 03

years.

II. The following documents shall be submitted along with the application for prequalification of Bid:

1. Duly filled “Questionnaire” signed by competent person, name, phone no and company seal.

2. List of documents of proof submitted along with BQC for S.No. 1 & 2.

3. 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.

III. 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.

TECHNICAL SPECIFICATION OF EOT CRANES (07Nos.)

M - 1

I

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

mentioning required details. Bidder can add more information and details, if required, by attaching

separate 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 cranes 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.

II

Bidder shall submit complete information asked in Qualification Criteria for qualifying for bid with all

information’s, 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.

III THE FOLLOWING INFORMATION/ DOCUMENTS SHALL BE SUBMITTED

ALONG WITH QUOTATION.

Confirm whether

attached & up loaded

in e-portal

III.a

Acceptance of Technical Specifications with Point-wise Specifications to all

points as given in this "Specification cum Compliance Statement" (given in

the following FORMAT). Bidder shall agree/accept for all technical

specifications/terms & conditions by filling acceptance columns and signing

conditions by filling acceptance columns and signing with company seal in all

the pages of this tender specifications.

III.b Bidder Qualification Criteria with duly furnished information, as given along with

this specifications.

III.c Schematic GA Diagram/ Clearance drawing of EOT Cranes showing major

dimensions & clearances as per following specifications.

III.d

Deviations with respect to specifications given below are not acceptable.

However, Bidder can submit / suggest improvements, if any, separately by

indicating the clause no. in this specifications.

III.e Bids/Quotations without above documents/Information, will not be considered

for evaluation and will be rejected.

SL.NO. DESCRIPTION ISRO-SHAR SPECIFICATION Bidder’s Confirmation

/ Acceptance

1

Scope of Work

Design, Manufacture, Inspection, Shop testing, Supply,

Erection, Commissioning and Performance proving of 7 nos.

of Flame proof, Top running, Double girder heavy duty

EOT cranes, along with LT gantry rails, power cable system as

per the following specifications, terms & conditions and in

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

codes and standards.


M - 2

1.1.A

Detailed Scope

of Work

1. 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, third

party inspection services, painting, load testing at

supplier works.

2. Packing, marking, loading on Trucks/ Trailers and safe

transportation of EOT cranes & other parts / items /

accessories from supplier site to SHAR site.

3. Erection of EOT cranes, Bridge rails, and LT Drag chain

power cable system at our site.

4. Testing & Commissioning of EOT Cranes shall be done as

per the Technical Specifications ,QAP & conditions and

also in accordance with latest editions of IS:3177, IS:807 &

relevant codes and standards.

5. 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, third

party inspection services, painting, load testing at

supplier works.

6. Packing, marking, loading on Trucks/ Trailers and safe

transportation of EOT cranes & other parts / items /

accessories from supplier site to SHAR site.

7. Erection of EOT cranes, Bridge rails, and LT Drag chain

power cable system at our site.

8. Testing & Commissioning of EOT Cranes shall be done as

per the Technical Specifications ,QAP & conditions and

also in accordance with latest editions of IS:3177, IS:807 &

relevant codes and standards.

1.1.B

Third party

inspection is in

the scope of

supplier

Arranging the third party inspection is in the scope of

supplier for the entire scope of work (Design approvals, Stage

inspections, & testing) as given above and as per QAP

enclosed. Supplier shall engage third party inspection agencies

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

DNV. The finalization of third party agency shall be done on

mutual agreement between ISRO and Supplier.

1.1.C General

EOT cranes shall meet requirements of these tender

specifications which contain different sections, and as per

relevant standards. In case of any difference / conflict

between various sections of specifications and to that of

standards, the stringent of all as per department

(purchaser’s) view shall be applicable.

1.1.D

VVVF Drive

Panels

Location

a) For Flameproof cranes (S. No. 1 to 3 of Cover Page)

VVVF panels shall be erected in a separate room at

ground level and cabling shall be done from this room to

the EOT cranes at gantry girder height.

b) For Normal(non-flameproof) Crane mentioned (S. No. 4)

the panel shall be mounted on the EOT Crane platform

only.


M - 3

1.2 Quantity of

Cranes

Cranes–1 (For HVM 1 & 2: Mixer Room, Flameproof 80t

capacity,02Nos.)

As mentioned in attached Table 2.

Cranes – 2 (For PMS–Premix Storage-2: Flameproof 50t

Capacity, 02Nos.) : As mentioned in attached Table 2.

NOTE: Both 50t Cranes travel in one facility bay on same

length of rails.

Cranes – 3 (For Bowl Cleaning -2: Flameproof 50t Capacity,

02Nos.): As mentioned in attached Table 2.

NOTE: Both 50t Cranes travel in one facility bay on same

length of rails.

Cranes – 4 (For HIL -3: Non-flameproof 40t Capacity, 01Nos.):

As mentioned in attached Table 2.

1.3

Hazardous area

conditions (For

FLP cranes)

EOT cranes shall be equipped with flame proof electrical

systems suitable for operating in hazardous area classified as

Zone1, Gas group IIA/IIB,T4 as per relevant IS/IEC standards.

1.4 Application

These EOT cranes are used for handling of dangerous/

hazardous materials like rocket flight hardware, rocket

motors, propellant containers, fuel/oxidizer powder tanks

etc., for positioning and assembly during processing of

space vehicles. In case of any failure of crane, there will be

heavy loss to property and life. Hence Supplier shall design,

manufacture and erect the cranes with emphasis on quality,

reliability and safety and shall ensure smooth & reliable

operation of cranes with long service life.

1.5

Usage period &

Desired life of

cranes

These EOT cranes will be put to use for 365 Days,

intermittent duty with Hoist CT, and LT movements. EOT

Cranes shall be designed for long service life with trouble

free operation.

1.6 Operating

Environment of

Cranes

Indoor, near to sea (i.e., saline atmosphere), with

ambient temperature 50ºC and with relative humidity 95%.

Weather conditions are tropical. Bidder shall consider

above while design of EOT cranes, electrical systems,

enclosures, painting of cranes and related parts.

2.0 MAIN PARAMETERS OF DG EOT CRANES (FLP – 6nos, & Normal – 01No.)

2.1 Type of Cranes Top running, Double girder, Flame proof/ Normal EOT

Cranes for Indoor use.

2.2 Class & Duty Structure Class-II ( M 5 ) duty as per IS: 807.

Mechanisms: Class – II (M5) as per IS:3177.

2.2.A

Duty Factor

(Cdf) for flame

proof Cranes/

Normal cranes

As cranes are used for handling dangerous materials, the

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

components in hoist motion.


M - 4

Cranes Description

2.3 EOT Cranes

capacities

80t (80,000kg) – 02 Nos.,

50t (50,000kg) – 02 Nos,

50t (50,000kg) – 02 Nos,

40t (40,000kg) – 01 No.

2.4 Span As mentioned in the cover page & table 2.

2.5 Lift of height

(above FFL) As mentioned in the cover page & table 2.

2.6

Distance from

Floor to top of

rail

As mentioned in the cover page & table 2.

2.7 Crane travel in

metre (LT) As mentioned in the cover page & table 2.

2.8 Operation Speeds (maximum) in m/min for both the cranes

i) Hoist in m/min Main-2.5/ Creep-0.25 (Through VVVF Drives).

ii) Long travel in

m/min

For 80t : Main-4.0/ Creep-0.4 (Through VVVF Drives).



iii) Cross travel in

m/min




iv) Creep speed

VVVF drives

Creep speed shall be provided through VVVF drives &

controls of make : M/s SIEMENS / M/s ABB

2.9 Side clearance (Distance from centre of gantry rail to nearest

obstruction) ~ 400 mm

2.10 Head Room

available

(Maximum) (Vertical distance from top of gantry rail to

lowest overhead obstruction) ~ 4.0meters

2.11 Hook

Approaches

EOT Cranes

CT: DSL side / Non DSL side: Refer Table 2

LT: Drive side / LT Non-Drive side: Refer Table 2

2.12 CT Wheel

diameter Not less than 400mm

2.13 LT Wheel

Diameter Not less than 500mm

2.14 Location of

VVVF Panels

a) For Flameproof cranes :

VVVF drive panels, DBR units, other electrical panels

shall be kept in separate room in ground level. Refer

clause no. 5.4 (h)

b) For Normal crane :

All panels shall be provided on the top of the crane i,e on

LT platforms .

2.15

Size of Cross

Travel Bridge

Girder Rail

Cranes CT Rails not less than CR-80 as per IS:3443. Only CR

rails shall be used.


M - 5

2.16

Size of Cranes

gantry rails for

Long Travel

Cranes LT Rails not less than CR-100 as per IS: 3443.

Only CR rails shall be used. LT Rails are in the Cranes

vendor's scope.

2.17 COMMON PARAMETERS FOR EOT CRANES

2.18

Number of

wheels for LT

drive

4

2.19 LT Drive

Horizontal type, Foot mounted, standard make gearboxes as

mentioned in the “Make of bought out items” shall be used.

Twin drive shall be for span above 15m.

2.20 Number of

wheels for

CT drive

4

2.21 CT Drive Central drive with Vertical type gearboxes of standard make

shall be used with proper lubrication arrangement for

gearbox.

2.22 Platform for

approach for

maintenance

of CT drive

Maintenance platform covered with chequered plate shall

be provided for maintenance of CT drive.

2.23 Type of bearings

for LT/CT wheels

Anti-friction, heavy duty double row Spherical Roller

Bearings.

2.24 Type of

mounting of

LT/CT wheels

"L" type brackets, fastened with fit bolts with nut and lock

nuts.

2.25

Operations

required

through

Floor operated pendant with down shop leads.

For 80t cranes plug in pendant on trolley shall be considered.

3 MECHANICAL ELEMENTS DESIGN & DETAILS

3.1 EOT cranes mechanisms components shall be designed for strength under case

I, II, III and IV loading conditions and load combinations as per clause no. 7.3.2

of IS:3177.

3.1.A Factor of safety and permissible stress shall be calculated as per clause no.

7.4.3 & 7.4.4 of IS: 3177 and technical specifications given and on the basis of

minimum ultimate tensile strength. However, for all load bearing mechanical

components’ factor of safety shall not less than 5 for case-I loading.

3.1.B Supplier shall consider above loading conditions & permissible stresses in

design of EOT Cranes and accordingly shall submit calculations for mechanism

components.

3.1.C The stresses in all components of hoist mechanism and gearboxes should

not exceed 66% of yield stress/proof stress of the material for the

component under break down conditions of motor i.e. pullout torque of

motor.


M - 6

3.1.D All mechanical components in Hoist (vertical load path), shall be designed for

infinite fatigue life. Fatigue analysis shall be based on the cranes maximum

rated load. Necessary calculations shall be submitted during detail engineering

as per code IS 3177.

3.1.E No cast iron part should be used /considered in mechanical load bearing

member on the cranes, except for electrical equipment. Similarly, wood or

combustible material and Bush bearing should not be used in any part of

the cranes.

3.2 Hoist hook type Forged, Single Shank Point hook with safety latch and Thrust

Bearing as per IS:3815 / IS:15560.

3.2 a Hook for 80t

cranes

High tensile steel grade point hook shall be used for 80t

crane hook. The dimensions of this point hook shall be

nearer to 50t hook (which is “L” grade). High tensile hook for

80t crane shall be imported, high quality of reputed makes

: M/s IRIZAR/ M/s CROSBY / M/s CM (STB).

3.2 b Hook for 80t

cranes

The hook dimensions of 80t shall be similar as far as

possible to the hook dimensions of 50t cranes as the

handling tackles and other fixtures are same for handling

with 80t crane & 50t cranes.

3.2 c Lubrication of

hook

Provision shall be made for lubrication of hook thrust

bearing and provide with dust cover.

3.3 Number of falls

for Hoist 08 (Eight).

3.4

Rope Drum

Rope Drum shall be of fabricated type made from steel

of IS: 2062 Grade ‘B’ and shall be duly stress relieved and

shall be made as per IS 3177.

3.5 Rope drum diameter shall be minimum 28 times the

diameter of wire rope.

3.5A

Rope Drum

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.

3.6

Rope drum shall be provided with not less than three dead

turns at each anchored end and at least one spare groove at

the other end. Grooves shall be finished smooth.

3.7

Rope dead ends shall be clamped with

minimum three clamping wedges with two numbers of bolts

on each clamp. The bolts shall be at the centre of clamp

and shall be wire locked.

3.7.A In the event of failure of drum shaft or bearing, the drum

must be retained on the trolley without falling.

3.8 Hoist wire rope

M/s USHA MARTIN make, Galvanized, 6x36, RHO lay,

core IWRC, Grade 1960MPa. Genuine wire rope shall be

used. No joints shall be used for wire ropes under this

specification.

3.8.A Factor of Safety

on wire rope Minimum Factor of safety on wire rope shall be 8 (eight)

on minimum breaking strength of wire rope.

3.9 Rope Sheaves

All sheaves shall be of forged steel only. Sheave

diameters shall be minimum 24 times rope diameter.

In the event of hook over travel, where the lower block

contacts the cranes trolley structure, the ropes shall not be

cut or crushed.


M - 7

All the sheaves shall be mounted above the trolley platform

with ease access to maintenance/repair and inspection.

All the top sheaves shall be positioned such that it can

be removed individually without removing other

components like equalizer pulley, rope drum etc.

3.9.1 Bearings for

Sheaves/ Pulleys

All the sheaves & pulleys shall be provided with standard

roller bearings of genuine make of SKF, FAG, INA, TIMKEN.

3.9.2 Lubrication of

Pulleys

Arrangement shall be provided for periodical

lubrication/ greasing of bearings.

Guards/covers shall be provided for all sheaves.

3.9.3 Equalizer

Pulley

Equalizer pulley shall be 18 to 20 times the wire rope

diameter and shall be mounted on swiveling arrangement.

3.9.4

Sheaves

1. Sheave grooves shall be machined smooth and support

wire rope uniformly at least 1360 angle of contact over

its circumference.

2. Wire rope fleet angle shall be not more than 2.50 for

sheaves.

3.10 Gear Boxes for

HOIST

Standard reputed make, Crane duty, Helical type, paralle

shaft, spilt type housing gearboxes, horizontal foot

mounted shall be used for hoist motion.

3.11 Gear Boxes for

CT & LT

Helical /Bevel helical, parallel shaft gearboxes of

Crane duty shall be used for CT & LT drives.

Vertical Gearboxes shall have an oil pump lubrication

system when vertical gearing exceeding three stages.

Tubing/ Piping for gearbox lubrication shall be

provided with SS316/SS304 and must be properly clamped.

No hoses shall be used. Visual indicator/ gauge for oil flow

shall be provided in line.

3.12

Standard make of

Gearboxes for all

motions of EOT

Cranes.

Makes shall be M/s. Elecon / Shanti Gears/ Premium-

GREAVES /Flender-Siemens only. Other makes & Own

make gearboxes are not acceptable.

3.12a Material of

gears & Pinions,

Shafts

All are Forged Alloy Steel / Case hardening steels, as per

standard manufacturer of gearboxes.

3.12b Torque rating of

Gearboxes/

Pinions/ Gears

1) Gearboxes selection shall consider starting torque of

motor (i.e., 2 times the full load torque) of selected

motors.

2) Due consideration shall be given for braking torque in

input shaft of Gearbox.

3) Service factor shall be 1.6 for hoist on the electrical

KW of selected motor.

4) Service factor shall be 1.5 for LT & CT on the

electrical KW of selected motor.


M - 8

5) The stresses in all components of hoisting machinery

& gearboxes should not exceed 66% of yield point

(proof stress) of the material for the components

under break down conditions of motor i.e., pull-out

torque of motor.

6) All the pinions shall be integral with the shafts.

7) Input shaft design calculations and torque rating

shall be considered with 2nos. of brakes for Hoist

Motion.

8) The noise level shall not be more than 80dBA during

the gearbox in operation measured at a distance of 1m

from gearbox.

3.12c

Details/

Drawings of

gearboxes

Drawings and Details of gear boxes, selection criteria,

Power rating & torque rating, materials, stresses

calculations, service factor, bearing details, data sheets

etc., shall be submitted for TPIA/ Purchaser for

approvals during design phase.

3.13 Gearboxes

construction

Gearboxes shall have fill and drain connections, Breathers,

lubricant level indicator, and shall have good accessibility

for checking, maintenance and oil filling.

The casings of gearboxes shall be made from

structural steel (IS:2062) and duly stress relieved.

No oil leakage is allowed from gearboxes. Oil drip pans

shall be provided around the gearbox.

Sufficient clearance need to be maintained between gear of

one stage to pinion of next stage of non- meshing sets to

avoid interference.

For hoist mechanism, the brake drum (02nos.) shall be

provided on each side of the input shaft of the gearbox.

Reliable oil seal arrangement i.e., double stage oil

sealing arrangement shall be provided for shafts of

gearboxes.

3.14 Brakes

3.15 Hoist Brakes Two nos. of imported electro hydraulic flameproof thruster

brakes with Manual release. Makes shall be M/s Witton

Kramer /M/s Bubenzer /M/s SIBRE /M/s GALVI. Thrusters

for brakes shall be Explosive Proof (Ex d), ATEX/ PTB

Certified. Make of thrusters: EMG, Germany or Brook

Crompton, UK, or Galvi. Explosion proof certificates shall be

submitted for Approvals during design phase.

3.16

Brake performance certificate, test certificate and Ex-Proof certificates shall

be provided from original manufacturer of brakes.

3.17

Hoist Brake

Rating

Torque rating of Each thruster brake shall be minimum 2

times motor full load torque. One of the hoist brake shall be

provided with operating delay in brake application from

brake to brake.

Minimum diameter of the brake drum shall be

Ø315mm for the hoist mechanism.


M - 9

3.18

Braking

distance/ brake

path

Hoist components and brake shall be selected such that

the braking distance for lowering motion as per IS 3177

with one brake at full rated speed. Necessary

calculations shall be submitted in this regard during

design phase.

3.19

Brakes for CT &

LT

For each motor, flame proof EHT brakes of M/s

Electromag/ M/s Kateel/ M/s Sterling Controls shall be

provided. Brakes shall be minimum 1.5 times full load

torque of selected motor.

Minimum brake drum diameter shall not be less than

Ø160mm.

3.20

Brake rating/

adjustment

for CT and LT

motions

In travel motion retardation with brakes shall not exceed

7cm/sec2. Necessary calculations shall be submitted in this

regard during design phase.

3.21 Brakes shall be mounted on the input pinion shaft of the gearboxes.

3.22 Brake Dru m

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

shall be completely machined and Static & dynamically

balanced. Hardness of surface of finished drum shall be 38-

43 Rc Width of the brake drum shall be 5 to 10mm more

than the width of the brake shoes.

3.23 Mounting of

equipment

All the gearboxes, motors, brakes, Wheel L brackets, bearing

pedestals, etc. shall be mounted on machined and leveled

surfaces. If shims are needed, only Stainless steel shims shall

be used.

3.24

Couplings

between

motor, brake

drum

Flexible Full geared couplings shall be used. Make of

Couplings shall be M/s Fenner only.

3.25

Couplings

between

gearbox and

rope drum for

hoist

Drum/ Barrel coupling of adequate rating shall be provided

between output shaft of hoist gearbox and rope drum

Make of drum/barrel coupling shall be M/s Malmedie /

M/s Jaure only.

Service factor of minimum 2.0 on the rated KW/ Full

Load torque of selected motor.

Selection criteria, calculations, service factor, Torque rating,

drawings shall be submitted for approval during design

phase.

3.26 Travel Wheels

All cranes wheels shall be made from forged steel like

C55Mn75 and minimum hardness shall be 300-350BHN

for a case depth of 10mm.

3.27 Travel Wheels

Wheels shall be double flanged with straight tread with

12 deg taper flanges with adequate flange thickness. Wheels

shall be accurately precision machined and shall be matched

in pairs with minimum deviations.

3.28 Drive shafts

Shafts shall be of forged steel C45. Angular

deflection of the shaft at torque corresponding to 1.33

motor rated torque during acceleration shall not

exceed 0.10deg./m of shaft length.


M - 10

3.29

Fasteners

Galvanized, high tensile fasteners of tensile quality 8.8 or

more shall be used in cranes parts, except for Fit bolts of

Girder.

Make of all fasteners shall be M/s TVS/ UNBRAKO/ LPS

only. Test certificates shall be provided.

Galvanizing shall be done by original manufacturer of

bolts.

3.29a Fasteners for

Couplings

High tensile Fit bolts (as per IS:3640) of Property class

min 8.8 shall be used for Couplings, and other power

transmission components as required.

3.30 Lubrication of

Cranes

Localized/ semi centralized lubrication system with easy

approach for all pedestal & pulley bearings, couplings,

wheel bearings etc., shall be used.

3.31

Maintenance

accessibility &

Safety

Safe access for maintenance and removal of all mechanical

and electrical parts must be ensured without any additional

scaffolding. All parts requiring replacement or inspection or

lubrication shall be easily accessible.

3.32 Keys & Keyways

All keys where ever used should be of parallel keys as per

IS:2048 (couplings / gearboxes / motor shafts).

Material of keys shall be 45C8 or alloy steel.

Proper fits and tolerances shall be used between key and

keyways; such that key should not get loosened in service

life. Key end arrestors shall be provided.

3.33 Bearings

Ball and roller antifriction bearings of approved make SKF /

TIMKEN / FAG 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

20,000hrs).

Special consideration shall be given to bearings which

operate at low speeds. Certified confirmation of the

bearings capacity at low speeds must be obtained from

the manufacturer during design phase.

All bearings shall be provided with proper lubrication and

means of lubrication. Mounting fits, tolerances and

clearances shall be as recommended by the bearing

manufacturer.

3.32 Bearing

Housings

All bearings housings shall be of STANDARD MAKE (SKF

/ FAG / TIMKEN) and made of cast steel or forged steel

or fabricated steel bolted to a rigid portion of cranes

structure by minimum 4 bolts. Housings shall be 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.

4.0 STRUCTURAL DETAILS OF EOT CRANES

4.1

Design of

structural work

The cranes should be rigid, robust and of sturdy

construction. The design of all structures shall be done

as per IS: 807 - Class –II (M5) and as per this technical

specifications.


M - 11

4.2

Material of

structural

items.

All the structural plates used in fabrication of Girders,

Trolleys and End carriages, etc., shall be of minimum

8mm thick of IS:2062. .TPIA stamping, heat no., lot no. and

standard makes mentioned in the annexure shall be made

available.

4.2.1 Platform cover

plates

M.S Chequered plates for trolley and platforms’

covering shall be minimum of 6mm.

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

construction having maximum rigidity.

4.4 Deflection of

Girders

The bridge girders shall not deflect more than

1/1000 of span with safe working load on the trolley,

with trolley stationed at mid span and excluding

deflection due to dead load.

4.5 Girder Joints

No splice joint 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.

4.6

Ratio of

span to

depth

For Box Girders Span to Depth ratio shall not exceed 18.

Accordingly other ratios as per heavy duty cranes shall be

selected as per standards.

4.7 Local Buckling

of top flange

Local buckling of top flange and compression

members shall be considered. Adequate top flange

thickness of not less than 20mm and bottom flange of

thickness of not less than 16mm shall be provided for

heavy duty structures/ girders and necessary calculation

shall be submitted for approval.

4.8 End Carriages

End carriage shall be fabricated as solid box section made

from rolled steel plates IS2062, except for essential

openings which shall be reinforced.

4.9 Structural bolted

Joints

Fit Bolts (as per IS3640 ) with property class 5.6 and reamed

holes shall be used for all structural joints between girder,

& end carriages, wheel L- bracket & end carriages etc.,

4.10 Trolley

The trolley frame shall be built up of rolled sections and

box sections to form a rigid structure and shall be arranged

to afford maximum accessibility to mechanical and electrical

parts placed on it.

The trolley frame shall be of highly rigid construction

such that lifted loads do not cause deflections that

impair the proper operation of machinery.

No parts shall be mounted under the trolley except for the

gravity limit switch weight. Top pulley block and all other

pulleys, equalizer pulley, fitments shall be mounted on the

top of trolley platform only.

4.11 Top chequered

plate of trolley

The top of the trolley frame shall be fully covered with 6mm

chequered plate all over except for openings required for

the ropes for bottom block etc., to pass.

Trolley and top pulley block shall be designed such that

at the highest position of hook there shall be a clear

distance of 700 mm between the lowest point of trolley

obstruction and the highest point of bottom block.


M - 12

4.12

Safe distance

Between trolley

& top pulley

block

Safe access for maintenance and removal of all mechanical

and electrical parts must be ensured without any additional

scaffolding.

All parts requiring replacement or inspection or lubrication

shall be easily accessible without the need for dismantling

of other equipments or structures.

4.13

CT

maintenance

platform

Maintenance platform covered with chequered plate shall

be provided under the CT mechanism (i.e below CT

gearbox). Access shall be there for draining of oil.

4.14 Hand rails for

trolley

Handrails of 1000mm height shall be provided on all the

four sides of the trolley.

4.15 CT rail wear

plate

Full length wearing plate of minimum 8mm should be

provided under the trolley rails and should be 10 to

12mm lesser in width than the rail base as per IS 807.

4.16 CT rail welding

CT rails shall be made continuous by welding standard

lengths. Welding shall be done as per standard procedure

approved by Third Party Inspection Agency / purchaser.

4.17 CT & LT rail

clamping

CT & LT Cranes rails shall be clamped to the girders with

double bolt clamping plates of M/s GANTREX / M/s

GANTRAIL make. The rail clamps shall be spaced not more

than 450mm apart.

4.18 Rail Clamps for

CT & LT rails

All the rail clamps & fasteners shall be of standard make

of M/s GANTREX/ M/s GANTRAIL.

4.19 Rail stoppers

/Wheel ramps

CT & LT Rails shall be prevented from creeping in the

longitudinal direction by welded rail stops and Wheel

ramps.

4.20 Jacking pads

Suitable jacking pads should be provided on end carriages

and trolley for jacking up the cranes for changing track

wheels.

4.21 Safety Pads

Safety pads shall be provided under the end carriages and

trolley to prevent the cranes from falling more than 25mm

in the event of breakage of a track wheel/axle.

4.22 End buffers Spring buffers of rated capacity shall be provided for long

travel and cross travel.

4.23 Metric

Component

All components including fasteners should be in metric

system only.

4.24 Locking of

fasteners

Bolts in rotating parts shall be locked with spring

washers and lock nuts.

All couplings and brake drums shall be provided with “Fit”

type bolts.

4.25

Make of

steel raw

materials

All the structural raw materials (plates, angles, beams) shall

be of NEW and fresh lot and of reputed make of M/s SAIL/

M/s JINDAL/ M/s ESSAR/ M/s TATA STEEL only.

4.26 Welded joints

All butt joints shall be 100% radiographed for both

compression and tension joints and in flanges / Webs. All

other welds shall be DP tested.


M - 13

4.27 Platforms

Full length chequered platform of width 750mm shall be

provided on both bridge Girders with hand rails of height

1000mm. The platforms shall be bolt jointed.

4.28 Toe guards Toe guards shall be provided for all openings, on trolley

and on bridge platforms with minimum height of 100mm.

4.29

Machine

bases on

trolley/ LT

platform

Parts of steel frames carrying machinery should be provided

with doubling plates (including stiffeners) of adequate

thickness welded and machined to true surface.

All the drive system bases shall be made rigid to take all the

loads.

4.30

Protection

Guards for

rotating

equipment

Guards: All the moving parts should be duly covered with

guards as per safety norm. Proper guard / cover / tray

to prevent falling of bolts from coupling etc should also be

provided, wherever required.

4.31

Welded snugs shall be fitted against the feet of all pedestals, gearboxes,

brakes etc., except motors. Motors shall be provided with alignment screws

for side alignment.

4.32 Ladders

4.32.1 Approach Ladders shall be provided from catwalk to end carriage and to LT

platforms in all four corners.

4.32.2 Approach ladders to be provided for reaching the trolley at two

locations along the span of the girder.

4.33

Protection

Guards for

rotating

equipment

Guards: All the moving parts couplings, shafts shall 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.

4.34 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 EOT CRANES (07Nos.)

E - 1

ISRO/SHAR Technical Specification Bidder’s Confirmation

/ Acceptance

5 ELECTRICAL SYSTEMS (FOR FLAMEPROOF CRANES)

5.1 Electrical Equipment Environment

a)

Items supplied should be suitable for Hazardous Area:

Zone1, Gas Group IIA/IIB, T4 as per IS5572, IS 5571, IS 2148 and IS

5780 or equivalent IEC standards.

b) Item supplied should be suitable for tropical and humid climate:

Temperature of 50°C & RH not less than 95%.

c)

De-rating:

All the drive motors, power cables etc., shall be done for ambient

temperature of 50°C.

d) Item supplied should be suitable for the following power supply variation:

Voltage ±10 % and Frequency ±3 %.

5.2 Voltage

a) Power supply to motors:

3 Ph, 4 Wire, 415 V AC ± 10%, 50 Hz ± 3%.

b)

Control Voltage inside the Electrical Panel:

1 Ph, 2 Wire, 110 V AC for all contactors, relay, indication lamps, etc.

1 Ph, 3 Wire, 230 V AC for all lights, power sockets, etc.

24 V, DC supply for Drive auxiliary supply (if required).

c) Control Voltage in the Pendant push button:

8.9 V, Intrinsic safe supply (interfaced to hazardous to safe area).

5.3 Electric Motor

a)

Should accept the input from VVVF drive, 60% CDF, min of with 300 starts

per hours, IP55, Inverter Duty, Class ‘F’ insulation, suitable for hazardous

area mentioned above.

b) Hoist motor shall have a provision to connect encoder in its shaft.

c) Rating of the CT and LT motors shall be of same and it shall be selected

based on higher rating within CT and LT motors.

d) Terminal blocks of all

motors

1. Preferably on top of the motor

2. Wherever it is on the side of the motor, a

minimum clearance of 600 mm (without

affecting hook approaches) to be

maintained to approach for maintenance.

e) Thermistor

1. All the motors shall be housed with inbuilt

THERMISTOR. (For CT and LT motors only,

TRIP Thermistor alone shall be provided)

2. Independent thermistor relay need to be

used. The relay shall have a provision of

NO / NC contacts and remote resetting.

3. Alarm (Only Hoist motor) and Trip (All

motors) input to be wired separately as

an input to VVVF control unit.

4. Protection like switch OFF / TRIP the

motor in case of increase in surface

temperature more than T4 classification.

f) Bearing

1. Type: ‘ZZ’ bearing.

2. If not suitable lubrication provision to be

provided.

3. Insulated bearing to be used in case of

motor rating more than 55 kW.

g) Torque rating of Motors 1. Pull out torque of motors shall be not less

than 2.75 times of full load torque.


E - 2

2. Motor full load torque rating shall be

minimum 120% of calculated torque with

duty factors as per IS: 3177.

h) Speed rating of Motors Shall be of 750 RPM.

i) Current drawn by the

Motors

Maximum Current drawn by all motors (rating

more than 2 hP) with SWL should not exceed

80 % of the full load rated current even at

slower speeds.

j) Over load capability

150% of full load current for 2 minutes

without damage or permanent deformation

from zero to base speed.

5.4 VVVF Drives

The power (kW) rating of VVVF drive shall be

one step higher than the selected motor

electrical power (kW).

a) Main Hoist Drive

1. Shall be supplied with 2 Nos. (1 Working;

1 Standby).

2. Three positions-maintained selector

switches shall be provided for the above

selection.

3. The selected drive shall be indicated by

means of indication lamp.

4. It shall have a provision for

communicating either via. PROFINET /

Ethernet protocol.

b) CT & LT Drives

1. Shall be supplied with 1 No. (1 Working)

for CT and 1 No. for LT.

2. Shall be supplied with 1 No. of common

spare for both CT & LT Drive.

3. Common spare drive shall be selected by

selector switch.

4. All the necessary interlock, inputs and

outputs shall be wired in the common

control unit.

5. The selected drive input and output

power isolation need to be interlocked

with chosen drive (for which it is standby)

input and output power.

6. It shall have a provision for

communicating to the automation

system via. PROFINET / Ethernet

protocol.

c) Drive Control Unit

1. Shall be supplied with 2 Nos. (1 Working;

1 Standby) for all Motion Drives.

2. Three positions-maintained selector

switches shall be provided for the above

selection.

3. The selected control unit shall be

indicated by means of indication lamp if

it can be connected as onboard and

wired.


E - 3

d) DI & DOs

20 % additional DI / DOs in control unit with

respect to the used/assigned terminals for

future usage. The same will be counted after

completing the commissioning of the EOT

crane at site.

e) Operator Panel

1. Combined (One for MH, CT and LT

Motors together) advanced operator

panel need to be provided on the panel

door. (Qty: 2 Nos. 1 Working + 1 Standby)

2. Operator panel shall be capable of

commissioning the individual drive.

3. Provided with fault history read and

logging facility.

4. It needs to be mounted on the panel

door.

f) Drive Software

1. Suitable software need to be supplied

along with drive.

2. Supplied software shall have a valid

license for its operation and the same

shall be accessible for entire program

structure of the drive.

3. This software to be loaded on the laptop

(laptop is in the scope of department).

Suitable software if any also needs to be

installed.

4. Drive communication cable suitable for

support either USB or RJ45 of the laptop

need to be supplied.

g) Make & Model of VVVF

Drives

1. M/s SIEMENS: S-120.

2. M/s ABB: ACS 880.

h) Location of Panel

1. Identified in the safe area in ground level

in a separate room at floor level for FLP

cranes.

2. Cable Lengths shall be considered from

VVVF Panel Room to Junction box and

Junction Box to top of EOT Crane as

mentioned in the Specifications Booklet.

3. Approximate distance from VVVF panel

room to gantry girder level is ~40m for

each crane.

4. All the cables routing from panel room to

plug-in pendants (for 80t cranes) and

supply to the top of the EOT crane must be

done through the perforated cable trays

with G.I. coated.

5. All the cable distances mentioned in the

Specification Booklet are as per the

routing provision provided as per the site

requirement.

5.5 Input and Output Choke

Suitable input choke for controlling the

harmonics and output choke for reducing

dv/dt and terminal peak voltages at MOTOR.

5.6 Dynamic Braking Resistor

1. DBR of suitable capacity/rating shall be

provided to all VVVF drives (in feed re-

generative model shall not be selected).


E - 4

2. 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.

3. Necessary forced cooling needs to be

planned. Controlling of the cooling fans

needs to be linked with control supply

ON.

5.7 Dynamic Braking Unit

Suitable rated Dynamic Braking Unit (DBU)

need to be provided for individual drives

including spare VVVF drive.

5.8 Encoder for MH Motor

Flame proof hollow shaft incremental

encoder - To be used to achieve vector control

mode of operation for Hoist application.

All Encoders signals shall be suitable for VVVF

drive input.

Screened cable as per manufacturer

(Encoder) recommendations shall be used for

all encoders. It shall be of M/s LAPP or M/s

IGUS make cable only.

The supplied encoder shall have a provision to

send two signals from the single encoder.

Encoder shall have a terminal strip

termination for connecting the cables.

5.9 Brakes Control

All the brakes shall be supplied with OPEN /

CLOSE limit switches.

The same shall be wired individually up to

panel to enable for the interlocks. Nowhere it

shall be combined till intrinsic safe isolator at

panel.

All the brakes need to be powered with

suitable rated Motor Protection Circuit

Breaker (MPCB)

5.10 Scheme to be followed for powering the Brakes

a) All Brakes

1. Logic for operation:

a. Opening: Monitoring min. of 20% of

current built in the motor.

b. Closing: Monitoring min. of 0%

speed of the motor.

2. No. of power contactor: 2 Nos. per brake

(only for MH Motor)

3. Controlling of power contactor:

a. One no. of digital output/ contactor

from the control unit.

b. One no. of intrinsic safe relay/

contactor.

4. All the brake contactor status needs to be

monitored.

5. In case of any one power contactor got

welded/fused, the system has to operate

with flashing indication.

6. If both the power contactors got

welded/fused, main (line) contactor need


E - 5

to be switched OFF.

7. Similarly, MPCB trip status needs to be

wired as one digital input to control unit

for logic evaluation.

5.11 Limit Switches

1. Gravity Limit switch: Should control the

Entire power supply of the crane. (Qty: 1

No. for MH)

2. Rotary Limit switch: Should control the

Hoist motion of the crane. It shall have a

4 NC points. (Qty: 1 No. for MH)

3. 2-Way Lever Limit switch: Should control

the Cross Travel and Long Travel of the

crane. (Qty: 4 Nos. – 2 Nos. for each CT

and LT)

4. Door Limit switch: Should control the

panel lighting of the VVVF Drive panel.

Qty: As per panel design

5. Individual limit status need to be wired

individually and it shall not be looped in

series till intrinsic safe isolator point at

panel.

5.12 Junction Boxes

a) Flame Proof Junction

Boxes

1. FLP junction boxes need to be planned for

inter facing of all the equipment which are

powered not through intrinsic safe supply

(i.e., > 8.9 V)

2. All the terminal inside this box shall have

a provision for connecting ring type lugs

only.

3. The probable locations of the JBs are

a. Crane LT Girder.

b. Crane Platform.

c. Crane Trolley / platform.

4. Make: M/s FEPL / M/s BALIGA / M/s FCG /

M/s STAHL.

b) Non-Flame Proof Junction

Boxes

1. Non-FLP junction boxes need to be

planned for inter facing of all the

equipment which are powered through

intrinsic safe supply (i.e., pendant control,

limit switches, etc)

2. The probable locations of the JBs are

a. Crane LT Girder.

b. Crane Platform.

c. Crane Trolley / platform.

3. Make: M/s Rittal / M/s President.

5.13 Power Socket

1. On the Crane: Each side of the LT platform

1 No. of 1 phase, 230 Volts AC FLP switch

cum socket with plug top with necessary

isolating switch / MCB inside the panel.

2. Inside the Panel: 1 No. of 230 V AC power

sockets with ON / OFF switch for all the

panels.

5.14 Light Fittings & Bell 1. On the Crane:


E - 6

a. Under slung FLP, 150 Watts LED light

fitting need to be planned. Qty: 4 Nos.

b. FLP bell need to be planned. Qty: 1

No.

2. Inside the Panel: 1 No. of 230 V AC LED

light fittings need to be planned for all the

panels.

3. Make of LED light fitting: BALIGA

5.15

Pendant (Plug in Pendant

– Only for Mixer Cranes

80T)

Push Button Station (PBS):

1. Shall be provided with Key way switch

Lockable at OFF (used for Control ON),

Mush room head Emergency OFF.

2. Control ON & OFF indication lamp

powered through Intrinsic Safe circuit.

3. Shall be provided with push buttons for

controlling main and creep of all motions.

i.e., Hoist: UP/down; CT: right/left; LT:

forward/reverse and bell

4. All the push buttons materials shall be of

stainless steel.

5. All the push button commands to be

routed through 1NO + 3 NC auxiliary

contactor.

6. Shall also provide with 2-way Switch for

Under Bridge Lights.

7. Minimum 30 % Spare Core shall be

provided in PBS with respect to the used

cores.

8. All push buttons are to be powered

through intrinsic safe module only apart

from other control elements like limit

switch, etc.,

9. Enclosure and Chain for the pendant shall

be Stainless-steel.

Connection to pendent:

1. Trailing cable supported on anti-friction

bearings wheeled trolleys.

2. The pendant control cables are to be

routed properly in suitable cable trays

along the building structure.

Push button Station Type: Either push button

station supported by trailing cable or of

movable trolley.

5.16 Cables All the cables need to laid and end-terminated

as per the site requirement.

a) Encoder Cable

The following cables need to be supplied:

1. The Encoder cables shall be minimum of 8

cores only.

2. The cable shall be of screened cables and

it should have the provision of connecting

the shield to earth.

3. There is ‘NO’ joint of cable is allowed

between the panel end to the encoder

end. Hence, cable shall be of flexible cable

only.


E - 7

4. Qty of cable with full length: 2 Nos. To be

connected to both the signals of the

proposed encoder.

5. Make: M/s LAPP or M/s IGUS

b) Power Cables

The following area cables need to be supplied:

1. All the power cables shall be of 4 core

only.

2. Minimum size shall be of 4 sq.mm.

3. The cable running between panel to field

equipment, other than the cable running

in Drag Chain are of 1.1 kV Grade, XLPE

insulated, copper conductor, G.I.

armoured cables only.

4. From power supply source at SDSC SHAR

to Protective Panel Incomer. Distance: ≈50

mtrs.

5. From Protective panel to all the other

panels, field equipments like motor,

brakes, lights, bell, etc.

Power cables towards the motors are to be

selected as follows:

1. Selected / approved motor electrical kW

and rated current to be selected for the

voltage drop calculation.

2. Maximum 3% of Voltage drop only will be

accepted in the selected cables.

3. Incomer cables rating to be considered for

maximum of three different motions

along with EOT Crane lights and other

transformers loads.

c) Control Cables

The following area cables need to be supplied:

1. All the control cables shall be minimum of

12 core which are running between

junction box to junction box and panel.

2. The cable running between panel to field

equipment, other than the cable running

in Drag Chain are of 1.1 kV Grade, XLPE

insulated, copper conductor, G.I.

armoured cables only.

3. From Protective panel to all the other

panels, field equipment like brake limit

switches, various limit switches, pendant,

etc.

4. Out of used cores, 30% of core shall be

kept as spare with respect to each size of

the cables from panel to junction boxes.

d) Cable Identification

1. Cable tags indicating the source and

destination to be provided for all the

cables.

2. The ferrules shall be of ring type and of

non-deteriorating material.

e) Inside the panel

The following cable management to the

planned:

1. Power circuit – Minimum size: 4 Sq.mm

2. Control circuit – Minimum size: 2.5 Sq.mm


E - 8

3. Signal wire (for Control Unit and Encoder

module) - Maximum size: 0.5 Sq.mm

4. Colour coding should be followed as:

b. 110 V AC Phase – Grey without sleeve.

c. 240 V AC Phase – Grey with RED

sleeve.

d. 110 V &240 V AC Neutral– Grey with

BLACK sleeve.

e. 415 V AC – Black with RED, YELLOW,

BLUE and / BLACK.

f. 24 V DC Positive– Red.

g. 24 V DC Negative– Blue.

h. 8.9 V DC – Orange.

i. Signal cable – As per the standard of

LAPP/IGUS cable.

j. Earth cable – Green & Yellow.

3. All the limit switch terminals (Hoist, CT, LT

and Brakes, etc) need to be wired up to

the terminal block of the VVVF panel.

4. Interconnecting / looping of above

terminals need to be carried out in the

VVVF panel intrinsic safe module

terminals only.

5. Interconnecting of above terminals in the

equipment’s and bringing the common

terminals to the VVVF panel is not

acceptable.

f) Earthing

The following area cables/strips need to be

supplied:

1. Earth strip (min. 25 x 6 mm) need to be

supplied.

2. LT Rail at both the sides of the crane needs

to be earthed.

3. All the equipment including the

mechanical structure needs to be

grounded effectively with double

earthing.

4. Suitable bridge clamp need to be

positioned on the crane for tapping of

earth points.

5. Panel shall be provided with earthing

provision at both the ends. Same shall be

connected with plant earth (which is 20

mtr. away from the panel location).


E - 9

g) Drag Chain

1. Drag chain need to be planned for LT and

CT motions.

2. Necessary supports (like beam / angles,

guided cable tray, etc) for running the

drag chain along the LT and CT motions

need to be supplied.

3. Maintenance cage (LT) shall be provided

for attending the drag chain maintenance.

4. All the cables running inside the drag

chain are of same make as that of the drag

chain.

5. Make: M/s IGUS / M/s LAPP.

5.17 MCCB

1. Protective Panel - MCCB with adjustable

overload, adjustable short circuit

protection, adjustable ground fault and

Instantaneous protection to be provided.

2. Protective Panel - MCCB handle (door

operated) shall have an illumination kit for

indicating ON / OFF / TRIP.

5.18 MCB

1. Voltage input to the Multifunction meter

shall be routed through 4-pole MCB

2. Individual components control shall be

planned by a dedicated MCB control.

3. All the MCBs shall have the provision for

ON, OFF and Alarm contact provisions.

The same shall be wired for the control

logics (to meet the logical operation).

5.19 Switch Dis-connector

Fuse (SDF) unit

1. All motion Panel - Switch Dis-connector

Fuse unit shall be provided.

2. All SDF to be provided with semi-conductor

fuse with fuse indication cum monitoring

device.

3. All SDF to be provided with auxiliary switch

to ensure the ON / OFF status of SDF Unit.

Same to be wired up to drive input to

enable the drive for operation.

4. All the semi-conductor fusing indication to

be wired as the drive input in series with

the above point to enable the drive for

operation.

5. All the isolating switches are to be provided

with door interlocking and defeating

provision.

6. All the isolating switches (either MCCB /

SDF) are to be located uniformly in the

height of from FFL.

5.20 Fuses

Hoist, CT and LT power supply to VVVF drives

to be routed through Semiconductor fast

acting Fuses or as per the Drive

manufacturer’s recommendation of adequate

rating. Fuses shall have an indicator for fusing.

5.21 Cable Tray 1. Perforated G.I. cable trays need to be


E - 10

planned for routing the cables from the

panel to top of the crane.

2. Necessary supports (like beam/ angles,

etc) for running the cable tray inside the

trench (bottom of the panel), on the wall,

on the crane, etc need to be supplied.

3. Entire length of the cable trays need to be

covered with G.I. sheet cover with bolts

and nuts and all bolts and nuts shall be of

G.I coated.

4. No cables are routed without cable trays

and cover anywhere from panel room to

top of the crane.

5. The cable trays are also to be earthed

with respect to the common ground.

6. Aluminum strip shall not be used for

earthing the cable tray. Only G.I strip

alone shall be used.

7. All the cables routing from panel room to

plug-in pendants and supply to the top of

the EOT crane must be done through the

perforated cable trays with G.I. coated.

8. The cable tray shall have the width of 300

mm.

9. Length of all the cable trays shall meet

above specified cable lengths and for

each crane cable.

5.22 Motor Protection Circuit

Breaker (MPCB)

1. Rating shall be selected as per the type-2

co-ordination chart with respect to fuse-

less feeder.

2. All the brakes need to be powered with

suitable rated motor protection circuit

breaker.

3. To be provided for each motor where the

output of single VVVF drive is driving two

or more nos. of motors.

4. Trip status to be wired as one no. of Digital

Input to control unit to create logic as per

the user requirement.

5. ON/OFF status also to be wired as one no.

of Digital Input to control unit to create

logic as per the user requirement.

6. More than 1 motor shall not be powered

through single MPCB.

5.23 Contactor

a) Auxiliary Contactor

1. Shall be used as intermediate contactors

to the power contactors.

2. All the field interlocks need to be wired to

the auxiliary contactor level.

3. Suitable surge suppressor need to be

supplied along with auxiliary contactor.

4. It shall be utilized for contact

multiplication instead of add-on NO, NC

contacts for power and auxiliary

contactor.


E - 11

b) Power Contactors

1. Duty: AC-3

2. The contactors shall be able to withstand

their rated current for one second without

welding / fusing of the contacts

3. Individual Power Contactors are to be

provided for each motion for controlling.

4. All the power contactors need to be

powered viz. auxiliary or interposing

contactors / relays with suitable rating

along with surge suppressor.

5. Any multiplication of NO, NC points –

auxiliary contactor need to utilize.

6. NO add-on blocks will be allowed for

power contactors.

7. Suitable power isolation (both input and

output side) using this power contactors

need to be planned for the selection of

spare drives.

5.24 Intrinsic Safe Relay

Input Relay:

1. All the field signals like pendant push

button, limit switches (motion & status) to

be wired to this relay.

2. This relay shall be located in safe area

(inside the panel) only. Make: M/s P&F

3. All this relay shall be selected to suitable

for operating with 110V AC supply.

Output Relay:

1. These relay shall be used for powering

indication lamps in the hazardous

location.

2. This relay shall be located in safe area

(inside the panel) only. Make: M/s P&F

3. All this relay shall be selected to suitable

for operating with 110V AC supply.

Interlock:

1. All the output commands from control

unit shall be directly given as the input of

this relay.

2. All the interlock wiring (if required) as per

the logic need to be carried out in this

relay itself.

3. No relay board shall be used for creating

any interlock inside the panel.

Make: P&F only (both input and output relays)

5.25 Panel

a)

Individual panel (without patrician between panel) to be planned towards

effective utilization of panel AC. Make: M/s Rittal/ M/s President (both

panel and AC)

Protective Panel (1 No.), Hoist Panel (4 Nos.), Hoist control panel (1 No.)

Aux. Hoist Panel (1 No.), CT Panel (1 No.), LT Panel (2 Nos.), Common

control panel for Aux. Hoist, CT and LT (1 No.) - (all together in a same

panel), Control & Lighting Transformer Panel (1 No.) & DBR Panel – All the

panels height shall be maintained and the same need to be get it cleared

from department before ordering the panel.


E - 12

b) Protective panel shall be provided with mushroom head emergency switch

to disable power supply during maintenance

c) Painting

1. Paint shade – RAL 7032 / 7035.

2. Base frame – Matt black.

3. Mounting plate – Orange.

d) Indication Lamps

1. It shall be of cluster LED provided with

translucent lamp covers

2. Cluster LED module shall be suitable for

direct operation on 230 V / 110 V, 50 Hz

AC or 24 V DC.

3. Panel shall have the 3-phase indication

lamps in the metering cubicle controlled

by 3-pole MCB.

e) Design & Construction

1. Enclosure – Indoor, Floor mounting, Front

operated free standing

2. Frame, Mounting plates, Doors & Covers –

2.0 mm Thickness CRCA

3. Lifting arrangements - Suitable Lifting

Arrangement shall be provided for each

panel on the Top on all four sides

4. Base frame – ISMC 100 x 50 with Matt

black

5. Glass door – shall be provided in the

overall control panel (where control unit,

communicating systems, IS barriers,

contactors, etc is arranged)

6. Degree of protection – IP 54.

7. Shrouding – As per standard (to be

provided inside the panel, in front of

power components and power terminals).

8. Cable entry (power and control) – bottom.

9. The panels to be provided with panel A/C

along with water drain hose of sufficient

length (min. 2 mtrs)

10. The panels need to be provided with panel

lamps (LED) along with door limit

switches.

f) Name Plate (Panel and

components)

1. Material – Transparent acrylic.

2. Colour of letter – white letter in black

background.

g) Earth busbar

1. Size – Minimum '30 X 10 Cu' with nuts,

bolts & washers at each end is to be

provided per panel

2. Necessary earth strip need to be supplied

for the following

a. To link panel to rail at the gantry

girder.

b. To link rail and all the electrical

elements on the EOT Crane.

c. To link the panel to the earth strip.

h) SMPS

1. 24 V DC power supply to be provided (2

Nos.)

2. Shall be used as common supply to all the

motion including protective panel.

3. ORing diode needs to be supplied.


E - 13

4. The DC power supply failure shall be

noticed via. Digital inputs.

5. If either the SMPS or ORing diode fails a 24

V DC missing indication lamp need to be

provided.

6. Qty: 2 Nos.

i) Multifunction meter

1. Panel shall be provided with Multifunction

meter

2. Along with Add-on DI / DO modules – 1

No.

3. Communication: PROFINET modules

4. Make: M/s SIEMENS; Model: PAC 4200

j) Terminal blocks

1. Terminal blocks shall be of 750 Volts grade

of the stud type and shrouded.

2. Insulating barriers shall be provided

between adjacent terminals.

3. All the terminal blocks are grouped with

respect to the following:

a. 24 V Power distribution (separately

for positive and negative).

b. 110 V Power distribution (separately

for phase and neutral).

c. 230 V Power distribution (separately

for phase and neutral).

d. 415 V Power distribution if any

e. Motor and brake power distribution

4. Short linked Terminal blocks are to be

used for terminal multiplication. More

than one wires need to be avoided in one

terminal block.

5. VVVF Drive Control unit wires

multiplication also shall be carrying out in

a separate and identified terminal blocks

only.

6. All future interlocks to be provided with

permanent shorting link

7. Interlocking between the panels is to be

routed through respective panel terminal

blocks only. Direct wiring between the

components of two different panels to be

avoided.

8. Power & Control circuit –Ring type end

termination of suitable size

9. All the terminals needs to be provided

with group markers

10. 25% Spare Terminals Shall be provided for

both Power and Control in each Panel

11. Make: Connectwell / Wago / Elmex

k) Panel Space Heater

1. Panel Space heater is to be mounted in

such a way that, Power & Control Cables

must not run in close vicinity of it.

2. All the Panels shall be provided with space

heaters to avoid moisture condensation.

3. Necessary thermostat need to be supplied

along with the space heaters.


E - 14

4. ON / OFF Control of space heaters shall be

interlocked with main contactor. i.e.,

whenever main contactor is in OFF

condition, power shall be available at

space heater terminals.

l) Rubber mats

1. Rubber mats to be supplied and provided

in-front of all the panels as per the

designed length of panels including

Transformer and DBR panels.

2. The length to be supplied is 30 mtrs.

3. Class ‘A’, 3.3 kV ac (rms), 2.0mm ± 10%

thickness as per IS 15652/2006

4. Width: 1 mtrs. (maximum)

m) Layout details

1. 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

2. Selector switches, indication lamps and

operator panel needs to be provided on

the panel door

3. Routing of Signal & Power/Control cables

is to be done separately wherever possible

4. All Communication cables shall be routed

through wire channel

5. Shield of all Signal Cables is to be properly

clamped to Body of the Device/structure.

5.26 Documents to be submitted during Detail Design Review and clearance:

a) Motors

1. No. of motors, Power of motor, Frame

size, make, duty, no. of starts/hr, type and

No. of poles, Insulation, Amb. temp,

applicable IS for construction, bearing,

accessories, terminal position from drive

end, drawing nos. used for FLP

certification, etc.

2. Torque and speed curves, thermal

withstand time curve, efficiency and

power factor with respect to loading of

the motor, speed and time with respect to

current and complete G.A of motor,

terminal box / boxes by mentioning the

approved drawing reference and nos.

b) Test Reports

1. Flame proof electrical fittings / equipment

test reports along with approved drawings

(Either by CIMFR / ERTL (E)) with respect

to all the annexure and amendment if

available need to be submitted for review

and acceptance of all FLP items.

2. Space heaters and its thermostat.

3. Transformers.

4. Dynamic Braking Resistor.

5. VVVF Drives and its components.

6. Certificate for obsolesce for all the major

electrical items with not less than 15 years

from the date of acceptance of the crane.


E - 15

c) Sizing Calculation

1. Control Transformer (with considering

closed VA).

2. Lighting Transformer.

3. Dynamic Braking Resistor.

4. SMPS with and without loading.

5. Power Cables and its schedule.

6. Control Cables with respect to no. of

cores.

7. Heat loss calculation towards panel AC

selection.

d) Technical Catalogue / data

sheets

1. VVVF Drives.

2. Switchgear components.

3. Power and Control Cables.

4. Encoder.

5. Cable Drag chain and its cables.

6. Limit switches.

7. Intrinsic safe relays.

8. Panel.

5.27 To be considered during Detailed Engineering:

a) Panel

1. All the panels are to be maintained the

uniform height. Height of the panel not

less than 2000 mm excluding the base

frame of 100 mm. Overall height of the

panel not less than 2100 mm.

2. Width of all the panels is to be maintained

uniformly. Door opening and rear access

will be decided based on the requirement

during detailed engineering.

3. All the panel line up to be taken care like a

bureau opening type.

4. Enamel Danger plates shall be provided on

the Panel inscribed in Hindi, Telugu and

English languages as directed by

department.

5. Drawing pocket needs to be considered.

6. Comfort handles with key to be

considered.

b) Interlock Scheme

1. Auxiliary Contactor level:

a. Hard wired interlocks for the push

button command are to be provided at

auxiliary contactor.

b. When Aux. contactor operates with

respect to the motion selected,

remaining Aux. contactors with respect

to other motions should not be

operated. Aux. contactor shall be

operated only when main power

contactor is in ON condition.

2. In VVVF Drive Logic control:

a. It is to be programmed such a way only

one motion has to be selected for

operation at a time in the VVVF drive.

c) ON Interlock for Hoist

motion

1. Selection of group

2. Rotary limit switches i.e hoist and lower,

Gravity limit switch.


E - 16

3. Thruster Brakes' MPCB condition.

4. Brake Close limit switch condition.

5. Encoder for both motor and drum.

6. Provision shall be made for two extra

interlocks for future usage.

d) ON Interlock for Aux. Hoist

motion

1. Rotary limit switches i.e hoist and lower,

Gravity limit switch.



4. Encoder of motor.



e) ON Interlock for Cross

Travel motion

1. Right and Left limit switches for respective

motion of the drive.





f) ON Interlock for Long

Travel motion

1. Forward / Reverse limit switches for

respective motion of the drive.





P - 1

S.No Description of Specification Bidders Confirmation /

Acceptance

6.0 PAINTING OF CRANES (DFT shall be measured at the time of final inspection)

6.1

Surface Cleaning

The entire surface of fabricated materials, girders, frames,

platforms, trolley, end carriage, wheels etc., are to be sand/

grit/ abrasive blasted to white metal finish (SA 2½ quality)

and cleaned properly off rust, grease, & dirt.

6.2

Painting with

Epoxy Primer

(Total thickness

of 80 microns)

Two 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.

6.3

Painting Epoxy

Paint

(Total thickness

120 microns)

Two coats of epoxy paints of different colours for each

crane running in the same bay (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

aesthetic looking of cranes.

6.4 Total Paint

Thickness

Including Primer

Not less than 200 microns, this will be tested during final

inspection at supplier works/ at the time of dispatch.

Necessary paint thickness measuring instrument shall be

provided by supplier at the time of inspection.

TECHNICAL SPECIFICATIONS OF EOT CRANES (07 Nos.)

T – 1

7.0

DESIGN APPROVALS: DRAWINGS/DOCUMENTS TO BE SUBMITTED AFTER

PLACEMENT OF ORDER

1. Supplier shall submit following list of drawings/ calculations/

documents for approval before manufacture of cranes within one

month after placement of purchase order (7.1 to 7.16).

2. It is the responsibility of the supplier to get the drawings/ documents

approved from TPIA/Purchaser.

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

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

consideration.

4. All the load bearing structure & drive mechanisms shall be designed

by taking dead loads, operational loads, transportation loads, erection

loads, loads due to sudden actuation of brakes and acceptance testing

loads.

5. All the drawings and calculations, and data sheets, and flameproof

approvals shall be submitted as a whole set, at a time, within one month

from Order date for verification & approvals.

6. Three sets of following drawings/calculations shall be submitted in HARD

COPIES to Department/Purchaser (ISRO) for review.

7. At the same time, Supplier shall be responsible for proper submission of

following drawings & calculations along with technical specifications to

Third party inspection agency and get Design Approvals from them.

8. Supplier shall submit delivery schedule/ bar chart within 10days after

receipt of PO. After approval of drawings, supplier shall plan sequence of

delivery of EOT crane as per the readiness of site/building which will be

informed by the purchaser.

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

materials & makes along with dimensions of hook.

7.2 GA Assembly Drawing of Trolley with all components.

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

7.4 Constructional Drawings of Girder, end carriage, and trolley their

connections

7.5 Sub-assembly drawings for rope drum assembly, wheel assemblies, hook blocks, pulley system etc.,

7.6 GA drawings, details and selection criteria, power & torque calculations for gear boxes with manufacturer data sheets

7.7 Calculations for selection of Machine elements like wire rope, rope drum, couplings, wire ropes, pulleys etc.,

7.8 Calculation for bridge girder with deflection & camber, trolley frame, end carriage, with weight breakup and wheel loads.

7.9 Calculations for selection of wheels, bearings and Calculations for selection of CT & LT rails.


T – 2

7.10 Calculations for drive shafts and Plummer block bearings.

7.11 Calculations for Selection & sizing of bearings for EOT cranes.

7.12

Selection of keys, key ways couplings.

7.13 Selection of sheaves and sheave pin with calculations.

7.14 Bridge Girder CT rail arrangement drawing to scale with BOM.

7.15 LT rail arrangement (on Gantry Girders) drawing to scale with Bill of Materials

(BOM).

7.16

Calculation for selection of motors, brakes etc., along with manufacturer

datasheets & Exproof certificates (wherever applicable), etc. For Motors

necessary torque and speed curves, efficiency and power factor with

respect to loading of the motor, speed and time with respect to current and

complete G.A of motor, terminal box / boxes by mentioning the approved

drawing reference and nos. shall be submitted for approval.

7.17 Calculation for selection of motors and brakes with manufacturer motor

/brake datasheets & Exproof certificates.

7.18 Electrical/electronic circuit diagrams for total cranes containing details of components with rating, make, type and settings

7.19 GA drawing of electrical, VVVF panels, Pendant, DBR Panels and layout of

components within the panels. Heat losses / load calculation inside the drive

panels.

7.20 Flameproof approval certificates for motors, all electrical components and brake thrusters.

7.21 Selection criteria/calculations for VVVF drives, DBRs and related components. Heat loss calculation towards panel AC selection.

7.22 Sizing calculations for Control Transformer (with considering closed VA),

Lighting Transformer, SMPS with and without loading.

7.23 Selection of Cable sizes selection and ratings.

7.24 Drawings for Mounting and panels layout in the panel room with cable routing layout.

7.25 Drawing of Cable route from panel room to cranes equipment with location of junction boxes & cable trays with support lugs on cranes

7.26 Earthing layout of all the equipments connected in the EOT Cranes to be submitted for approval.

7.27 Necessary under / over current devices to be planned for tripping the

lubrication pump.

7.28

TEST REPORTS shall be submitted for flame proof electrical fittings /

equipment (along with approved drawings (Either by CIMFR / ERTL (E)) with

respect to all the annexure and amendments need to be submitted for review

and acceptance of all FLP items.


T – 3

7.29 TEST REPORTS shall be submitted for Space heaters and its thermostat,

Transformers, Dynamic Braking Resistors, VVVF Drives and its components.

7.30

TECHNICAL DATASHEETS shall be submitted for Motors, Brakes, VVVF

Drives, Switchgear components, Power and Control Cables, Encoders, Cable

Drag chain and its cables, Limit switches, Intrinsic safe relays and panels.

7.31 Quality Assurance Plan (QAP) for total cranes manufacture, erection &

testing as mentioned in this booklet.

Supplier shall submit following along with supply of EOT Cranes: List of Manuals/

drawings/documents/certificates to be submitted at the time of inspection of cranes

at supplier's works and at the time of commissioning at ISRO,SHAR (clause 8.1 to 8.10)

8.1

QAP/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 &

clearance report.

8.2

Test certificates of all items like raw materials, hooks, wire ropes, motors

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

agency" as per QAP & standards.

8.3 4 sets of Cranes operation & maintenance manuals

8.4 2Nos. of spare parts manuals.

8.5 4sets of as built Drawings of all systems of cranes as mentioned above

approval drawings.

8.6 Manufacturer maintenance manuals, test certificates and Warranty/

Guarantee Cards for all Bought-Out-Items.

8.7 Trouble Shooting Chart for Main and all Sub-Systems.

8.8 VVVF drive drives manuals soft copy

8.9 VVVF drive parameters list soft copy

8.10 Final test certificate of EOT cranes from TPIA with inspection report

8.11

Final as built drawings of cranes 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.

8.12

Final as built drawings of cranes control circuit, cable schedule with

length of each cable in mtrs. along with source and destination, shall be

supplied in hard form.

9 Tolerances: Supplier shall ensure that the cranes shall be manufactured

as per the tolerances specified below.

9.1 Span over LT

wheels +4mm maximum

9.2 Diagonal on

wheels ±5mm maximum


T – 4

9.3 Parallelism of

Girders

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

interval)

9.4 Verticality of

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

9.5 Verticality of End

Carriages

<1mm (measured at every 1m interval)

9.6 Trolley wheel gauge ± 2mm (measured at every1m interval)

9.7

Difference in

height between

trolley rails

<1/1000 of wheel gauge maximum at 1m interval

9.8

CT Rail alignment

w.r.t Girder centre ±1 mm(measured at every 1m interval)

9.9

Tilt of wheels(both

horizontal &

vertical)

<D/1000mm where D=diameter Of wheels

9.10 CT/LT wheel

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

9.11

Squareness

of Girders

to End

carriages

Within 1.60mm(for wheel base of~4000mm)

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

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

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

10.

INSPECTION & TESTING DURING MANUFACTURE OF CRANES

10.1

DESIGN/

DRAWINGS

APPROVALS&

CERTIFICATE

from TPIA

before cranes

manufacture.

Supplier shall obtain APPROVALS for all design

calculations & drawings from third party inspector (TPIA)

and/or ISRO before starting cranes's production. Cranes

& 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.

10.2 QAP & Third

party agency

INSPECTION and testing shall be carried out as per

QAP enclosed here with this booklet. Supplier shall hold

the manufacturing at specified "HOLD (H)" 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


T – 5

10.3

Raw materials

identification &

stamping

Raw material identification for structures, wheels, hoist

members, Gears, load pins etc., shall be done by Third

party inspectorate and/or department. Raw material test

certificates, traceability of materials with identification

marks shall be made available during identification and

during inspection of cranes.

10.4 All load bearing members shall be provided with heat no. & lot no along with

TPIA stamping on them which shall be visible after fabrication also.

10.5

Welding

inspection &

Testing

All Butt Welded Joints (both compression & tension

flanges / web joints) shall be subjected to 100% X- Ray

Testing and X-Ray Films to be produced for TPIA

and/or ISRO/SHAR for evaluation and shall form part

of the quality documentation.

10.6

Inspection

major parts and

records

Inspection of Bridges, End–Carriages, trolley, rails gauge,

Wheels and Measurement of Camber, mechanical

assemblies checking as per QAP.

10.6.1

Inspection of Electrical motors & other electrical parts

Test certificate with approvals shall be provided for all

motors such they are suitable for inverter duty, flame

proof. Test certificate for thermisters heating/tripping

temperature shall be provided. Test certificate for all

other electrical components shall be provided as per

QAP. ,

10.7

Dimensional

inspection&

alignment checking

& records

Inspection of Span & Diagonal Dimensions (10Kg pull should be applied while checking), Checking bridge & end carriages' squareness, Checking of Wheel Alignments, Mechanical drive Assemblies alignment and Pulley blocks alignment.

10.8 Record of inspection

All the inspections made shall be made with drawing

representation like span, diagonal, wheel straightness,

rail alignment, with dimensions & tolerances mentioned.

10.9

The cranes 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.

10.10

Load tests

No load test, Dynamic tests at Rated Load and

Deflection measurement as per as per QAP and as per IS

3177.

10.11

Testing of Cranes at OVER-LOAD (125%SWL) capability

Check and Permanent Set Measurement. All motions of

the cranes shall be tested with 25% overload in which

case the specified speeds need not be attained but the

cranes shall show itself capable of dealing with the

over load.


T – 6

10.12

Clearance

for

dispatch

The equipment shall be dispatched only after

satisfactory testing/inspection at supplier's works and

on written clearance from ISRO/SHAR.

11 ERECTION & COMMISSIONING OF EOT CRANES

11.1 Erection, testing and commissioning at ISRO-SHAR works is in the part

of supplier's scope as per QAP.

11.2

Initial unloading of EOT cranes parts shall be done by supplier’s manpower

& supervision. Equipment support with available equipments like

Mobile cranes / Forklift / Hydra etc., will be spared for unloading of cranes

parts by department at free of cost.

11.3

If the cranes components are unloaded outside/any other facility of SHAR,

the same will be transported to the site of erection by the departments

equipment at free of cost. However work shall be carried out by supplier with

their manpower & supervision.

11.2 Erection

Supervision

Supplier shall depute required qualified personnel

along with Engineers/ supervisor and qualified team for

carrying out quality erection work at our site.

11.3

Material required

during erection

(lifting equipment

like winch, lifting

tackles, etc inside

the facility).

Lifting machinery, tools and accessories are in the scope

of supplier. All lifting machinery, tools and tackles of

standard make only shall be used during erection inside

the facility. Test certificate for all the lifting/handling

equipments shall be submitted to the SHAR before

handling.

If required by supplier department can provide erection

hooks on the roof in the facility for lifting of cranes

components. However capacity & location of hooks

shall be given by manufacture during detail

engineering.

11.4

Initial lubricants and

commissioning

spares

Initial filling of lubricants/grease and spare parts required for commissioning at site shall be provided by the supplier.

11.5

Performance

Proving & Smooth

running of EOT

cranes at purchaser

site.

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 Cranes’s Capacity and Smooth

Functioning of the Cranes at Full load (SWL) and

Overload (125%SWL) shall be the responsibility of the

supplier.

11.6

Test/Clearance

certificates for

cranes

Part of supplier's scope. 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 cranes .


T – 7

12 General TERMS & CONDITIONS during Supply and Installation :

12.1

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.

12.2

Arrangements shall be made by the supplier for the inspection and testing of

the crane during different stages of its manufacture starting from 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.

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

12.4

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.

12.5

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.

12.6 The supplier should satisfy himself about the site condition beforehand to

avoid any difficulty during erection and commissioning of the crane

12.7

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.

12.8

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.

12.9

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

testing and commissioning of the crane at the site.

Supplier shall make his own arrangements for welding and gas-cutting works if

any, that are required for erection and commissioning of Cranes.

12.10

For unloading the crane parts at site (in respective building) material handling

support like Forklifts (~12 ton cap.) and available mobile crane will be provided

by department at free of cost.

12.11

A toolbox containing all necessary tools as given in Page no. “Tools – 1”

required for the maintenance of the crane should be from part of supply along

with the Crane.


T – 8

12.12

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.

12.13

Bidder should quote separately for spares as considered necessary

for two years of normal operation of crane as given in this booklet. 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.

13 COMMERCIAL TERMS & CONDITIONS :

13.1

Delivery Schedule :

Case 1 :

• If order placed on one bidder for all 7nos. of cranes, then delivery shall

be minimum 6 months for 1no. of crane and maximum 18 months for

all cranes from the date of PO.

Case 2 :

• If order placed on one bidder for all 3nos. of cranes, then delivery shall

be minimum 6 months for 1no. of crane to maximum 15 months for all

cranes from the date of PO.

Case 3 :

• If order placed on one bidder for all 1no. of crane, then delivery shall

be minimum 6 months from the date of PO.

13.2 Prices quoted shall be F.O.R Sriharikota.

13.3

Taxes and other costs, if any: Percentage of GST applicable for the quoted

items along with HSN Code, shall be provided.(As per the Notifications

No.47/2017 -Integrated Tax(Rate) dated 14.11.2017 issued by Ministry of

Finance(Department of Revenue), SDSC SHAR is eligible for a reduced rate of

5% IGST only wherever IGST is applicable. Accordingly Exemption Certificate

will also be provided).

13.4

Customs Duty: ISRO is Exempted from payment of Customs Duty vide

Notification No.05/2018 Customs dated 25.01.2018.(We will provide Customs

Duty Exemption Certificate in case of Import orders/Imported supplies/High

sea sales).

Note : The list of items for which CDEC is required shall be mentioned along

with quotation.

13.5

Liquidated Damages: In case of delay in Supply beyond the stipulated delivery

period, Liquidated Damages will be levied @ 1/2% per week or part thereof

subject to a maximum of 10% of total order value


T – 9

13.6

INSURANCE: - Being a Govt. Of India Dept., Insurance is not required at our

cost. Please ensure the safe delivery of the ordered item with proper transport

worthy packing.

13.7

Security Deposit : You shall be submit @ 10% of order value within 10 days of

receipt of order as security in the form of Demand Draft/Bank Guarantee or

Fixed Deposit Receipt from a Nationalised/Scheduled Bank valid up to the

supply, erection and commissioning plus two months.

This SD does not carry any interest, and shall be returned to you only after

successful completion of contractual obligations. In case of poor

performance/non-performance SD shall be forfeited.

13.8

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.

13.9

Performance Bank Guarantee: You shall submit performance Bank Guarantee

for 10% order value valid from a Nationalised / Scheduled Bank till completion

of Warranty period plus Sixty days as claim period. This PBG shall be submitted

along with dispatch documents such as invoice, warranty certificate etc.

13.10 Payment Terms : Vendor shall comply with following payment terms only :

13.10A

Our standard Payment term: 100% by RTGS within 30 days after receipt and

acceptance of above items at our site. Please furnish your bank account details

in the invoice for arranging payment.

Or

13.10B Payment Terms in four stages :

i) Advance along with Order 20% of order value against Bank guarantee

ii) Payment after crane receipt

at site 60% of order value along with taxes & duties.

iii)

Payment after erection,

commissioning, inspection &

acceptance of crane.

10% of order value

iv)

Balance Payment after

submission of Performance

Bank Guarantee

Balance 10% of order value

13.11 Validity of Offer shall be minimum period of 180days from the tender due

date.

Date : Signature & Office Seal of the bidder


Tools – 1

List of Tools to be supplied along with the crane (Ref : 12.11)

(INDIVIDUAL TOOL BOX SHALL BE SUPPLIED FOR EACH CRANE)

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 No 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”)

Nos

Nos

02

02

10 Extended cylindrical special spanner for tightening the MH gearbox Nos. 2nos. each

size.

11 Special tool driver kit suitable for SIEMENS Drives No 01

12 Nut driver kit suitable for selected terminal blocks inside the panel No 01

13 Calibrated steel tape of 30m length of reputed make. Nos. 02

14 Suitable hydraulic jack capacity 30t. Nos. 02

15 Noise level meter of make : M/s No 01

16 Pneumatic/Electric grease gun of capacity 1kg No 01

17 Special type electrical tool kit for accessing the VVVF Drive Nos. 02

18 AC / DC Clamp meter – Range ‘mA’ to 3 A; Make: M/s. Megger / Fluke No 01

19 AC / DC Clamp meter – Range ‘SWL with all three motion in operation’;

Make: M/s. Megger / Fluke No 01

20 Digital Insulation Tester – Range: Test Voltage as 1000V; Make: M/s.

Megger No 01


BOM - 1

LIST OF MANUFACTURERS / SPECIFIC BRANDS FOR BOUGHTOUT ITEMS

FOR FLAME PROOF EOT CRANE/ SAFE AREA EOT CRANE

1 Gear boxes : Elecon / Shanti Gears / Premium-GREAVE / Flender-

Siemens/ only.

2 Wire ropes (All galvanised) : Usha Martin/ CASAR Germany/ BRIDON USA.

3 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.

4 Forged steel materials

wheels, shafts, keys, gears

: SAIL / JINDAL / TATA STEEL / ESSAR / VIZAG-RINL / TIMKEN / Mahindra Ugine Steel (MUSCO) / BHARTH FORGE/ VIKRANTH FORGING/ KALYANI FORGING

5 Bearings : SKF/FAG/ TIMKEN/ INA

6 Hooks

: For Main Hoist : M/s IRIZAR- FORJAS/ CROSBY / CM (STB).

For Auxiliary Hoist : EEK/ Hercules/ IRIZAR- FORJAS/ CROSBY / Shilpa Udyog/ STEEL FORGINGS

7 Couplings

: FENNER

: Drum/Barrel coupling – M/s. Malmedie, Germany / M/s JAURE, Spain

8 Rails : M/s. SAIL / IISCO / JINDAL / ARCCELOR / TATA STEEL /

ESSAR

9

Flame proof Panels, Light

fittings, Glands, Junction Boxes etc.,

:

M/s. Baliga/FCG/FEPL

10 Power & control cables

: IGUS / LAPP make for cables used in cable drag chain

system and Pendant. LAPP / HAVELLS / Finolex / GLOASTER

11 Flame proof electric motors : M/s. Kirloskar/ Crompton Greaves/ Bharat Bijilee/ Alstom/

SIEMENS

12 Thrusters brakes for hoist

: M/s WittonKramer/Pintch Bubenzer/ SIBRE/ GALVI

13 Thrusters brakes for CT & LT

: M/s Electromag methods (EMM)/Kateel/Sterling Control

14 Power supply unit , Switch gears

: M/s SIEMENS only

15 Limit switches : M/s Speed-o-Control/ Electromag/ Sterling control

16 Contactors, Over load Relays

: M/s SIEMENS only

17 Intrinsic Safe relays : M/s P & F

18 VVVF Drive : M/s Siemens/ABB

19 Cable chain drag system : M/s IGUS/LAPP

20 Electrical Drive Panel &

Non FLP JBs

: M/s Rittal /Siemens

21 Encoder : M/s P&F, Hengstler, Hubner, Kubler, Schnider (Flameproof /

Intrinsic safe) Hollow shaft type encoder can be planned.

22 LT Power & Control Cables : M/s Lapp / Universal / CCI / Finolex / RPG / Uniflex.

23 Terminal Blocks : M/s Elmex / M/s. Connectwell / M/s. Wago

24 Pushbutton switches : M/s Werner with configurable tiles.

25 Paints : M/s Berger, Asian paints, Jenson & Nicholson, Nerolac,

Dulex, Poly coat


Codes - 1

CODES AND STANDARDS FOR FLAMEPROOF 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 Crane and Hoists.

IS:3177 Code of Practice for Design of Overhead Traveling Crane and Gantry

Crane other than Steel Works Crane.

IS:2062 Steel for general structural purpose.

ANSI/AWS D14.1 Code of welding practice for Industrial crane, Mill crane 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/ IS 15560 Specification for point hooks with shank for general engineering purposes

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 Crane.

IS:2147 Degrees of protection provided by enclosures for low voltage switch gear and

control gear.

IS:5571 Guide for selection and installation of electrical equipment for hazardous

areas

IS:5572 Classification of Hazardous Areas (Other than Mines) having flammable gases

and vapours for electrical installations.


Codes - 2

IS/IEC 60079-

1:2007

Explosive Atmospheres – Part 1 Equipment protection by Flameproof

enclosures “d”

IS 2206 : Specification for Flameproof Electric Lighting Fittings

IS/IEC 60079-

11:2006 Explosive Atmospheres – Part 11 Equipment protection by Intrinsic Safety “i”

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 : s

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

IS 15880 : 2009 Three Phase cage induction motors when fed from IGBT converters –

Application Guide

IS 15881 : 2009 Three Phase cage induction motors specifically designed for IGBT converter

supply – Specification

IS 12065 : 1987 Permissible limits of noise levels for rotating electrical machines

IS 7098 : Part – 1 Specification for crosslinked polyethylene insulated PVC sheathed cables for

working voltage up to and including 1100 volts.

CC

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PBS - 1

SCHEMATIC OF PUSH BUTTION OPERATING STATION FOR EOT CRANES

Crane Motion / Requirement

Selector

Switch

No. of

push

button

Indication

lamps

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

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Main Reverse

1

Creep Forward

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Creep Reverse

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Emergency Stop with Lockable Key

-

1

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Control ON

-

1

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Control OFF

-

1

-

Control ON Indication lamp (red)

-

-

1

Push Button for Bell/ Hooter

-

1

-

UB lights

1

-

-

Note :

1. Pendant hanging from crane (DSL type) with Stainless steel chain.

2. Pendant enclosure shall be with stainless steel only.

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d o

f

che

ck

E

xte

nt

of

che

ck

R

ef.

Do

cum

en

t

A

cce

pta

nce

No

rm

F

orm

at

of

reco

rd

Ag

en

cy

R

em

ark

s

Performed

Witnessed

Verified

A

B

C

D

E

F

G

H

I J

K

i)

Ide

nti

fica

tio

n o

f R

aw

ma

teri

als

str

uct

ura

l

pla

tes,

fo

rge

d s

tee

l

ma

teri

al,

Allo

y s

tee

l etc

.,

All

raw

ma

teri

als

sh

all

be

off

ere

d w

ith

te

st c

ert

ific

ate

s fo

r id

en

tifi

cati

on

fo

r C

ran

e m

an

ufa

ctu

re

be

fore

sta

rt o

f fa

bri

cati

on

. St

am

pin

g s

ha

ll b

e d

on

e o

n p

late

s w

ith

he

at

nu

mb

er

& lo

t n

um

be

r

such

th

at

it is

vis

ible

aft

er

cra

ne

ass

em

bly

for

ve

rifi

cati

on

.

Co

mp

on

en

t G

r.

Stam

pin

g o

n

1

-

-

All

ma

teri

als

sh

all

be

Id

en

tifi

ed

by

Th

ird

Pa

rty A

ge

ncy

/ IS

RO

(H

OLD

) H

B

Sp

ecs

./ IS

p

art

s &

2

06

2/

IS1

57

0/

BS

Ide

nti

fica

tio

n

9

70

re

cord

1

STR

UC

TU

RA

L W

OR

KS

: B

RID

GE

GIR

DE

RS

, EN

D C

AR

RIA

GE

S, C

RA

B F

RA

ME

, DR

IVE

BA

SE

S &

PLA

TF

OR

MS

ET

C.

1.1

Ma

teri

als

- P

late

s/

rolle

d s

ect

ion

s

Ch

em

ica

l co

mp

osi

tio

n/

Ma

jor

T.C

. C

orr

ela

tio

n

On

e p

er

Ap

pro

ved

A

pp

rove

d

Ma

teri

al T

. C.

/

Sup

plie

r's

Te

st

Re

po

rt

3

-

2,

1

Re

po

rts

/ TC

re

vie

w b

y T

PIA

/ I

SR

O

Me

cha

nic

al

Pro

pe

rtie

s (w

ith

lo

t n

o.

&

he

at

dra

win

gs/

d

raw

ing

s /

Te

ch.

h

ea

t n

o.)

Sp

ecs

./ IS

20

62

Sp

ecs

./ IS

20

62

1.1

.1

Lam

ina

tio

n /

Inte

rna

l M

ajo

r U

ltra

son

ic

10

0%

A

ST

M A

-43

5

AST

M A

-43

5

Sup

plie

r IR

3

-

2,

1

For

a l

l pla

tes

of

thic

kne

ss >

20

mm

,

UT

qu

alif

ica

tio

n (

vo

lum

etr

ic t

est

) d

efe

cts

Te

stin

g

1.2

W

eld

ing

W

eld

ing

pro

ced

ure

&

We

lde

rs q

ua

lific

ati

on

. C

riti

cal

Te

st p

iece

vis

ua

l

& p

hys

ica

l te

st.

On

e f

or

ASM

E S

ec.

IX

ASM

E S

ec.

IX

WP

S/ P

QR

2

-

1

e

ach

fo

rma

t

po

siti

on

1.2

.1

a

) W

eld

ing

qu

alit

y &

Surf

ace

de

fect

s

C

riti

cal

Vis

ua

l &

D.P

.

Te

st,

MP

T

1

00

%

IS:3

65

8 &

IS

:36

58

&

Su

pp

lier’

s IR

2

-

1

V

isu

al i

nsp

ect

ion

& U

se w

eld

gau

ge

s fo

r m

ea

sure

me

nt

of

we

ld

size

Lo

ad

B

ea

rin

g

Bu

tt

AW

S D

14

.1

AW

S D

14

.1

we

lds

(bo

th t

en

sile

an

d

com

pre

ssio

n)

b

) Su

b s

urf

ace

de

fect

s

Cri

tica

l

R

ad

iog

rap

hy

1

00

%

A

SME

Se

c.V

III

A

SME

Se

c.V

III D

iv

I

Su

pp

lier’

s IR

2

-

1

R

evi

ew

of

rad

iog

rap

hy f

ilms

by I.A

.

Div

I

Q

UA

LIT

Y A

SS

UR

AN

CE

, IN

SP

EC

TIO

N A

ND

TE

ST

ING

PLA

N F

OR

EO

T C

RA

NE

S

QA

P -

2

Leg

en

d

1 T

hir

d P

art

y I

nsp

ect

ion

Ag

en

cy

2 V

en

do

r (C

ran

e S

up

pli

er)

Pla

ce

Da

te:

Sig

na

ture

of

Cra

ne

Ve

nd

or

wit

h D

esi

gn

ati

on

3 S

ub

Ve

nd

or

/ It

em

Su

pp

lie

r

S

l.

No

C

om

po

ne

nts

/

Op

era

tio

ns

C

ha

ract

eri

stic

to b

e c

he

cke

d

C

ate

go

ry

T

yp

e /

Me

tho

d o

f

che

ck

E

xte

nt

of

che

ck

R

ef.

Do

cum

en

t

Acc

ep

tan

ce

No

rm

F

orm

at

of

reco

rd

Ag

en

cy

R

em

ark

s

Performed

Witnessed

Verified

A

B

C

D

E

F

G

H

I J

K

1.2

.2

Oth

er

tha

n lo

ad

B

ea

rin

g B

utt

we

lds

&

fille

t w

eld

s

Surf

ace

de

fect

s &

Siz

e

Ma

jor

Vis

ua

l & D

PT

1

00

%

IS

:36

58

IS

:36

58

Su

pp

lier’

s IR

2

-

1

Use

we

ld g

au

ge

s fo

r

me

asu

rem

en

t o

f w

eld

siz

e

Vis

ua

l

che

ck &

DP

te

st

10

%

ran

do

m

1.2

.3

Bri

dg

e G

ird

er

& E

nd

Ca

rria

ge

insp

ect

ion

b

efo

re c

losi

ng

th

e b

ox

Vis

ua

l, &

We

ldin

g

Me

asu

rem

en

t

Ma

jor

Vis

ua

l &

Vis

ua

l C

om

po

ne

nt

Co

mp

on

en

t Su

pp

lier’

s IR

2

1

-

Use

we

ld g

au

ge

s fo

r

me

asu

rem

en

t o

f w

eld

siz

e

(HO

LD)

H

we

ldin

g q

ua

lity

10

0%

/ D

PT

- d

raw

ing

AW

S

dra

win

g/

AW

S

ran

do

m o

f D

14

.1

D1

4.1

10

%

1.2

.4

Fin

al W

eld

ing

V

isu

al I

nsp

ect

ion

M

ajo

r In

spe

ctio

n o

f 1

00

%

Sp

eci

fica

tio

n/

AW

S D

14

.1

Sup

plie

r’s

IR

2

-

1

V

isu

al f

ina

l w

eld

ing

insp

ect

ion

by

TP

IA

Insp

ect

ion

W

eld

ing

qu

alit

y

AW

S D

14

.1

1.2

.5

Fin

al I

nsp

ect

ion

of

fab

rica

ted

co

mp

on

en

ts

Gir

de

rs,

En

d c

arr

iag

es,

Tro

lley,

LT

dri

ve f

ram

e,

etc

..,

Dim

en

sio

na

l , C

am

be

r ,

stra

igh

tne

ss, le

vel,

Pa

ralle

lism

, ve

rtic

alit

y,

etc

.,

Ma

jor

Me

asu

rem

en

t 1

00

%

Te

ch.

Te

ch.

Sup

plie

r’s

IR

2

-

1

Me

asu

red

Dim

en

sio

ns

sha

ll b

e

ma

rke

d o

n c

om

po

nen

t d

raw

ing

.

Re

vie

w o

f re

po

rts

at

ne

xt s

tag

e b

y

TP

IA. (

HO

LD)

tole

ran

ces

as

Sp

eci

fica

tio

n/

Sp

eci

fica

tio

n/

pe

r C

om

po

ne

nt

Co

mp

on

en

t

spe

cifi

cati

on

s d

raw

ing

/IS

dra

win

g/I

S 8

07

8

07

2.0

R

OP

E D

RU

M F

ab

rica

ted

M

ate

ria

l co

mp

osi

tio

n/

Ma

jor

T.C

. Co

rre

lati

on

O

ne

pe

r Sp

ec/

dra

win

g/

Spe

c/d

raw

ing

/ M

ate

ria

l T. C

. /

Sup

plie

r’s

Te

st

Re

po

rt

3

-

2, 1

R

ep

ort

s /

TC /

pre

ssu

re t

est

rep

ort

s re

vie

w b

y T

PIA

M

ech

an

ica

l P

rop

ert

ies

he

at

AST

SM

A1

06

/ A

STSM

A1

06

/

UT

S, Y

S, %

elo

ng

ati

on

IS 2

06

2

IS 2

06

2

2.1

R

OP

E D

RU

M j

oin

t

We

ldin

g

We

ldin

g J

oin

t q

ua

lity &

We

ldm

en

t d

efe

cts

Cri

tica

l V

isu

al/

DP

1

00

%

Co

mp

on

en

t A

SME

Se

c.V

III

Sup

plie

r’s

IR

3/2

2

1

M

ea

sure

d D

ime

nsi

on

s sh

all b

e

mark

ed

on

co

mp

on

en

t d

raw

ing

. T

est

/RT

/ U

T

dra

win

g

Div

I

Stre

ss r

elie

vin

g

Ma

jor

Ve

rifi

cati

on

1

00

%

Mfg

’s s

td.

Stre

ss r

elie

vin

g

Sup

plie

r’s

IR

3/2

2

1

ch

art

Q

UA

LIT

Y A

SS

UR

AN

CE

, IN

SP

EC

TIO

N A

ND

TE

ST

ING

PLA

N F

OR

EO

T C

RA

NE

S

QA

P-3

Le

ge

nd

1 T

hir

d P

art

y I

nsp

ect

ion

Ag

en

cy

2 V

en

do

r (C

ran

e S

up

pli

er)

Pla

ce

Da

te:

Sig

na

ture

of

Cra

ne

Ve

nd

or

wit

h D

esi

gn

ati

on

3 S

ub

Ve

nd

or

/ It

em

Su

pp

lie

r

S

l.

No

C

om

po

ne

nts

/

Op

era

tio

ns

C

ha

ract

eri

stic

to b

e c

he

cke

d

C

ate

go

ry

T

yp

e /

Me

tho

d o

f

che

ck

E

xte

nt

of

che

ck

R

ef.

Do

cum

en

t

Acc

ep

tan

ce

No

rm

F

orm

at

of

reco

rd

Ag

en

cy

R

em

ark

s

Performed

Witnessed

Verified

A

B

C

D

E

F

G

H

I J

K

3.0

G

ea

r b

ox

Ho

usi

ng

s

Fab

rica

ted

Ma

teri

al

com

po

siti

on

/

Me

cha

nic

al

Pro

pe

rtie

s

UT

S, Y

S, %

elo

ng

ati

on

Ma

jor

T.C

. Co

rre

lati

on

O

ne

pe

r

he

at

Spe

c/d

raw

ing

/

IS 2

06

2

Spe

c/d

raw

ing

/

IS 2

06

2

Ma

teri

al T

. C.

3,2

-

2, 1

Re

po

rts

/ TC

to

be

revi

ew

by T

PIA

3.1

St

ress

re

lievin

g

Ma

jor

Ve

rifi

cati

on

1

00

%

Mfg

's s

td.

Stre

ss r

elie

vin

g

cha

rt

Sup

plie

r's

IR

2

-

1

SR

ch

art

will

be

re

vie

we

d b

y T

PIA

.

3.2

Su

rfa

ce d

efe

cts

&

dim

en

sio

na

l ch

eck

Ma

jor

Vis

ua

l/D

P T

est

/

Me

asu

rem

en

t D

PT

10

%

ran

do

m &

10

0%

visu

al

IS:3

65

8/

Co

mp

on

en

t

dra

win

g

IS:3

65

8/A

WS

D1

4.1

Su

pp

lier'

s IR

2

-

1

Me

asu

red

Dim

en

sio

ns

sha

ll b

e m

ark

ed

on

co

mp

on

en

t d

raw

ing

4.0

a

) P

latf

orm

b)

LT F

ram

e

c) H

an

d R

ails

d)

che

qu

ere

d P

late

s

Dim

en

sio

na

l

Co

nfo

rmit

y/

Vis

ua

l ch

eck

ing

/

Mfr

’s T

C

Min

or

Me

asu

rem

en

t 1

00

%

Cri

tica

l

dim

en

sio

n

s /

oth

ers

at

ran

do

m

Co

mp

on

en

t

dra

win

g/

Mfr

’s

TC

/ In

du

stri

al

sta

nd

ard

s

Co

mp

on

en

t

dra

win

g/

Mfr

’s

TC

/ In

du

stri

al

sta

nd

ard

s

Sup

plie

r's

IR

2

-

1

M

ea

sure

d d

ime

nsi

on

s sh

all

be

ma

rke

d o

n d

raw

ing

s.

5

ME

CH

AN

ICA

L C

OM

PO

NE

NT

S –

GE

AR

BO

XE

S

5.1

H

ois

t, C

T &

LT

Inp

ut

sha

fts,

Ge

ars

, P

inio

ns,

keys

, sp

ace

rs (

for

all

ge

arb

oxe

s)

Ma

teri

al

com

po

siti

on

/

Me

cha

nic

al

pro

pert

ies

Ha

rdn

ess

va

lue

/

UT

/

MP

T/

DP

T o

f m

ate

ria

ls

Ma

jor

Co

rre

lati

on

w

ith

Mfr

’s T

C

10

0%

Sp

eci

fica

tio

n

IS:1

57

0 /

BS

97

0

/ IS

:20

48

Co

mp

on

en

t

dra

win

g/

IS2

04

8

Spe

cifi

cati

on

/

IS:1

57

0 /

BS

97

0

Mfr

's T

C/

Sup

plie

r's

IR

2

-

1

1)

1

00

% U

T v

olu

me

tric

te

st f

or

wro

ug

ht

or

forg

ed

ma

teri

als

as

pe

r A

ST

ME

11

4 a

nd

A3

88

.

2)

1

00

% D

PT

or

MP

T s

ha

ll b

e

pe

rfo

rme

d a

s p

er

AS

TM

A 2

75

,

E7

09

5.1

.1

Ma

chin

ed

co

mp

on

en

ts

for

Ge

ar

bo

xes

like

inp

ut

sha

fts,

ge

ars

, p

inio

ns,

keys

, sp

ace

rs e

tc.,

Dim

en

sio

na

l co

nfo

rmit

y

Ha

rdn

ess

o

f g

ea

r te

eth

/

Be

ari

ng

s/

Oil

sea

ls/

keys

an

d k

ey w

ays.

Ma

jor

Me

asu

rem

en

t/

Vis

ua

l

exa

min

ati

on

fo

r

fin

ish

ing

10

0%

C

om

po

ne

nt

dra

win

g/

IS4

46

0/

AG

MA

/DIN

IS:2

04

8

Co

mp

on

en

t

dra

win

g/

IS4

46

0/

AG

MA

/DIN

/ H

ea

t

tre

atm

en

t ch

art

Sup

plie

r's

IR

2

-

1

Ke

y

wa

ys

sha

ll

be

in

spe

cte

d

by

TP

IA

be

fore

a

sse

mb

ly

of

ge

arb

oxe

s.

Me

asu

red

Dim

en

sio

ns

shall

be

mark

ed

on

co

mp

on

en

t d

raw

ing

s.

Q

UA

LIT

Y A

SS

UR

AN

CE

, IN

SP

EC

TIO

N A

ND

TE

ST

ING

PLA

N F

OR

EO

T C

RA

NE

S

QA

P -

05

S

l.

No

C

om

po

ne

nts

/

Op

era

tio

ns

C

ha

ract

eri

stic

to b

e c

he

cke

d

C

ate

go

ry

T

yp

e /

Me

tho

d o

f

che

ck

E

xte

nt

of

che

ck

R

ef.

Do

cum

en

t

Acc

ep

tan

ce

No

rm

F

orm

at

of

reco

rd

Ag

en

cy

R

em

ark

s

Performed

Witnessed

Verified

A

B

C

D

E

F

G

H

I J

K

5.1

.2

Ge

ar

bo

x

Ass

em

bly

D

ime

nsi

on

al

Ma

jor

Me

asu

rem

en

t/

10

0%

G

ea

rbo

x G

A

Ge

arb

ox

GA

Su

pp

lier'

s IR

3

, 2

-

1

Me

asu

red

Dim

en

sio

ns

sha

ll b

e m

ark

ed

a

llow

ed

dim

en

sio

na

l va

ria

tio

ns.

(HO

LD)

H

con

form

ity/

Insp

ect

ion

V

isu

al c

he

ck o

f d

raw

ing

D

raw

ing

.

o

f m

ach

ine

d

surf

ace

s

like

ge

arb

ox

base

,

be

ari

ng

mo

un

ts e

tc.,

.

Inte

rna

l p

ain

tin

g

5.1

.3

Ge

ar

bo

x a

sse

mb

ly

test

ing

(N

o lo

ad

ru

n t

est

for

min

imu

m o

f 4

ho

urs

)

Co

nta

ct r

ati

o o

f

surf

ace

s/ B

ack

lash

/

No

ise

leve

l &

Be

ari

ng

tem

pe

ratu

re/

Bre

ath

er/

Oil

leve

l ga

ug

e

Ma

jor

Me

asu

rem

en

t &

1

00

%

Ge

arb

ox

GA

G

ea

rbo

x G

A

Sup

plie

r's

IR

3

,2

1

-

No

Lo

ad

Te

st s

ha

ll b

e w

itn

ess

ed

by T

PIA

.

No

ise

le

ve

l o

f g

ea

rbo

xes

sha

ll b

e

≤

75

dB

A.

Te

mp

era

ture

ri

se

sha

ll b

e a

s p

er

ge

arb

ox

man

ufa

ctu

rer

sta

nd

ard

.

no

loa

d r

un

nin

g

dra

win

g /

d

raw

ing

/ IS

44

60

/

IS

44

60

/ A

GM

A

Sp

eci

fica

tio

n /

/

Sp

eci

fica

tio

n

No

ise

leve

l of

ge

ar

bo

x ≤

75

dB

A

5.2

M

EC

HA

NIC

AL

CO

MP

ON

EN

TS

– L

T A

ND

CT

DR

IVE

S

HA

FT

S

5.2

.1

Ma

teri

als

of

LT &

CT

Sha

fts,

an

d K

eyw

ays

&

Ke

ys

Ma

teri

al

com

po

siti

on

/ M

ajo

r C

orr

ela

tio

n

wit

h

10

0%

A

pp

rove

d

Ap

pro

ved

M

fr's

TC

/ T

est

rep

ort

s/

Sup

plie

r's

IR

3

, 2

-

1

10

0%

UT

of

wro

ug

ht

an

d f

org

ed

ma

teri

als

as

pe

r A

ST

M

10

0%

DP

T o

r M

PT

Me

cha

nic

al p

rop

ert

ies

Mfr

’s T

C (

if

no

t d

raw

ing

/ IS

20

48

/ d

raw

ing

/ IS

20

48

Ha

rdn

ess

of

ma

teri

al

/ te

st m

ate

ria

ls)

Sp

eci

fica

tio

n

Sp

eci

fica

tio

n/

UT

/ D

PT

IS:1

57

0/B

S97

0/

IS:1

57

0 /

BS

97

0

5.2

.2

Ma

chin

ing

of

LT &

CT

Sha

fts,

an

d K

eyw

ays

&

Ke

ys

( D

ime

nsi

on

al

me

asu

rem

en

t)

Stra

igh

tne

ss &

M

ajo

r D

ime

nsi

on

al

10

0%

A

pp

rove

d

Ap

pro

ved

Su

pp

lier'

s IR

2

-

1

Ke

ys &

ke

yw

ays

sha

ll b

e i

nsp

ect

ed

by

TP

IA b

efo

re a

sse

mb

ly.

Dim

en

sio

na

l co

nfo

rmit

y M

ea

sure

me

nt/

d

raw

ing

/ d

raw

ing

/ IS

20

48

Ch

eck

s &

Insp

ect

ion

of

Vis

ua

l Sp

eci

fica

tio

n

Sp

eci

fica

tio

n/

Ke

y w

ays.

e

xam

ina

tio

n

IS:1

57

0 /

IS

:15

70

/ B

S 9

70

BS

97

0/I

S20

48

/I

S 2

04

8

5.3

C

OU

PLI

NG

S

Co

up

ling

s S

ize

/

Ma

teri

al c

om

po

siti

on

/

Me

cha

nic

al

pro

pe

rtie

s /

Ha

rdn

ess

va

lue

/ U

T /

DP

T

Ma

jor

Co

rre

lati

on

wit

h

10

0%

A

pp

rove

d

Ap

pro

ved

M

fr's

TC

/

3,

2

-

1

Ke

ys &

ke

ywa

ys

sha

ll b

e in

spe

cte

d b

y

TP

IA b

efo

re a

sse

mb

ly.

UT

of

wro

ug

ht

an

d f

org

ed

ma

teri

als

as

pe

r A

STM

a)

Ma

teri

als

M

fr’s

TC

d

raw

ing

/ d

raw

ing

/ IS

20

48

Su

pp

lier'

s IR

b

) To

rqu

e c

ap

aci

ty

Sp

eci

fica

tio

n

Sp

eci

fica

tio

n/

c)

Ke

y w

ay

s

IS:1

57

0 /

BS

97

0

IS:1

57

0 /

BS

97

0

o

n G

ea

rbo

x G

A d

raw

ing

s w

ith

Le

ge

nd

1 T

hir

d P

art

y I

nsp

ect

ion

Ag

en

cy

2 V

en

do

r (C

ran

e S

up

pli

er)

Pla

ce

Da

te:

Sig

na

ture

of

Cra

ne

Ve

nd

or

wit

h D

esi

gn

ati

on

3 S

ub

Ve

nd

or

/ It

em

Su

pp

lie

r

Q

UA

LIT

Y A

SS

UR

AN

CE

, IN

SP

EC

TIO

N A

ND

TE

ST

ING

PLA

N F

OR

EO

T C

RA

NE

S

QA

P -

05

Leg

en

d

1 T

hir

d P

art

y I

nsp

ect

ion

Ag

en

cy

2 V

en

do

r (C

ran

e S

up

pli

er)

Pla

ce

Da

te:

Sig

na

ture

of

Cra

ne

Ve

nd

or

wit

h D

esi

gn

ati

on

3 S

ub

Ve

nd

or

/ It

em

Su

pp

lie

r

S

l.

No

C

om

po

ne

nts

/

Op

era

tio

ns

C

ha

ract

eri

stic

to b

e c

he

cke

d

C

ate

go

ry

T

yp

e /

Me

tho

d o

f

che

ck

E

xte

nt

of

che

ck

R

ef.

Do

cum

en

t

Acc

ep

tan

ce

No

rm

F

orm

at

of

reco

rd

Ag

en

cy

R

em

ark

s

Performed

Witnessed

Verified

A

B

C

D

E

F

G

H

I J

K

5.4

P

lum

me

r b

lock

s &

b

ase

s P

B &

be

ari

ng

siz

es/

Ma

teri

al c

om

po

siti

on

/

Me

cha

nic

al

pro

pe

rtie

s

dim

en

sio

na

l

insp

ect

ion

Ma

jor

Co

rre

lati

on

wit

h

10

0%

A

pp

rove

d

Ap

pro

ved

M

fr's

TC

/

2

-

1

Re

vie

w o

f T

est

ce

rtif

ica

tes

by T

PIA

an

d

issu

e C

om

plia

nce

ce

rtif

ica

te.

Me

asu

red

Dim

en

sio

ns

sha

ll b

e m

ark

ed

on

Co

mp

on

en

t d

raw

ing

s w

ith

allo

we

d

dim

en

sio

na

l va

ria

tio

ns.

Mfr

’s T

C

dra

win

g/

dra

win

g/

Su

pp

lier'

s IR

Sp

eci

fica

tio

n

Sp

eci

fica

tio

n/

5.5

LT

&

CT

W

he

els

5.5

.1

a)

Ma

teri

al F

org

ed

ste

el

C5

5M

n7

5

Ma

teri

al

com

po

siti

on

/ M

ajo

r C

orr

ela

tio

n w

ith

1

00

%

Ap

pro

ved

A

pp

rove

d

Mfr

's T

C/

Te

st

rep

ort

s/

Sup

plie

r's

IR

3

, 2

-

1

Re

vie

w o

f T

est

ce

rtif

ica

tes

by T

PIA

an

d

issu

e C

om

plia

nce

ce

rtif

ica

te.

Me

cha

nic

al p

rop

ert

ies

Mfr

’s T

C

dra

win

g /

Te

ch.

dra

win

g /

Te

ch.

Ha

rdn

ess

of

ma

teri

al /

Sp

eci

fica

tio

n

IS:1

57

0/B

S97

0

Sp

eci

fica

tio

n

IS:1

57

0/B

S97

0

UT

of

forg

ed

bla

nks

M

ajo

r U

T c

he

ckin

g

10

0%

A

STM

A-3

88

A

SM A

-38

8

Mfr

's T

C

3

, 2

-

1

R

evi

ew

of

Te

st c

ert

ific

ate

s b

y T

PIA

an

d

issu

e C

om

plia

nce

ce

rtif

ica

te.

Su

pp

lier'

s IR

5.5

.2

b)

Wh

ee

ls a

fte

r

mach

inin

g w

ith

Ke

ys

&

key w

ays

Dim

en

sio

na

l Co

nfo

rmit

y

Ma

jor

Me

asu

rem

en

t 1

00

%

Ap

pro

ved

A

pp

rove

d

Sup

plie

r's

IR

2

-

1

Me

asu

red

Dim

en

sio

ns

sha

ll b

e m

ark

ed

on

ea

ch C

om

po

ne

nt

dra

win

gs

wit

h

allo

we

d d

ime

nsi

on

al v

ari

ati

on

s.

for

Bo

re,

wh

ee

l tre

ad

, C

om

po

ne

nt

Co

mp

on

en

t

tap

er

of

fla

ng

e /

Ha

rdn

ess

/de

pth

dra

win

g

dra

win

g

5.6

W

HE

EL

AX

LES

wit

h k

ey

wa

ys

& k

ey

s

Ma

teri

al

co

mp

osi

tio

n/

Ma

jor

Co

rre

lati

on

wit

h

10

0%

A

pp

rove

d

Ap

pro

ved

M

fr's

TC

/ T

est

rep

ort

s/

Sup

plie

r's

IR

3,2

-

1

Me

asu

red

Dim

en

sio

ns

sha

ll b

e m

ark

ed

on

ea

ch C

om

po

ne

nt

dra

win

gs

wit

h

allo

we

d d

ime

nsi

on

al v

ari

ati

on

s.

Me

cha

nic

al

pro

pe

rtie

s M

fr’s

TC

/

dra

win

g /

Te

ch.

dra

win

g /

Te

ch.

Dim

en

sio

na

l in

spe

ctio

n

Me

asu

rem

en

t Sp

eci

fica

tio

n

Sp

eci

fica

tio

n

UT

& D

PT

/M

PT

IS:1

57

0/B

S97

0

IS:1

57

0/B

S97

0

5.7

P

ulle

ys

wit

h R

oll

er

Be

ari

ng

s

5.7

.1

a)

Ma

teri

al (

Fo

rge

d S

tee

l )

Ma

teri

al

com

po

siti

on

/ M

ajo

r C

orr

ela

tio

n w

ith

1

00

%

Ap

pro

ved

A

pp

rove

d

Mfr

's T

C/

Te

st

rep

ort

s/

Sup

plie

r's

IR

3

, 2

-

1

Re

vie

w o

f T

est

ce

rtif

ica

tes

by T

PIA

an

d

issu

e C

om

plia

nce

ce

rtif

ica

te.

Me

cha

nic

al p

rop

ert

ies

Mfr

’s T

C

dra

win

g /

Te

ch.

dra

win

g /

Te

ch.

Ha

rdn

ess

of

ma

teri

al

/ U

T &

DP

T /

MP

T

Sp

eci

fica

tio

n

IS:1

57

0/B

S97

0

Sp

eci

fica

tio

n

IS:1

57

0/B

S97

0

Q

UA

LIT

Y A

SS

UR

AN

CE

, IN

SP

EC

TIO

N A

ND

TE

ST

ING

PLA

N F

OR

EO

T C

RA

NE

S

Leg

en

d

1 T

hir

d P

art

y I

nsp

ect

ion

Ag

en

cy

2 V

en

do

r (C

ran

e S

up

pli

er)

3 S

ub

Ve

nd

or

/ It

em

Su

pp

lie

r

Sig

na

ture

of

Cra

ne

Ve

nd

or

wit

h D

esi

gn

ati

on

Pla

ce

Da

te:

S

l.

No

C

om

po

ne

nts

/

Op

era

tio

ns

C

ha

ract

eri

stic

to b

e c

he

cke

d

C

ate

go

ry

T

yp

e /

Me

tho

d o

f

che

ck

E

xte

nt

of

che

ck

R

ef.

Do

cum

en

t

Acc

ep

tan

ce

No

rm

F

orm

at

of

reco

rd

Ag

en

cy

R

em

ark

s

Performed

Witnessed

Verified

A

B

C

D

E

F

G

H

I J

K

5.7

.2

b)

Vis

ua

l In

spe

ctio

n

c) D

ime

nsi

on

al I

nsp

ect

ion

O

vera

ll vi

sua

l in

spe

ctio

n

/ A

ll d

ime

nsi

on

s a

s p

er

dra

win

g li

ke

bo

re,

wid

th, g

roo

ve,

etc

.,/h

ard

ne

ss o

f

Ma

jor

Me

asu

rem

en

t 1

00

%

Co

mp

on

en

t C

om

po

ne

nt

Mfr

's T

C

3

-

1

,2

Me

asu

red

Dim

en

sio

ns

sha

ll b

e m

ark

ed

on

ea

ch C

om

po

ne

nt

dra

win

gs

wit

h

allo

we

d d

ime

nsi

on

al v

ari

ati

on

s.

wit

h v

ern

ier

/ d

raw

ing

/

dra

win

g /

Mic

rom

ete

r Sp

eci

fica

tio

n

Sp

eci

fica

tio

n

No

ise

leve

l of

ge

ar

bo

x <

80

db

5.8

S

na

tch

blo

ck C

ross

h

ea

d

Ma

teri

al

co

mp

osi

tio

n/

Ma

jor

Co

rre

lati

on

wit

h

10

0%

A

pp

rove

d

Ap

pro

ved

M

fr's

TC

/ T

est

rep

ort

s/

Sup

plie

r's

IR

UT

re

po

rts

3,2

-

1

Me

asu

red

Dim

en

sio

ns

sha

ll b

e m

ark

ed

on

ea

ch C

om

po

ne

nt

dra

win

gs

wit

h

allo

we

d d

ime

nsi

on

al v

ari

ati

on

s.

Me

cha

nic

al

pro

pe

rtie

s M

fr’s

TC

/

dra

win

g /

Te

ch.

dra

win

g /

Te

ch.

Dim

en

sio

na

l M

ea

sure

me

nt

Sp

eci

fica

tio

n

Sp

eci

fica

tio

n

insp

ect

ion

/ 1

00

% U

T &

M

PT

IS:1

57

0/B

S97

0

IS:1

57

0/B

S97

0

AS

TM

5.9

S

na

tch

blo

ck a

sse

mb

ly

Dim

en

sio

na

l Co

nfo

rmit

y M

ajo

r M

ea

sure

me

nt

10

0%

A

pp

rove

d

Ass

em

bly

Su

pp

lier'

s IR

2

-

1

R

evi

ew

of

rep

ort

s b

y T

PIA

B

ill o

f m

ate

ria

ls

Ass

em

bly

dw

g .

Dra

win

g

5

.10

Ho

ok

Ma

teri

al c

om

po

siti

on

/ M

ajo

r C

orr

ela

tio

n

10

0%

C

om

po

ne

nt

Co

mp

on

en

t M

fr's

TC

3

-

2

, 1

Pro

of

loa

d t

est

fro

m G

ovt.

ap

pro

ved

test

ho

use

as

pe

r sp

eci

fica

tio

ns.

M

ech

an

ica

l p

rop

ert

ies/

w

ith

TC

. d

raw

ing

/ IS

18

75

d

raw

ing

/IS

18

75

a

nd

10

0%

UT

& D

PT

/

MP

T

Pro

of

Loa

d T

est

M

ajo

r T

est

ing

1

00

%

IS3

81

5

IS3

81

5

Mfr

's T

C

3

-

2, 1

Stre

ss r

elie

vin

g

Ma

jor

Ve

rifi

cati

on

1

00

%

Co

mp

on

en

t C

om

po

ne

nt

Ve

nd

or

TC

3

-

2

,1

d

raw

ing

/ IS

38

15

d

raw

ing

/IS

38

15

5.1

1

Bra

ke

Dru

ms

wit

h k

ey

an

d K

ey

wa

ys

Ma

teri

al c

om

po

siti

on

/ M

ajo

r C

orr

ela

tio

n w

ith

1

00

%

Ap

pro

ved

co

mp

. A

pp

rove

d c

om

p.

Mfr

's T

C/

Te

st

rep

ort

s/

Sup

plie

r's

IR

3

,2

-

1

Me

asu

red

Dim

en

sio

ns

sha

ll b

e m

ark

ed

on

ea

ch C

om

po

ne

nt

dra

win

gs

wit

h

allo

we

d d

ime

nsi

on

al v

ari

ati

on

s.

Me

cha

nic

al

pro

pe

rtie

s M

fr’s

TC

/

dra

win

g /

Te

ch.

Spe

cifi

cati

on

IS:1

57

0/I

S10

30

dra

win

g /

Te

ch.

Spe

cifi

cati

on

IS:1

57

0/I

S10

30

5.1

2

Dim

en

sio

ns/

sta

tic

an

d

Dyn

am

ic b

ala

nci

ng

/ K

ey

wa

y a

nd

ke

y in

spe

ctio

n.

Ma

jor

Ba

lan

cin

g te

st/

10

0%

C

om

po

ne

nt

Co

mp

on

en

t M

fr's

TC

3,2

-

1

1. D

ynam

ic b

ala

nce

re

po

rt s

ha

ll b

e

revi

ew

ed

by T

PIA

.

2. M

ea

sure

d D

ime

nsi

on

s sh

all

be

ma

rke

d o

n e

ach

Co

mp

on

en

t d

raw

ing

s

wit

h a

llow

ed

dim

en

sio

na

l va

ria

tio

ns.

Me

asu

rem

en

t d

raw

ing

/

dra

win

g /

wit

h

ve

rnie

r /

m

icro

me

ter

Sp

eci

fica

tio

n

Sp

eci

fica

tio

n

QA

P -

06

Q

UA

LIT

Y A

SS

UR

AN

CE

, IN

SP

EC

TIO

N A

ND

TE

ST

ING

PLA

N F

OR

EO

T C

RA

NE

S

Leg

en

d

1 T

hir

d P

art

y I

nsp

ect

ion

Ag

en

cy

2 V

en

do

r (C

ran

e S

up

pli

er)

3 S

ub

Ve

nd

or

/ It

em

Su

pp

lie

r

Sig

na

ture

of

Cra

ne

Ve

nd

or

wit

h D

esi

gn

ati

on

Pla

ce

Da

te:

S

l.

No

C

om

po

ne

nts

/

Op

era

tio

ns

C

ha

ract

eri

stic

to b

e c

he

cke

d

C

ate

go

ry

T

yp

e /

Me

tho

d o

f

che

ck

E

xte

nt

of

che

ck

R

ef.

Do

cum

en

t

Acc

ep

tan

ce

No

rm

F

orm

at

of

reco

rd

Ag

en

cy

R

em

ark

s

Performed

Witnessed

Verified

A

B

C

D

E

F

G

H

I J

K

6

BO

UG

HT

-OU

T &

Oth

er

ite

ms

6.1

Wir

e R

op

e

Dim

en

sio

na

l,

Ge

nu

ine

M

ajo

r M

fr's

TC

/

10

0%

C

om

po

ne

nt

Co

mp

on

en

t M

fr's

TC

3

,2

1

-

Re

vie

w o

f M

fr's

TC

by T

PIA

.

Vis

ua

l exa

min

ati

on

of

wir

e r

op

e f

or

an

y

de

fect

s b

y 2

& 1

.

of

ma

ke,

Lay,

co

re a

nd

m

ea

sure

me

nt

dra

win

g/

BO

M/

dra

win

g /

BO

M /

sta

nd

s, T

en

sile

gra

de

IS 2

26

6

IS 2

26

6

Bre

aki

ng

Lo

ad

te

st

Ma

jor

Mfr

's T

C

10

0%

IS

22

66

IS

22

66

M

fr's

TC

3

-

1

6.2

B

ea

rin

gs

Be

ari

ng

No

./ G

en

uin

e

ma

ke c

on

form

ity

Ma

jor

Mfr

's T

C/

10

0%

A

pp

rove

d m

ake

SK

F/FA

G/T

IMK

EN

M

fg T

C/

2

1

-

In

voic

e

an

d t

ype

Su

pp

lier

IR

6.3

M

ach

ine

d F

it B

olt

s &

N

uts

Ma

teri

al c

om

po

siti

on

/ M

ajo

r C

orr

ela

tio

n w

ith

1

00

%

Ap

pro

ved

co

mp

. A

pp

rove

d c

om

p.

Mfr

's T

C/

Te

st

rep

ort

s/

Sup

plie

r's

IR

3

,2

-

1

Me

asu

red

Dim

en

sio

ns

sha

ll b

e m

ark

ed

on

ea

ch C

om

po

ne

nt

dra

win

gs

wit

h

allo

we

d d

ime

nsi

on

al v

ari

ati

on

s.

Me

cha

nic

al

pro

pe

rtie

s /

Mfr

’s T

C /

d

raw

ing

/ T

ech

. d

raw

ing

/ T

ech

. M

ea

sure

dim

en

sio

ns

Me

asu

rem

en

t Sp

eci

fica

tio

n /

IS

Sp

eci

fica

tio

n

IS:1

57

0/I

S3

64

0

6.4

FA

ST

EN

ER

S (

Bo

lts,

nu

ts,

wa

she

rs, l

ock

nu

ts)

Typ

e /

Ge

nu

ine

ma

ke

con

form

ity /

me

asu

rem

en

t

Ma

jor

Mfr

's T

C/

10

0%

A

pp

rove

d m

ake

T

VS/

UN

BR

AK

O

Mfg

TC

/

2

-

1

Co

nso

lid

ate

d lis

t o

f si

ze f

ast

en

ers

wit

h (

stre

ng

th c

lass

an

d m

ake

sh

all

be

su

bm

itte

d)

Invo

ice

a

nd

typ

e

Su

pp

lier

IR

7

ELEC

TR

ICA

L E

QU

IPM

ENT

7.1

E

lect

rica

l Co

ntr

ol

Dim

en

sio

na

l, V

isu

al

Ma

jor

Ele

ctri

cal t

est

1

00

%

Ele

ctri

cal C

ircu

it

Ap

pro

ved

Su

pp

lier'

s IR

3

1

Re

vie

w o

f te

st c

ert

ific

ate

s o

f a

ll b

ou

gh

t

ou

t it

em

s b

y IA

P

an

els

( V

VV

F d

riv

e

Se

qu

en

ce /

Fu

nct

ion

al

dia

gra

m/

dra

win

g/

pa

ne

ls)

an

d h

igh

vo

ltag

e T

est

A

pp

rove

d

Sp

eci

fica

tio

n.

dra

win

g/

Sp

eci

fica

tio

ns

7.2

M

oto

r V

isu

al/

Nam

e P

late

M

ajo

r N

am

e P

late

1

00

%

IS 3

25

/ Sp

ec

IS 3

25

/sp

ec

Mfr

's T

C

2

-

1

7.2

.1

Ro

uti

ne

/ N

o lo

ad

te

st

Ma

jor

Ele

c. t

est

1

00

%

IS 3

25

IS

32

5

Mfr

's T

C

3

-

2, 1

R

evi

ew

of

TC

& F

lam

ep

roo

f ce

rtif

ica

tes

by

TP

IA

7.2

.2

Flam

ep

roo

f te

st c

ert

. M

ajo

r G

ap

me

asu

re

10

0%

IS

21

48

/ C

MR

I IS

21

48

/ C

MR

I T

ype

te

st c

ert

.

3

-

2

,1

Q

UA

LIT

Y A

SS

UR

AN

CE

, IN

SP

EC

TIO

N A

ND

TE

ST

ING

PLA

N F

OR

EO

T C

RA

NE

S

Leg

en

d

1 T

hir

d P

art

y I

nsp

ect

ion

Ag

en

cy

2 V

en

do

r (C

ran

e S

up

pli

er)

3 S

ub

Ve

nd

or

/ It

em

Su

pp

lie

r

Sig

na

ture

of

Cra

ne

Ve

nd

or

wit

h D

esi

gn

ati

on

Pla

ce

Da

te:

QA

P -

07

Q

UA

LIT

Y A

SS

UR

AN

CE

, IN

SP

EC

TIO

N A

ND

TE

ST

ING

PLA

N F

OR

EO

T C

RA

NE

S

Leg

en

d

1 T

hir

d P

art

y I

nsp

ect

ion

Ag

en

cy

2 V

en

do

r (C

ran

e S

up

pli

er)

Pla

ce

Da

te:

Sig

na

ture

of

Cra

ne

Ve

nd

or

wit

h D

esi

gn

ati

on

3 S

ub

Ve

nd

or

/ It

em

Su

pp

lie

r

S

l.

No

C

om

po

ne

nts

/

Op

era

tio

ns

C

ha

ract

eri

stic

to b

e c

he

cke

d

C

ate

go

ry

T

yp

e /

Me

tho

d o

f

che

ck

E

xte

nt

of

che

ck

R

ef.

Do

cum

en

t

Acc

ep

tan

ce

No

rm

F

orm

at

of

reco

rd

Ag

en

cy

R

em

ark

s

Performed

Witnessed

Verified

A

B

C

D

E

F

G

H

I J

K

7.3

B

rake

s a

nd

Th

rust

ers

,

Bra

ke C

oil

Vis

ua

l/ N

am

e p

late

/

Ma

ke T

orq

ue

& T

hru

st /

Ma

teri

al T

C v

eri

fy /

Te

st

cert

ific

ate

/ E

x p

roo

f

cert

ific

ate

Acc

ess

ibili

ty o

f p

art

s.

Ma

jor

Nam

e p

late

de

tails

, m

ake

Ve

rifi

cati

on

of

TC

,

Ve

rifi

cati

on

of

Ex-

pro

of

TC

10

0%

A

pp

rove

d

Dra

win

g/

Ma

ke/

BO

M/S

pe

c

Ap

pro

ved

Dra

win

g/

Ma

ke/

BO

M/S

pe

c/

AT

EX

- P

TB

/

IS2

14

8 -

CM

RI

Mfr

's T

C/

Typ

e

test

ce

rt f

or

Flam

ep

roo

f /

Sup

plie

r IR

3

-

1

Re

vie

w o

f T

C &

Ex-

pro

of

cert

ific

ate

s

by

TP

IA

7.4

R

esi

sta

nce

bo

x M

eg

ge

r te

st,

Re

sist

an

ce

valu

e

Ma

jor

Ele

ctri

cal

test

1

00

%

BO

M/

dra

win

g

/ Sp

eci

fica

tio

ns.

BO

M/

dra

win

g /

Spe

cifi

cati

on

s.

Mfr

's T

C

3

-

1

R

evi

ew

by T

PIA

.

7.5

M

ast

er

con

tro

ller

/ Li

mit

sw

itch

es

/ Sw

itch

G

ea

r

Seq

ue

nce

, N

um

be

r

of

cam

s, Id

le

op

era

tio

na

l te

st

Ma

jor

Vis

ua

l 1

00

%

BO

M/

dra

win

g /

Spe

cifi

cati

on

s.

BO

M/

dra

win

g /

Spe

cifi

cati

on

s.

Mfr

's T

C

3

-

1

Re

vie

w o

f T

C b

y I.

A.

7.6

C

ab

les

Ro

uti

ne

te

st

Ma

jor

Te

st

On

e p

er

BO

M/s

pe

c.

BO

M/s

pe

c.

Mfr

's T

C

3

-

1

Re

vie

w o

f T

C b

y I.

A.

8 H

A

SSEM

BLY

OF

CR

AN

E

(Be

fore

ass

em

bly

of

EO

T c

ran

e a

ll p

art

s sh

all

be

insp

ect

ed

by

TP

IA/P

urc

has

er.

Su

pp

lier

shal

l in

form

re

ad

ine

ss o

f a

ll p

art

s)

(HO

LD)

8.1

B

rid

ge

Gir

de

r &

En

d c

arr

iag

e

ass

em

bly

.

Ove

rall

Dim

en

sio

n s

Stru

ctu

ral A

lign

me

nt

&

LT W

he

el a

lign

me

nt.

Spa

n m

easu

rem

en

t

Dia

go

na

l Ch

eck

s

Ma

jor

Me

asu

rem

en

t/

visu

al

insp

ect

ion

10

0%

A

pp

rove

d

Ge

ne

ral

Arr

an

gem

en

t

dra

win

g /

Spe

cifi

cati

on

s

Ap

pro

ved

Ge

ne

ral

Arr

an

gem

en

t

dra

win

g /

Spe

cifi

cati

on

s

Sup

plie

r's

IR

2

1

-

Me

asu

red

Dim

en

sio

ns

/

alig

nm

en

t va

lue

s sh

all

be

mark

ed

on

Ass

em

bly

/co

mp

on

en

t d

raw

ing

s w

ith

allo

we

d

dim

en

sio

na

l va

ria

tio

ns.

8.2

C

rab

ass

em

bly

wit

h

Ma

in

Ho

ist

& C

T m

ach

ine

ry

Dim

en

sio

na

l & C

T

Wh

ee

l a

lign

men

t

Co

up

ling

s’ a

lign

me

nt

Ma

jor

Me

asu

rem

en

t 1

00

%

Ap

pro

ved

dra

win

g /

Spe

cifi

cati

on

s

Ap

pro

ved

dra

win

g /

Spe

cifi

cati

on

s

Sup

plie

r's

IR

2

1

-

Me

asu

red

Dim

en

sio

ns

/

alig

nm

en

t va

lue

s sh

all

be

mark

ed

on

GA

/co

mp

on

en

t d

raw

ing

s w

ith

allo

we

d d

ime

nsi

on

al v

ari

ati

on

s/

Alig

nm

en

t va

lue

s.

QA

P -

08

Q

UA

LIT

Y A

SS

UR

AN

CE

, IN

SP

EC

TIO

N A

ND

TE

ST

ING

PLA

N F

OR

EO

T C

RA

NE

S

Leg

en

d

1 T

hir

d P

art

y I

nsp

ect

ion

Ag

en

cy

2 V

en

do

r (C

ran

e S

up

pli

er)

Pla

ce

Da

te:

Sig

na

ture

of

Cra

ne

Ve

nd

or

wit

h D

esi

gn

ati

on

3 S

ub

Ve

nd

or

/ It

em

Su

pp

lie

r

S

l.

No

C

om

po

ne

nts

/

Op

era

tio

ns

C

ha

ract

eri

stic

to b

e c

he

cke

d

C

ate

go

ry

T

yp

e /

Me

tho

d o

f

che

ck

E

xte

nt

of

che

ck

R

ef.

Do

cum

en

t

Acc

ep

tan

ce

No

rm

F

orm

at

of

reco

rd

Ag

en

cy

R

em

ark

s

Performed

Witnessed

Verified

A

B

C

D

E

F

G

H

I J

K

9

H

LOA

D T

EST

ING

AT

WO

RK

S

(HO

LD)

9.1

N

O L

OA

D T

EST

N

O L

oa

d t

est

/

Pe

rfo

rma

nce

& S

afe

ty

syst

em

s ve

rifi

cati

on

spe

ed

, C

urr

en

t e

tc.,

Ma

jor

NO

Lo

ad

te

st/

Me

asu

rem

en

t

of

pa

ram

ete

rs

10

0%

A

pp

rove

d d

wg

/

IS8

07

/ IS

31

77

/Sp

eci

fica

tio

n

Ap

pro

ved

dw

g /

IS8

07

/ IS

31

77

/Sp

eci

fica

tio

n

Sup

plie

r's

IR &

Loa

d t

est

Form

at

2

1

-

Me

asu

re G

ea

r B

ox

No

ise

. (N

ois

e

Leve

l sh

ou

ld b

e <

75

dB

A).

(M

H , C

T &

LT

me

cha

nis

ms)

9.2

FU

LL L

OA

D (

SW

L) T

ES

T A

T W

OR

KS

FO

R H

OIS

T &

CT

MO

TIO

NS

9.2

.1

DE

FLE

CT

ION

TE

ST

De

fle

ctio

n

Ma

jor

Me

asu

rem

en

t 1

00

%

Sp

eci

fica

tio

ns/

Sp

eci

fica

tio

ns/

Su

pp

lier'

s IR

&

Loa

d t

est

Form

at

2

1

-

De

fle

ctio

n <

Sp

an

/10

00

. R

eco

rd

pro

ced

ure

of

test

& m

ea

sure

me

nt

wit

h s

ketc

h.

Wit

h S

afe

Wo

rkin

g L

oa

d

as

pe

r ap

pro

ve

d

pro

ced

ure

.

IS8

07

/ IS

31

77

IS

80

7/

IS 3

17

7

9.2

.2

Ho

ist

Wit

h S

afe

Wo

rkin

g

Loa

d

Pe

rfo

rma

nce

, d

uty

cycl

e,

Spe

ed

s, C

urr

en

t, ,

Sa

fety

syst

em

s e

tc.,

Ma

jor

Full

Lo

ad

te

st/

Me

asu

rem

en

t

of

pa

ram

ete

rs

10

0%

A

pp

rove

d d

wg

/

IS8

07

/ IS

31

77

/Sp

eci

fica

tio

n

Ap

pro

ved

dw

g /

IS8

07

/ IS

31

77

/Sp

eci

fica

tio

n

Loa

d t

est

2

1

-

Me

asu

re G

ea

r B

ox

No

ise

. (N

ois

e

Leve

l sh

ou

ld b

e <

80

dB

A)

. re

po

rt

/Su

pp

lier'

s IR

9.2

.3

CT

Me

chan

ism

Wit

h S

afe

Wo

rkin

g L

oa

d

Pe

rfo

rma

nce

, d

uty

cycl

e,

Spe

ed

s, C

urr

en

t, ,

Sa

fety

syst

em

s e

tc.,

Ma

jor

Full

Lo

ad

te

st/

Me

asu

rem

en

t

of

pa

ram

ete

rs

10

0%

A

pp

rove

d d

wg

/

IS8

07

/ IS

31

77

/Sp

eci

fica

tio

n

Ap

pro

ved

dw

g /

IS8

07

/ IS

31

77

/Sp

eci

fica

tio

n

Loa

d t

est

2

1

-

Me

asu

re G

ea

r B

ox

No

ise

. (N

ois

e

Leve

l sh

ou

ld b

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. re

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rt

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pp

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O

VE

R L

OA

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12

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SW

L)

TE

ST

(Ho

ist

& C

T)

Sta

tic

test

/ C

ap

ab

ility

of

all

mo

tio

ns/

P

erm

an

en

t

set

Ma

jor

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pa

bili

ty o

f C

T

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t m

oti

on

/

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asu

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en

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/

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/ IS

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AIN

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d/

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all

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rt o

f in

spe

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xtu

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al i

nsp

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SS

PC

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/2

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h p

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t th

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om

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in µ

m /

Vis

ua

l D

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AN

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N A

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ce

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ub

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l.

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ep

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ce

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rm

F

orm

at

of

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rd

Ag

en

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R

em

ark

s

Performed

Witnessed

Verified

A

B

C

D

E

F

G

H

I J

K

10

.3

Ep

oxy

pa

int

Pa

inti

ng

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o c

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ts o

f 8

0 µ

m &

40

µm

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ea

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an

do

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/ e

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ter

. Fin

al

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in p

rese

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of

TP

IA.

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RE

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ON

AT

SIT

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NT

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R R

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ntr

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jor

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00

%

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pp

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d

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pp

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-

1

To

lera

nce

s:

of

pa

ram

ete

rs

dra

win

g /

IS 8

07

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cifi

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on

/

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17

7

dra

win

g /

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07

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cifi

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on

/

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7

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il sp

an

: ±

5m

m; Slo

pe

of

rail

: 1

/10

00

at

2m

inte

rva

l; H

eig

ht

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f :

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be

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en

LH

& R

H r

ails

; R

ail

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p :2

mm

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igh

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f ra

ils:

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mm

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ER

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ITE

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/ IS

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est

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at

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1

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Me

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ea

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ox

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ise

. (N

ois

e L

eve

l

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<7

5d

BA

).

(MH

, C

T &

LT

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ms)

12

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DE

FLE

CT

ION

TE

ST

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Sp

an

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00

. R

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rd

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rep

ort

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12

.4

CT

Me

chan

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h S

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07

/ IS

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ved

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/ IS

31

77

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n

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d t

est

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1

-

Me

asu

re G

ea

r B

ox

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ise

. (N

ois

e L

eve

l

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uld

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<8

0d

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) .

rep

ort

/Su

pp

lier'

s IR

QA

P -

10

QU

ALI

TY

AS

SU

RA

NC

E, I

NS

PE

CT

ION

AN

D T

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TIN

G P

LAN

FO

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OT

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AN

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l.

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om

po

ne

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/

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ns

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ha

ract

eri

stic

to b

e c

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cke

d

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ate

go

ry

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yp

e /

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d o

f

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ck

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xte

nt

of

che

ck

R

ef.

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cum

en

t

Acc

ep

tan

ce

No

rm

F

orm

at

of

reco

rd

Ag

en

cy

R

em

ark

s

Performed

Witnessed

Verified

A

B

C

D

E

F

G

H

I J

K

12

.5

LT M

ech

an

ism

Wit

h

Safe

Wo

rkin

g L

oa

d

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rfo

rma

nce

, d

uty

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en

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0%

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/

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/ IS

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pro

ved

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/ IS

31

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est

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ort

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pp

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s IR

2

1

-

Me

asu

re G

ea

r B

ox

No

ise

. (N

ois

e L

eve

l

sho

uld

be

<8

0d

BA

) .

12

.6

Bra

ke P

ath

Te

st/

Bra

kes

Eff

ect

ive

ne

ss

test

ing

fo

r a

ll m

oti

on

s

Ea

ch B

rake

ho

ldin

g

Bra

ke

pa

th /

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lay

be

twe

en

tw

o b

rake

s

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jor

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asu

rem

en

t

of

pa

th &

Bra

ke

cu

rre

nts

10

0%

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eci

fica

tio

ns/

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ke

pa

th

≤1

7m

m fo

r H

ois

t

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cifi

cati

on

s/

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ke

pa

th

≤1

7m

m fo

r H

ois

t

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d t

est

rep

ort

/Su

pp

lier'

s IR

2

1

-

12

.7

OV

ER

LO

AD

(1

25

%

SWL)

TE

ST

(M

H, C

T a

nd

LT m

oti

on

s)

Sta

tic

test

/ C

ap

ab

ility

of

all

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tio

ns/

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erm

an

en

t

set

Ma

jor

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pa

bili

ty o

f C

T

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rem

en

t

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0%

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pp

rove

d d

wg

/

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/ IS

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n

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pro

ved

dw

g /

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07

/ IS

31

77

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fica

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n

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plie

r's

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d t

est

rep

ort

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Re

cord

pro

ced

ure

fo

llow

ed

fo

r te

st &

me

asu

rem

en

t w

ith

ske

tch

. Aft

er

test

ing

che

ck f

or

an

y d

amag

e, cr

ack

s/p

ain

t

fla

kin

g

in lo

ad

be

ari

ng

mem

be

rs.

13

.

Fin

al P

ain

tin

g &

to

uch

up

A

est

he

tic

loo

k o

f cr

an

e/

DFT

me

asu

rem

en

t

Ma

jor

T

hic

kne

ss

me

asu

rem

en

t

Ra

nd

om

T

ech

.

Spe

cifi

cati

on

s.

T

ech

.

Spe

cifi

cati

on

s.

Sup

plie

r's

IR

2

1

-

Fi

na

l DFT

me

asu

red

in p

rese

nce

of

TP

IA /

IS

RO

14

Safe

ty f

ea

ture

s lik

e li

mit

swit

che

s, o

verl

oa

d r

ela

ys,

bu

ffe

rs,

sto

pp

ers

etc

.,

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rfo

rma

nce

, in

terl

ock

s

Min

or

Pe

rfo

rma

nce

10

0%

Te

ch .

Spe

cifi

cati

on

s./

IS3

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7

Te

ch .

Spe

cifi

cati

on

s./

IS3

17

7

Sup

plie

r’s

IR

2

1

-

Leg

en

d

1 T

hir

d P

art

y I

nsp

ect

ion

Ag

en

cy

2 V

en

do

r (C

ran

e S

up

pli

er)

Pla

ce

Da

te:

Sig

na

ture

of

Cra

ne

Ve

nd

or

wit

h D

esi

gn

ati

on

3 S

ub

Ve

nd

or

/ It

em

Su

pp

lie

r

QA

P -

11

Spares - 1

LIST OF SPARE PARTS

(LUMPSUM PRICE FOR EACH CRANE MUST BE MENTIONED SEPERATELY )

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 hoist No. 1

II Mechanical

7 Brake liner for Hoist Set 2

8 Thruster assembly for Imported Main hoist Brake (flame proof) (Thruster

type selected for the crane during detailed engineering) 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 AH gearbox. Nos. 2

13 Sealing rings for geared coupling (each type - 1no.) Set 2

14 Main hoist thruster brake springs Nos. 2

15 LT rail clamps Sets 5

16 CT rail clamps Sets 5

17 Special grease nipples of different sizes (Each) No 10

TOTAL COST OF SPARES (Rs.)

S a t i sh Dhawan Spac e Cen t e r SHAR S a t i sh Dhawan Spac e Cen t e r SHAR S a t i sh Dhawan Spac e Cen t e r SHAR S a t i sh Dhawan Spac e Cen t e r SHAR

Welcome, Materials Master (isro)31 August 2017,

17:16:08 IST

MAIN VIEW HELP

Preview For STANDARD TERMS AND CONDITIONS

Page Destination: Tender Header Format Type : Normal

. :

GOVERNMENT OF INDIA

DEPARTMENT OF SPACE

SATISH DHAWAN SPACE CENTRE

PURCHASE DIVISION

Tele No.08623-225023/225174/225127 Fax No.08623-225170/22-5028 e-Mail ID : [email protected], [email protected], [email protected]

STANDARD TERMS & CONDITIONS

1.OFFERS SHALL BE SENT ONLINE ONLY USING STANDARD DIGITAL SIGNATURE CERTIFICATE OF CLASS III WITH ENCRYPTION / DECRYPTION. THE TENDERS AUTHORISED ONLINE ON OR BEFORE THE OPEN AUTHORISATION DATE AND TIME ONLY WILL BE CONSIDERED AS VALID TENDERS EVEN THOUGH THE BIDS ARE SUBMITTED ONLINE.

2.THE TENDERER MUST AUTHORISE BID OPENING WITHIN THE TIME STIPULATED IN THE SCHEDULE BY SDSC SHAR. OTHERWISE THE ONLINE BID SUBMITTED WILL NOT BE CONSIDERED FOR EVALUATION. PHYSICAL COPY WILL NOT BE CONSIDERED EVEN THOUGH IT IS RECEIVED BEFORE THE BID SUBMISSION DATE. In case of two-part tenders, parties shall submit their offers as follows:-

1) Part-I – Techno-commercial Bid (No price details shall be mentioned in this bid and shall not upload the details of price along with the techno-commercial bid) 2) Part-II – Price Bid

In view of Two Part Tender, the Offers submitted contrary to above instructions will be summarily rejected. 3.In case, the tenderer is not interested to participate in the tender, the tenderer shall submit regret letter giving reasons, failing which future enquiries will not be sent. 4.Offer Validity: The validity of the offers / tenders should be 90 days (in case of single part tender) and 120 days (in case two part

tender) from the date of opening of the tenders. Tenders with offer validity less than the period mentioned above, will not be considered for evaluation. 5.GST - GST and/or other duties/levies legally leviable and intended to be claimed should be distinctly shown separately in the tender. GST details are given below

GSTIN: 37AAAGS1366J1Z1 LEGAL NAME : SATISH DHAWAN SPACE CENTRE SHAR VALIDITY FROM:29/08/2017

TYPE OF REGISTRATION:REGULAR 6.Customs Duty - SDSC-SHAR is eligible for 100% Customs Duty exemption as per Notification No. 050/2017 539 (b) Dt: 30.06.2017.

This may be taken into account while quoting for import items, if any. In case tenderers offering items considering customs duty exemption, they should also indicate the bill of materials and price, separately, with Customs Duty component and terms and conditions thereto. 8.Advance Payment - Wherever advance payment is requested, Bank Guarantee from any Nationalized Bank/Scheduled Bank should be

furnished. In case of advance payments, if the party is not supplying the material within the delivery schedule, interest will be levied as per the Prime Lending Rate of RBI plus 2% penal interest. Interest will be loaded for advance payments/stage payments as per the prime lending rate of RBI and will be added to the landed cost for comparison purpose. In case of different milestone payments submitted by the parties, a standard and transparent methodology like NPV will be adopted for evaluating the offers.

9.Liquidated Damages - In all cases, delivery schedule indicated in the Purchase Order/Contract is the essence of the contract and if the party fails to deliver the material within the delivery schedule, Liquidated Damages will be levied @ 0.5% per week or part thereof subject to a maximum of 10% of total order value. 10.Performance Bank Guarantee - Performance Bank Guarantee for 10% of the order value should be furnished in the form of Bank

Guarantee from nationalized/scheduled bank or by Demand Draft valid till warranty period plus sixty days as claim period.

Page 1 of 3

11.Security Deposit – Security Deposit for 10% of the order value is mandatory, if the ordered value is Rs.5.00 lakhs and above. Party shall furnish the Security Deposit in the form of Bank Guarantee from nationalized/scheduled bank or by Demand Draft valid till

completion of the contract period plus sixty days towards claim period for faithful execution of the contract. 12.BANK GUARANTEE FOR FIM: Supplier has to submit Bank guarantee for equal value of Free Issue of Materials (FIM) issued by the Department from Nationalised / Scheduled Bank valid till receipt and acceptance of supply and satisfactory accounting of FIM plus sixty days as claim period.

13.The delivery period mentioned in the tender enquiry, IF ANY, is with the stipulation that no credit will be given for earlier deliveries and offers with delivery beyond the period will be treated as unresponsive. 14.The Department will have the option to consider more than one source of supply and final orders will be given accordingly.

15.The bidders should note that conditional discounts would not have edge in the evaluation process of tenders. 16.Non-acceptance of any conditions wherever called for related to Guarantee/ Warranty, Performance Bank Guarantee, Security Deposit, Liquidated damages are liable for disqualification. 17.Wherever installation/ commissioning involved, the guarantee/warrantee period shall reckon only from the date of installation and

commissioning. 18.Purchase/Price Preference will be extended to the MSMEs under the Public Procurement Policy for MSMEs formulated under the Micro, Small and Medium Enterprises Development Act, 2006 and instructions issued by Government of India from time to time. Vendors who would like to avail the benefit of MSME should clearly mention the same and submit all the documentary evidences to substantiate their claim along with tender itself.

19.The drawings, specifications, end use etc., given by the Centre/Unit along with the tender enquiry are confidential and shall not be disclosed to any third party. 20.SPECIAL CONDITIONS FOR SUBMITTING QUOTATIONS IN FOREIGN CURRENCY BY THE INDIAN AGENTS

The Tenderer should submit the following documents/information while quoting:- a)Foreign Principal's proforma invoice/quote indicating the commission payable to the Indian Agent and nature of after sales service to be rendered by the Indian Agent. b)Copy of Agency agreement with the Foreign Principal and the Indian Agent, precise relationship between them and their mutual

interest in the business. c)Registration and item empanelment of the Indian Agent. d)Agency Commission will be paid only Indian Currency.

e)Compliance of the tax laws by the Indian Agent. 21. High Sea Sales- Against High Sea Sale transactions: a.Offers shall be on all inclusive basis including delivery upto Sriharikota at the risk and cost of the supplier. Customs Clearance is the responsibility of the supplier and at his cost and risk.

b.100% payment will be made within 30 days after receipt and acceptance of the items at our site. c. GST as applicable d.Customs Duty Exemption Certificate and other relevant documents required for Customs clearance will be provided.

e.High Sea Sales Agreement furnished by the supplier in accordance with the terms and conditions of our purchase order will be signed and issued by SDSC-SHAR. 22.The following information/ documents are to be submitted wherever applicable.

1.Product Literature 2.Core banking account number of SBI, RTGS Details 3.PAN No. in quotation and invoices

4.GST Registration details. 5.In case of MSME, registration details / documents from Competent Authority. 23.EXCLUSION OF TENDERS

The following tenders shall be summarily rejected from the procurement process a.Tenders received from vendors who have not qualified in terms of their registration. b.Tenders received against publishing of a limited tender in the CPP portal.

c.Tenders of vendors who have been removed from the vendor list or banned/debarred from having business dealings. d.Unsolicited tenders from vendors. e.The tenders which materially depart from the requirements specified in the tender document or which contain false information.

f.The tenders which are not accompanied by the prescribed Earnest Money Deposit. g.The tenders of vendors who have not agreed to furnish Security Deposit, Performance Bank Guarantee and Liquidated Damages. h.The validity of the tenders is shorter than the period specified in the tender enquiry.

i.The tenders received from vendors or their agents or anyone acting on their behalf, who have promised or given to any official of the Centre/Unit/Department, a gratification in any form, or anything of value, so as to unduly influence the procurement process. j.The tenders received from vendors, who, in the opinion of the Centre/Unit, have a conflict of interest materially affecting fair competition.

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k.The tenders received from Indian agents on behalf of their foreign Principals/OEMs (in cases where the Principals/OEMs also submit their tenders simultaneously for the same item/product in the same tender).

l.In case two or more tenders are received from an Indian agent on behalf of more than one foreign Principal/OEM, in the same tender for the same item/product. m.If a firm quotes ‘NIL’ charges / consideration, the bid shall be treated as un-responsive and will not be considered.

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