ANNEXURE - I - ISRO · 2018-06-01 · As the crane is intended to be used in hazardous area, the electrical motors, junction boxes, light fittings etc., should be of flame proof in

ANNEXURE - I

� SCOPE OF WORK

� Design, manufacture, supply, erection, testing and commissioning of 12 no’s of EOT Cranes

A. Flame Proof EOT Cranes:

1. 2t Flameproof Top Running Double Girder with Conventional Micro EOT Crane - 1 No

2. 7.5t Flame Proof Top Running Double Girder with Conventional Micro EOT Crane- 1 No

3. 1.5t Flame Proof Top Running Single Girder EOT Crane - 1 No

4. 1.5t Flame Proof Under Running Single Girder EOT Crane Suitable for ISMB 350 -1No

5. 7.5t Flame Proof Top Running Double girder with conventional micro EOT Crane - 1 No

6. 3.0 t Flame Proof Top Running Double Girder with Conventional micro EOT Crane - 1 No

7. 3.0t Flame Proof Top Running Double girder with conventional micro EOT Crane - 1 No

8. 2.0t Flame Proof Top Running Single girder EOT Crane - 1 No

9. 7.5t Flame Proof Top Running Double girder with VVVF Drive Micro EOT Crane - 1 No

10. 3.5 t Flame Proof Top Running Double Girder with Conventional Micro EOT Crane - 1 No

B. Non Flame Proof EOT Cranes:

11. 1.0t Non Flame Proof Top Running Single Girder EOT Crane - 1 No

12. 1.0t Non Flame Proof Top Running Single Girder EOT Crane - 1 No

(as per IS 3177 and as per IS:807 with latest amendments)

Note: 1. for non FLP Cranes intrinsic safe circuit are not required.

2. For Single girder EOT Cranes under bridge lights are not required.

� Supply and installation of down shop leads (Drag Chain system) and its accessories for the above cranes.

� Engaging third party agency like M/S Loyds register, M/S M.N. Dhastur, M/S BVQI and Det Norske Veritas (DNV) only, and its expenses towards the same.

� As the crane is intended to be used in hazardous area, the electrical motors, junction boxes, light fittings etc., should be of flame proof in nature and pendent station shall be interfaced with intrinsic safe barrier.

� Party shall fulfil and submit questionnaire and bid evaluation criteria as per Annexure – A

� Party shall fulfil the commercial terms and conditions as per Annexure – B

� Party shall quote in prescribed price bid format as per Annexure – C1, C2, C3, C4, C5, C6, C7, C8,

C9, C10, C11 & C12

� Main parameters are enclosed in Annexure – II A, II B, II C, II D, II E, II F, II G, II-H, II-I, II-J, II-K & II-L

� The list of approved make of items are as detailed in Annexure – III A & III B.

� Party shall submit calculations & Drawing as per in Annexure- IV.

� Code and standards that are to be followed are listed in Annexure- VA & VB.

� Party shall follow the detailed General and Technical specifications as in the specified Annexure- VI A & VI B.

� Party shall submit quality assurance plan(QAP) as per in the Annexure- VII.

� Party shall submit reports and test certificates as per in the Annexure- VIII A & VIII B.

� Key plan of facility enclosed in the Annexure – IX-A, IX-B, IX-C, IX-D, IX-E, IX-F, IX-G, IX-H, IX-I, IX-J, IX-K & IX-L for party reference.

ANNEXURE – IIA

Crane No. 01: 2t Flameproof Top Running Double Girder with

Conventional Micro EOT crane:

MAIN PARAMETERS

Sl. No

Description Specification

01 Safe Working Load (t) 2 ton

02 Type Flameproof Top running Double girder with Conventional Micro EOT crane

03 Duty

Class M5 (equivalent Class II) as per IS: 807-1976. IS: 3177-1999 with latest amendment for structure. This crane is intended to handle hazardous and highly explosive rocket segments, So that duty factor(cdf)shall be taken as 1.7 while designing on hoist.

04 Location Indoor (AP Storage facility)

05 Ambient temperature 20-50 degree centigrade

06 Atmospheric condition Near sea shore humidity

07 Area classification Hazardous area Zone 1, Gas group IIA, IIB as per IS: 5571, 5572, and IS: 8239,Temp ClassT4

08 Span 19400 mm (Distance between Centre of LT Rails)

09 Height of lift 5000 mm

10 Bay length 51500 mm

11

Vertical distance from top of the rail to nearest overhead obstruction (Head room)

2000 mm

12 Vertical Distance from FFL to Top of the Rail

5500 mm

13

Distance from center of the rail to nearest side obstruction (side clearance)

300 mm

14 Operating

speed(m/min)

Hoist main

2.5 m/min

LT

main 6.0m/min

CT

main

6.0m/min

15 Operating

speed(m/min)

Hoist micro

0.25 m/min through conventional micro Drive

LT micro

0.6m/min through conventional micro Drive

CT

micro 0.6m/min through conventional micro Drive

16 Nearest position of hook to the Centre of gantry rail (mm) CT

Not exceeding 800mm Left

Not Exceeding 750mm Right

(Left and Right with respective LT Drive)

17 Hook approach clearance (LT)

Not exceeding 2000mm Non Drive End

Not exceeding 2200mm Drive End

18 Bridge girder Fabricated out of plate box type construction

19 Type of hook Standard forged single point “C” hook with safety latch confirming to IS: 3815:1969, IS15560:2005 amendment No:March,2007 and IS1875

20 Type of wheel Double flanged wheels machined out of C55Mn75 forging, hardened as per IS: 3177 and mounted on ‘L” type bearings housings.

21 a)Wire rope Galvanized,6x36,RHO, IWRC, Tensile strength Min 1960Mpa

b) Factor of safety 6.0

22 Brakes (EHT)

The torque capacity of brakes shall be 2.0 times the rated full torque of the selected motor for main and for LT & CT the torque capacity of brakes shall be 1.5 times the rated full torque of the selected motor

2Nos of Imported brakes for main hoist and 1 no indigenous brake each for LT & CT operations of approved makes only.

23 Bearings Anti-friction ball roller bearings shall be provided

24 Lubrication Individual grease nipples shall be provided for grease lubrication points.

25 Gear box

Oil splash lubricated, fully enclosed type gear boxes with EN24/EN9 pinions and gears, and shall be duly hardened to 250-280 BHN. Main Hoist Gear box shall be Horizontal type.

The noise level shall not be more than 80dB when the Gear box operated alone, measured at 1m distance from the gear box. Note: if vertical gear box selected for CT, lubrication pump shall be provided. Own gear boxes are not acceptable.

26 Couplings Full gear couplings of make as per list

27 Motor

High starting torque, 60% CDF, S4 duty, IP 55, class F insulation, 300 starts / hour, Flame proof squirrel cage induction motors in TEFC enclosure as per IS: 325 shall be provided for all the motions. The full load torque rating of the motor shall be 20% excess of the capacity calculated as per IS: 3177. The pull out torque shall not be less than 2.75 times of full load torque. The motor shall not draw more than 80% of its rated current at full load.

28 Limit switches

One number of gravity type limit switch to trip entire control supply in case of activation during hoisting up. One number of rotary type (for up& down) for hoist system and shall have two additional NC points. Four Nos of Two Way lever type for LT & CT operations.

29 Power supply 415 Volts +/-10%, 50 Hz +/-3%, 3 Phase supply.

30 Control supply Contactor circuit 110 V, AC,230 VAC for lamps & socket, intrinsic safe supply for pendent control.

31 Pendent Control

Operation from floor through light weight pendent push button station moveable along the bridge girder on four wheeled cable trolleys with anti-friction ball bearing running on a separate track with Intrinsic Safe Control confirming to IS: 5780

32 Cable Drag Chain system and Cable tray

The LT & CT Movements shall be planned with Cable Drag chain system with necessary supporting system like beam/angles , cable tray etc., need to be considered. The cables shall also be of

IGUS/LAP make suitable for Drag chain application. Perforated cable trays need to be planned for routing the cables from panel to top of the crane. The tray shall be covered and Earthed to common grounding.

33 Cables PVC sheathed, flexible cables with multi strand copper conductors cable shall be provided.

34 Power Supply at DSL The power available at 415 volts, 3 phase, 4 wire, 50 HZ near by the crane panel.

35 Cross Travel cable arrangement

PVC sheathed, flexible cables with multi strand copper conductors cable & chain drag system shall be provided.

36 Power feed arrangement for the hoist

PVC sheathed, flexible cables with multi strand copper conductors cable chain drag system.

37 Pendent Pendent cable shall be on independent “T” track.

38 Buffer Rubber buffers for LT & CT

39 Painting

The entire crane structure will be provided with one coat of zinc rich primer, one coat of golden yellow finish paint before dispatch at site and one more coat of golden yellow finish paint after crane erection at site.

40 Other points

1. Parties shall follow as per annexures I to IX. 2. The crane shall be load tested for no load, full load and

125% over load test prior to dispatch. 3. The noise level: shall not be more than 85 dB when the

crane is operated at full load – measured at 1m distance from the crane gear box

4. Load testing at site after erection.

ANNEXURE – IIB

Crane No. 02: 7.5t Flame Top Running Proof Double girder with conventional micro EOT crane

MAIN PARAMETERS

Sl. No


01 Safe Working Load (t) 7.5 ton

02 Type Flame proof Double girder with conventional micro EOT crane

03 Duty


04 Location Indoor (AP Bin Storage facility)




08 Span 14400 mm (Distance between Centre of LT Rails).


10 Distance from FFL to Top of the Rail

8500 mm


12


3000 mm

13


300 mm

14 Operating

speed(m/min)

Hoist main

2.5 m/min

LT

main 6.0m/min

CT

main

6.0m/min

15 Operating

speed(m/min)

Hoist micro


LT micro


CT














22 Brakes (EHT)





25 Gear box


The noise level shall not be more than 80dB when the Gear box operated alone, measured at 1m distance from the gear box. Note: if vertical gear box selected for CT, lubrication pump shall be provided. Input Power Transmissions, Elements, pinions and gears shall be inspected with UT/Suitable Radiography test. The Service factor of Gear Box shall be 2 over the motor kW rating. Own gear boxes are not acceptable.


27 Motor

High starting torque, 60% CDF, S4 duty, IP 55, class F insulation, 300 starts / hour, Flame proof squirrel cage induction motors in TEFC enclosure as per IS: 325 shall be provided for all the motions. The rating of the motor shall be 20% excess of the capacity calculated as per IS: 3177. The motor shall not draw more than 80% of its rated current at full load. The motor shall be provided with thermistor embedded in the winding.

28 Limit switches Limit switches Gravity (for up) & Rotary Type (for up& down) for motion speed hoist system and two way lever type (1 no) each for LT & CT operations.

29 Power supply 415 Volts, 50 Hz, 3 Phase supply.

30 Control supply Contactor circuit 110 V, AC

31 Pendent Control


32 DSL PVC sheathed, flexible cables with multi strand copper conductors cable chain drag system shall be provided.


PVC sheathed, flexible cables with multi strand copper conductors cable chain drag system shall be provided.





37 Painting


38 Other points

1 Parties shall follow as per annexures I to IX. 2 The crane shall be load tested for no load, full load and 125%

over load test prior to dispatch. 3 The noise level: shall not be more than 85 dB when the crane

is operated at full load – measured at 1m distance from the crane gear box

4 Load testing at site after erection.

ANNEXURE – IIC

Crane No. 03: 1.5t Flameproof Top Running Single Girder EOT crane

MAIN PARAMETERS

Sl. No



02 Type Flameproof Single girder Top running EOT crane

03 Duty


04 Location Indoor (AP Grinding facility Collection Room)






10 Distance from FFL to Top of the Rail

6500 mm


12


1500mm

13


300 mm

14 Operating speed(m/min)

Hoist main

1.5 m/min

LT main

3.0m/min

CT main

3.0m/min













21 Brakes (EHT)





24 Gear box


The noise level shall not be more than 80dB when the Gear box operated alone, measured at 1m distance from the gear box. Note: if vertical gear box selected for CT, lubrication pump shall be provided.


26 Motor


27 Limit switches




30 Pendent Control



The LT & CT Movements shall be planned with Cable Drag chain system with necessary supporting system like beam/angles , cable tray etc., need to be considered. The cables shall also be of IGUS make suitable for Drag chain application. Perforated cable trays need to be planned for routing the cables from panel to top of the crane. The tray shall be covered and Earthed to common grounding.

32 Cables PVC sheathed, flexible cables with multi strand copper conductors cable chain drag system shall be provided.








38 Painting


39 Other points


125% over load test prior to dispatch. 3. The noise level: shall not be more than 85 dB when the

crane is operated at full load – measured at 1m distance from the crane gear box


ANNEXURE – II D

Crane No. 04: 1.5t Flameproof Under Running Single Girder EOT Crane

MAIN PARAMETERS

Sl. No



02 Type Flameproof Under running Single girder EOT crane

03 Duty


04 Location Indoor (AP Grinding facility Feeder Room)




08 Span 7400 mm (Distance between Centre of ISMBs) suitable to ISMB:350



11 Vertical distance between FFL to bottom of ISMB

9500 mm

12

Distance from center of the ISMB to nearest side obstruction (side clearance)

300 mm

13 Operating speed(m/min)

Hoist main

1.5 m/min

LT main

3.0m/min

CT main

3.0m/min






Not exceeding 1500mm Non Drive End Not exceeding 1500mm Drive End



18 Type of wheel Flanged wheels machined out of C55Mn75 forging, hardened as per IS: 3177.



20 Brakes (EHT)





23 Gear box




25 Motor


26 Limit switches




29 Pendent Control



The LT & CT Movements shall be planned with Cable Drag chain system with necessary supporting system like beam/angles , cable tray etc., need to be considered. The cables shall also be of IGUS/LAP make suitable for Drag chain application. Perforated cable trays need to be planned for routing the cables from panel to top of the crane. The tray shall be covered and Earthed to common grounding.









37 Painting


38 Other points





ANNEXURE – II E

Crane No. 05: 7.5t Flame Proof Top Running Double girder with conventional micro EOT crane

MAIN PARAMETERS

Sl. No




03 Duty


04 Location Indoor (AP Drying facility)






10 Vertical distance from FFL to Top of the Rail

10000 mm


12


3000mm

13


300mm

14 Operating

speed(m/min)

Hoist main

2.5 m/min

LT

Main 6.0m/min

CT

main

6.0m/min

15 Operating

speed(m/min)

Hoist micro


LT micro


CT














22 Brakes (EHT)





25 Gear box




27 Motor





31 Pendent Control









37 Painting


38 Other points


125% over load test prior to dispatch. 3. The noise level: shall not be more than 85 dB when the crane



ANNEXURE – II F

Crane No. 06: 3.0 t Flame Proof Top Running Double girder with Conventional micro EOT crane

MAIN PARAMETERS

Sl. No




03 Duty


04 Location Indoor (Al. Powder processing facility)






10 Vertical distance from FFL to top of the Rail

9000 mm


12


3000mm

13


300mm

14 Operating

speed(m/min)

Hoist main

2.5 m/min

LT

main 6.0m/min

CT

main

6.0m/min

15 Operating

speed(m/min)

Hoist micro


LT micro


CT














22 Brakes (EHT)





25 Gear box




27 Motor

High starting torque, 60% CDF, S4 duty, IP 55, class F insulation, 300 starts / hour, Flame proof squirrel cage induction motors Inverter Duty in TEFC enclosure as per IS: 325 shall be provided for all the motions. The full load torque rating of the motor shall be 20% excess of the capacity calculated as per IS: 3177. The pull out torque shall not be less than 2.75 times of full load torque. The motor shall not draw more than 80% of its rated current at full load.

28 Limit switches




31 Pendent Control



The LT & CT Movements shall be planned with Cable Drag chain system with necessary supporting system like beam/angles , cable tray etc., need to be considered. The cables shall also be of IGUS/LAP

make suitable for Drag chain application. Perforated cable trays need to be planned for routing the cables from panel to top of the crane. The tray shall be covered and Earthed to common grounding.









39 Painting


40 Other points





ANNEXURE – II G

Crane No. 07: 3.0t Flame Proof Top Running Double girder with conventional micro EOT crane

MAIN PARAMETERS

Sl. No




03 Duty


04 Location Indoor (Bin Storage facility for HTPB/DOA & Al. Powder)







7500 mm


12


2500mm

13


300mm

14 Operating

speed(m/min)

Hoist main

2.5 m/min

LT

main 6.0m/min

CT

main

6.0m/min

15 Operating

speed(m/min)

Hoist micro


LT micro


CT














22 Brakes (EHT)





25 Gear box




27 Motor


28 Limit switches




31 Pendent Control



The LT & CT Movements shall be planned with Cable Drag chain system with necessary supporting system like beam/angles , cable tray etc., need to be considered. The cables shall also be of IGUS/LAP

make suitable for Drag chain application. Perforated cable trays need to be planned for routing the cables from panel to top of the crane. The tray shall be covered and Earthed to common grounding.









39 Painting


40 Other points





ANNEXURE – II H

Crane No. 08 : 2.0t Flame Proof Top Running Single girder EOT CRANE

MAIN PARAMETERS

Sl. No



02 Type Flame proof Top Running Single girder EOT crane

03 Duty


04 Location Indoor (Agni Carton oven facility)







6000 mm


12


1000mm

13


300mm

14 Operating Hoist main

2.5 m/min

speed(m/min) LT Main

6.0m/min

CT main

6.0m/min










19 Type of wheel

(LT ONLY)

Double flanged wheels machined out of C55Mn75 forging, hardened as per IS: 3177 and mounted on ‘L” type bearings housings.

20

a)Wire rope Galvanized,6x36,RHO, IWRC, Tensile strength Min 1960Mpa


21 Brakes (EHT)





24 Gear box




26 Motor


27 Limit switches




30 Pendent Control



The LT & CT Movements shall be planned with Cable Drag chain system with necessary supporting system like beam/angles , cable tray etc., need to be considered. The cables shall also be of IGUS make suitable for Drag chain application. Perforated cable trays need to be planned for routing the cables from panel to top of the crane. The tray shall be covered and Earthed to common grounding.









38 Painting


39 Other points





ANNEXURE – II I

Crane No. 09: 7.5t Flame Proof Top Running Double girder with VVVF Drive EOT Crane

MAIN PARAMETERS

Sl. No



02 Type Flame proof Top running Double girder with VVVF Drive micro EOT Crane

03 Duty


04 Location Indoor (4.5t Mixer facility Feeder Room)







18500 mm


12


2500mm

13


350mm

14 Operating

speed(m/min)

Hoist main

2.5 m/min

LT

Main 6.0m/min

CT

main

6.0m/min

15 Operating

speed(m/min)

Hoist micro

0.25 m/min through VVVF Drive (Siemen/ABB)

LT micro

0.6m/min through VVVF Drive(Siemen/ABB)

CT

micro 0.6m/min through VVVF Drive(Siemen/ABB)











21

a)Wire rope Galvanized,6x36,RHO, IWRC, Tensile strength Min 1960Mpa


22 Brakes (EHT)





25 Gear box


The noise level shall not be more than 80Db when the Gear box operated alone, measured at 1m distance from the gear box. Note: if vertical gear box selected for CT, lubrication pump shall be provided. Input Power Transmissions, Elements, pinions and gears shall be inspected with UT/Suitable Radiography test. The Service factor of Gear Box shall be 2 over the motor kW rating. Own gear boxes are not acceptable.


27 Motor

High starting torque, 60% CDF, S5 duty, IP 55, class F insulation, 300 starts / hour, Flame proof squirrel cage induction motors Inverter Duty in TEFC enclosure as per IS: 325 shall be provided for all the motions. The rating of the motor shall be 20% excess of the capacity calculated as per IS: 3177. The motor shall not draw more than 80% of its rated current at full load. The motor shall be provided with thermistor embedded in the winding and to be interfaced with VFD.




31 Pendent Control


32 DSL


While selecting cable length following points shall be considered

1.) Distance from VFD panel room to junction box 60 meters 2.) Height of lift 18meters 3.) Bay length 21.6meters







37 Painting


38 Other points





39 SPARES of VVVF drives(Siemen/ABB) & Encoders

Control Unit -01 No Power Module-01No for each rating Power supply Unit-01No Encoder Module-01No Encoder-01No (or equivalent as applicable for ABB)

40 Redundant arrangement

Hoist/ CT/LT shall be provided with changeover arrangements by manually

actuating power & control switches in case VVVF Drive fails using contactor

& overload protections.

Necessary interlocking shall be provided in drive mode and in contactor

mode.

In redundant arrangement EOT crane will be operated with main speed to meet contingency requirements.

ANNEXURE – II J

Crane No. 10: 3.5t Flame Proof Top Running Double girder with Conventional micro EOT Crane

MAIN PARAMETERS

Sl. No



02 Type Flame proof, Top running double girder with conventional micro EOT Crane

03 Duty


04 Location Indoor (2.5t Mixer facility Feeder Room)






10 Vertical distance from FFL to Top of the Rail

12500 mm


12


2500mm

13


300mm

14 Operating

speed(m/min)

Hoist main

2.5 m/min

LT

main 6.0m/min

CT

main

6.0m/min

15 Operating

speed(m/min)

Hoist micro

0.25 m/min through Conventional micro Drive

LT micro

0.6m/min through Conventional micro Drive

CT

micro 0.6m/min through Conventional micro Drive













22 Brakes (EHT)





25 Gear box




27 Motor





31 Pendent Control









37 Painting


38 Other points





ANNEXURE – II K

Crane No. 11: 1.0t Non Flame Proof top running Single Girder EOT Crane

MAIN PARAMETERS

Sl. No



02 Type Non Flame proof top running Single girder EOT crane

03 Duty Class M5 (equivalent Class II) As per IS: 807-1976. IS: 3177-1999 with latest amendment for structure and mechanics.

04 Location Indoor (TDI Process & Bin Storage facility)






10


1500mm

11 Vertical distance from FFL to top of the rail

5500 mm

11


300 mm

12 Operating

speed(m/min)

Hoist main

2.5 m/min

LT

main 6.0m/min

CT

main 6.0m/min








16 Bridge girder Fabricated out of rolled steel beam of plate box type construction

17 Type of hook Standard forged single point “C” hook with safety latch confirming to IS: 3815/IS:15560 (latest version)

18 Type of wheel

(LT ONLY)


19 a)Wire rope

Galvanized,6x36,RHO, IWRC, Usha Martin- Make, Tensile strength Min 1960Mpa


20 Brakes (EHT)





23 Gear box

Oil splash lubricated, fully enclosed type gear boxes with EN24/EN9 pinions and gears, and shall be duly hardened to 250-280 BHN. Main Hoist and LT Gear boxes shall be Horizontal type.


• Own make Gear boxes are not acceptable.


25 Motor

High starting torque, 60% CDF, S4 duty, IP 55, class F insulation, 300 starts / hour, squirrel cage induction motors. The rating of the motor shall be 20% excess of the capacity calculated as per IS: 3177. The motor shall not draw more than 80% of its rated current at full load.

26 Limit switches Limit switches Gravity (for up) & Rotary Type (for up& down) for hoist system and two way lever type (1 no) each for LT & CT operations.



29 Pendent Control Operation from floor through light weight pendent push button station moveable along the bridge girder on four wheeled cable trolleys with anti-friction ball bearing running on a separate track.





PVC sheathed, flexible cables with multi strand copper conductors cable chain drag system of IGUS make only.



35 Painting


36 Other points

1. Parties shall follow as per annexures I to IX. 2. The crane shall be load tested for no load, full load and 125%

over load test prior to dispatch. 3. The noise level: shall not be more than 85 dB when the crane



ANNEXURE – II L

Crane No. 12: 1.0t Non Flame Proof top running Single Girder EOT Crane

MAIN PARAMETERS

Sl. No



02 Type Non Flame Proof top running Single girder EOT crane

03 Duty Class M5 (equivalent Class II) As per IS: 807-1976. IS: 3177-1999 with latest amendment for structure and mechanics.

04 Location Indoor (Minor Ingredient Processing facility)






10 Vertical distance from FFL to top of the rail

8500 mm

10


1500mm

11


300 mm

12 Operating

speed(m/min)

Hoist main

1.5 m/min

LT

main 3.0m/min

CT

main

3.0m/min








16 Bridge girder Fabricated out of rolled steel beam of plate box type construction

17 Type of hook Standard forged single point “C” hook with safety latch confirming to IS: 3815/IS:15560 (latest version)

18 Type of wheel

(LT ONLY)


19 a)Wire rope

Galvanized,6x36,RHO, IWRC, Usha Martin- Make, Tensile strength Min 1960Mpa


20 Brakes (EHT)





23 Gear box

Oil splash lubricated, fully enclosed type gear boxes with EN24/EN9 pinions and gears, and shall be duly hardened to 250-280 BHN. Main Hoist and LT Gear boxes shall be Horizontal type.


• Own make Gear boxes are not acceptable.


25 Motor

High starting torque, 60% CDF, S4 duty, IP 55, class F insulation, 300 starts / hour, squirrel cage induction motors. The rating of the motor shall be 20% excess of the capacity calculated as per IS: 3177. The motor shall not draw more than 80% of its rated current at full load.

26 Limit switches Limit switches Gravity (for up) & Rotary Type (for up& down) for hoist system and two way lever type (1 no) each for LT & CT operations.



29 Pendent Control Operation from floor through light weight pendent push button station moveable along the bridge girder on four wheeled cable trolleys with anti-friction ball bearing running on a separate track.





PVC sheathed, flexible cables with multi strand copper conductors cable chain drag system of IGUS make only.



35 Painting


36

Other points





ANNEXURE – III A

LIST OF MANUFACTURERS / SPECIFIC BRANDS FOR BOUGHTOUT ITEMS. Flame Proof EOT Cranes 1. Gear boxes : Elecon / Premium /Flenda-Siemens Shanti/GREAVE 2. Wire ropes (All galvanized) : Usha Martin/ CASAR Germany/ BRIDON USA,Kiswire – KOREA/MALAYSIA 3. Flame proof Panels, Light fittngs : Baliga/FCG/Flameproof equipment Pvt Ltd/Stahl Glands, Junction Boxes etc., 4. Power & control cables. : IGUS/LAPP make cables as applicable shall be used

in cable drag chain system. The cable drag chain & cable shall be of same make.

Incab/ cable corpn of India, Universal/ Asian/ Finolex/ Polycab/ Lapp/RPG/ HAVELLS – Pendent/ fixed power & control cables.

5. Flame proof electric motors: : Kirloskar, Crompton Greaves,Bharat Bijilee. Alstom. 6. Thrustor brake for hoist : M/S Witton cramer,M/S Bubenzer Bremzen,M/S SIBRE 7. Thrustor brake for CT & LT : M/S Electromag methods (EMM)/Kateel/Sterling

Control 8 Power supply unit : M/S SIEMENS only

9. Limit switches : Speed-o-Control, EMM, Sterling control 10. Contactors, Over load Relays, : M/S SIEMENS only 11. Intrinsic Safe relays : P & F 12. Electrical Switch gears : M/s. Siemens 13. Bearings : SKF, FAG, TIMKEN 14. Couplings : Fenner, Love-joy 15. Paints : Berger, Asian paints, Jenson& Nicholson, Nerolac, Dulex, Poly coat 16. Cable chain drag system : M/S IGUS/LAPP

ANNEXURE – IIIB

LIST OF MANUFACTURERS / SPECIFIC BRANDS FOR BOUGHTOUT ITEMS. NON-Flame Proof EOT Cranes 1. Gear boxes : Elecon / Premium /Flenda-Siemens Shanti/GREAVE 2. Wire ropes (All galvanized) : Usha Martin/ CASAR Germany/ BRIDON USA Kiswire – KOREA/MALAYSIA 3. Panel : RITTAL/Siemens authorized panel builder. 4. Power & control cables. : IGUS/LAPP make cables as applicable shall be used

in cable drag chain system. The cable drag chain & cable shall be of same make.

Incab/ cable corpn of India, Universal/ Asian/ Finolex/ Polycab/ Lapp/RPG/ HAVELLS – Pendent/ fixed power & control cables.

5. Non Flame proof electric motors: : Kirloskar, Crompton Greaves,Bharat Bijilee. Alstom/ Siemens / ABB 6. Thrustor brake for hoist : M/S Witton cramer,M/s. Bubenzer Bremzen,M/s. SIBRE, M/s. GALVI 7. Thrustor brake for CT & LT : M/S Electromag methods, Kateel (EMM),Sterling Control 8 Power supply unit : M/S SIEMENS only

9. Limit switches : Speed-o-Control, EMM, Sterling control 10. Switch gear, Contactors, MCB etc., : M/S SIEMENS only 11. Intrinsic Safe relays : P & F 12. Bearings : SKF, FAG, TIMKEN 13. Couplings : Fenner, Love-joy 14. Paints : Berger, Asian paints, Jenson & Nicholson, Nerolac, Dulex, Poly coat 15. Cable chain drag system : M/S IGUS/LAPP

ANNEXURE – IV

THE PARTY SHALL SUBMIT THE FOLLOWING CALCULATIONS ALONG WITH DRAWINGS I. SIZING CALCULATIONS

1. Motor Selection – i) Main Hoist

ii) Travel Motion for CT & LT 2. Brake Selection – i) ) Main Hoist

ii) LT iii) CT

3. Wire ropes - Main Hoist

4. Sheaves

5. Rope drum – i) Thickness ii) Diameter

iii) Length 6. Gear box selection – (M.H, CT &LT )

7. Gear box calculations –

8. Coupling selection – i) Input, ii) Output iii) Hoist, CT& LT

9. Bearing life & Selection –

10. Angular twist for shaft – i) CT ii) LT iii) Rigid shaft

( Not applicable to single girder and under running cranes)

11. Wheel selection & spacing – i) Load

ii) Diameter selection for CT & LT 12. Rail selection – CT & LT, Contact Stresses

( Not applicable to under running cranes)

13. Braking path calculations for – i) Main Hoist

ii) CT iii) LT

14. Calculation of fleet angle for pulleys

II. STRUCTURAL & DESIGN CALCULATIONS :

1) Main Girder calculations

2) Camber calculations

3) Deflection of Girder < L/1000

4) Welding design of Main girder and end carriage

5) Collision effects

6) End carriage calculations

7) Goose neck calculations

8) Diaphragm calculations – I) Main Girder, II) End Carriage

9) Connection of the main girder to the end carriage& splice joints etc.,

10) Crab calculations

III. Electrical:

1. Cable sizes & type selected for different current values with voltage drop.

2. Torque speed curves of individual motors.

IV. Drawings:

MECHNICAL:

1) G.A drawings

2) Main Girder drawings

3) Crab drawings

4) End carriage drawings

5) Hook approaches drawings

6) LT arrangement

7) Snatch Block assembly.

8) Gear boxes

9) Rope drum

10) Sub assembly of wheels

ELECTRICAL :

1. Power Circuit Diagram

2. Control Circuit Diagram

3. Cable Schedule

5. General Arrangement Drawing of panel with layout of all components.

6. Pendent schematic drawing.

ANNEXURE – V A

CODES AND STANDARDS:

The design, manufacture and testing of flame proof cranes shall conform to the latest editions of the following codes and standards wherever applicable: IS: 3177 Code of Practice for Design of Overhead Traveling Cranes and Gantry Cranes other than Steel Works Cranes. IS: 800 Code of practice for use of structural steel in general building construction.

IS: 807 Code of Practice for Design, Manufacture, Erection and Testing (Structural Portion) of Cranes and Hoists. 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:3973 Selection, installation, maintenance and technical supply conditions of wire ropes

IS: 3443 Crane Rail Sections

IS: 325 Three Phase induction Motors.

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

IS:5571 Guide for selection of electrical equipment for hazardous areas

IS:5572 Classification of Hazardous Areas (Other than Mines) for electrical installations.

IS 2148 : 1981 Flameproof enclosures for electrical apparatus

IS 5780 : 1980Specification for Intrinsically Safe Electrical Apparatus and Circuits. IS:4237 : General requirements of switch gears and control gears for voltages not exceeding 1000V AC.

IS 13947 : Part 4 : Sec 1 : 1993 /IEC Pub 947-4-1 : 1990 Specification for Low-Voltage Switchgear and Controlgear - Part 1 to Part 5 : Contractors and Motor-Starters - Section 1 : Electromechanical Contactors and Motor Starters

IS:2062 : Steel for general structural purpose.

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

ANSI/AWS D14.1 Structural Welding code: Code of welding practice for Mill cranes and other material handling equipment

IS 1024 : 1999 Use of Welding in Bridges and Structures Subject to Dynamic Loading - Code of Practice

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 8610 : 1977 Specification for Point Hooks with Shank Capacity Up to 25 Tonnes-Trapezoidal Section

IS 3815/ IS 15560: Specification for point hooks with shank for general engineering purposes

ANNEXURE – V B

CODES AND STANDARDS:

The design, manufacture and testing of the Non flame proof crane shall conform to the latest editions of the following codes and standards wherever applicable: IS:3177 Code of Practice for Design of Overhead Traveling Cranes and Gantry Cranes other than Steel Works Cranes.

IS:800 Code of practice for use of structural steel in general building construction.

IS:807 Code of Practice for Design, Manufacture, Erection and Testing (Structural Portion) of Cranes and Hoists. 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:3973 Selection, installation, maintenance and technical supply conditions of wire ropes

IS: 3443 Crane Rail Sections

IS: 325 Three Phase induction Motors.

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

IS:4237 General requirements of switch gears and control gears for voltages not exceeding 1000V AC.

IS 13947 : Part 4 : Sec 1 : 1993 /IEC Pub 947-4-1 : 1990 Specification for Low-Voltage

Switchgear and Controlgear - Part 1 to Part 5 : Contractors and Motor-Starters - Section 1 : Electromechanical Contactors and Motor Starters

IS:2062 Steel for general structural purpose.

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 ANSI/AWS D14.1 Structural Welding code : Code of welding practice for Mill cranes and other

material handling equipment

IS 1024 : 1999 Use of Welding in Bridges and Structures Subject to Dynamic Loading - Code of Practice

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 8610 : 1977 Specification for Point Hooks with Shank Capacity Up to 25 Tonnes-Trapezoidal

Section IS 3815/ IS 15560: Specification for point hooks with shank for general engineering purposes

ANNEXURE – VI A

General & Technical Specifications

A) Flame Proof EOT Cranes

I. General Specifications: 1.0 SCOPE OF WORK

Scope of work shall include design, detail engineering, manufacture, inspection, shop testing,

supply, erection, site testing & commissioning of EOT Crane required for Solid Propellant Space

Booster Plant of SDSC SHAR, ISRO, SRIHARIKOTA including importation of equipment/

components (if any), in full & good condition as per the specifications, procedure, completion

schedule and the terms & conditions furnished in this document. The scope of work shall also

include procurement of all materials including components required for completion of the work,

coordinated planning for manufacture, testing, painting, inspection, packing, marking, loading on

Trucks/ Trailers, safe transportation to site, unloading and handling of the work fully erected,

tested, commissioned as per Technical Specifications.

a. The place “Sriharikota” is located 20 km east of Sullurupeta (nearest town) which is 80 km north of Chennai Tamilnadu and 95km South of Nellore, District head quarter of SPSR Nellore District.

b. SDSC SHAR, Sriharikota is a prohibited place. Hence, no contractor, working personnel will be allowed to stay and they have to be accommodated in Sullurupeta by their own arrangements.

c. The Contractor may have to transport working personnel on day to day basis by his own arrangement. Location of the site is worked out to be 30 km from Sullurupeta. The contractor personnel have to undergo security checks by security force is CISF as per the prevailing guidelines.

d. All the working personnel shall comply with code of conduct during their stay inside the SDSC SHAR campus.

Arranging the third party inspection is in the scope of supplier for the entire scope of Work as given above.

2.0 GENERAL CONDITIONS: 2.1 Tender shall be accompanied with general arrangement drawing showing to scale the

elevation, cross section and plan of the EOT crane which shall indicate the information viz., clearances, construction of bridge structure, hook approaches, lift, wheel base, wheel loads and wheel diameters, motor ratings, speeds, arrangement of all the drives and other equipment installed on the crane. Also the tender shall contain Annexure duly filled up to enable the purchaser to assess the important technical features of the equipment offered. Tenders may be rejected, if compliance with this clause is not ensured. The tenderer shall also clearly specify any request for deviation from technical specification on particular items. Generalized statements like crane shall be manufactured as per IS standard and our specification etc. are not adequate. The reference number of applicable, standards shall be clearly mentioned.

2.2 After receiving the order, the contractor shall submit design details, calculations and drawings (four copies each) as mentioned in Annexure-IV to the purchaser and third party inspection agency for review, comments and approval prior to commencement of fabrication.

a) The general arrangement drawings containing all information as described in para 2.1.

In addition to this, the GA drawing shall clearly show the layout of electrical panels, DBR, etc. All the dimensions and clearances shall be clearly marked on the drawing.

b) Electrical schematic diagrams containing details of components such as make, type,

rating/range, settings etc., are to be marked on the schematic diagram. All contacts and coils of contact shall be numbered/ designated.

c) Detailed structural drawings for the bridge girders, end carriages, repair cages,

inspection platforms, trolley frame etc., with Bill of quantities and material specifications.

2.3.1 All the drawings and calculations required for the approval shall be submitted in stages

within 4 weeks of placement of order to the purchaser and third party inspection agency. 2.3.2 If the drawings and other particulars are returned by the purchaser, because they are

incomplete or faulty, the contractor shall make the necessary correction / modifications and resubmit the drawings and calculations within a reasonable time but in any case should not exceed two weeks from the date of receipt of purchase’s/third party inspection agencies comments.

2.3.3 Tendered shall give the break-up of weights of the cranes as mentioned below during

final design. a. Total weight of crane including electrical equipment. b. Total weight of trolley including electrical equipment. c. Weight of each bridge girder as assembled and ready for erection, with and

without mechanical and electrical components. d. Weight of each end carriage as assembled and ready for erection. e. Weight and name of individual heaviest mechanical components. f. Total weight of structural, mechanical and electrical components separately.

2.3.4 The granting of any approval by SDSC, SHAR shall not absolve the CONTRACTOR

of his responsibilities for the design or the correctness of drawings and specifications. Any such approval by SDSC, SHAR shall not constitute a waiver by SDSC, SHAR of any right.

2.3.5 The following information shall be supplied prior to commissioning of the crane:

a) Four copies of all drawings and data, which have been approved by the purchaser. b) Four copies of the following manuals/ drawings shall be submitted.

2.4 THIRD PARTY INSPECTION:

i. The supplier should engage Third Party Inspection Agency (INSPECTORATE) for carrying out design verification/stage inspection/ final inspection for supply items and for construction, erection and testing at supplier’s works and at SHAR site. Contractor shall extend all necessary help/ equipment/ tools/ measuring instruments as required for

carrying out necessary tests/ inspection at works/ site to the representatives of SDSC, SHAR/ INSPECTORATE.

ii. SDSC, SHAR/INSPECTORATE shall have the right of inspection and supervision of

the manufacturing process adopted by the Contractor 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 Contractor will be advised to adopt the correct manufacturing process which will be binding on the Contractor. SDSC, SHAR’s decision regarding the quality of work and its acceptability shall be final and binding on the Contractor.

iii. The Supplier shall give mutually agreeable reasonable time in advance to SDSC,

SHAR/INSPECTORATE for inspection and testing of any equipment on its being ready specifying the period likely to be required for such inspection and testing.

iv. The supplier should engage third party inspection agencies like M/S Loyds register, M/S

M.N.Dhastur, M/S BVQI and DET NORSKE VERITAS (DNV) only.

Arrangements shall be made by the contractor 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 INSPECTORATE at the suppliers site as per the following schedule.

a) Design verification b) Raw material identification, components like gears, shafts, keys, keyways sub-

assemblies of drive mechanism mechanical and electrical. c) Motor shaft, gear box shaft, brake unit, etc., proper alignment. d) Proper adjustment of brake shoes for optimum braking. Hoisting motion twin brakes –

each should be adjusted independently to take the full load. e) Measurement of noise level in dBA. f) Paint thickness measurements at various stages like primer, intermediate and final

coats. g) Radiographic / ultrasonic inspections of the critical weld joints of the girders, ropes

drums, end carriages etc. h) Testing and inspection of crane at the works prior to the dispatch. The test shall include

full load, no load, overload, insulation test, speed test, deflection test, etc. The crane shall be tested in all respects in conformity with section 4 of IS 3177-1999 in the presence of the purchaser or his representative before dispatch. The manufacturer shall submit detailed list on the item/tests to inspection agency and shall provide the necessary testing facility for the inspecting engineers during the test.

i) The crane is to be erected, tested and commissioning as per the approved specification

code at our site at Sriharikota in addition to the tests at manufactures’ works. j) Necessary test loads will be identified by the department in existing buildings where

EOT crane is available. Supplier shall make arrangements for loading and transporting these loads on trucks and trailers to building in which crane is being commissioned, and after completion of satisfactory load testing these loads shall be transported back

to respective original location. Trucks and trailers will be provided by department for the transportation of test loads at site. But necessary manpower, tools and tackles shall be arranged by the supplier at his own cost.

2.5 The contractor shall ensure that the cranes shall be manufactured as per the tolerances specified below. a) Span over L.T wheel : ± 4mm upto 19.5 meters maximum b) Diagonal on wheels : ± 5mm maximum. c) Long travel wheel alignment : ± 1mm maximum d) Tilt of wheels or balancer : ± 1mm / 100mm maximum (horizontal & vertical) e) Trolley wheel guage : ± 2mm for gauge up to 2.5m} max ± 3mm for gauge over 2.5m}

f) Difference in height between trolley rails. (H) in relation to the trolley track gauge (S) shall be within the following tolerances. “S” (mm) “H” mm up to 2500 3 above 2500 5

g) Speeds at full rated load, voltage, and frequency shall be as follows: I) Travelling & traversing : +10% -5% of specified speed. II) Hoisting : +10% -5% of specified speed. III) Lowering : +20%-5% of specified speed.

2.6 The contractor shall ensure that only minimum amount of assembly at site is necessary for early commissioning of the crane after delivery. Site welding shall be avoided. The contractor before proceeding with design details shall satisfy him self about the site condition so as to avoid any difficulty in erection due to peculiarity of site condition.

2.7 The tenderer shall also quote separately for erection, transport and unloading at site by

their own men, material, tools and tackles. The crane shall be transported at contractors risk and cost. The purchaser will not pay for any insurance.

2.8 The crane shall be completely assembled including wiring and other fittings in the

contractor’s shop before load testing of the crane. The crane hoist and traverse shall be tested to its rated load and over load at the supplier’s workshop before dispatch to site for erection.

2.9 The crane after erection shall be tested as given below: -

a) No load test: After completion of erection, crane shall be tested with no load to check the

performance of crane speeds, end clearance, hook approaches, height of lift, limit switch operations, no load current of motors, contacts, relays, inter locks etc.,

b) Deflection test:

The deflection of the bridge girders shall not exceed 1/1000 of span with the fully loaded trolley stationed at mid-span and the safe working load at rest. The measurement shall not be taken on the first application of load. The datum line for measuring the deflection should be obtained by placing the unloaded trolley on the extreme end of the crane span with smaller hook approach of the largest capacity hook.

c) Speed tests:

1) All the motions of the crane shall be tested with rated load and the rated speeds shall be attained within the tolerance limits indicated under clause 2.5(g).

2) All the motions of the crane shall be tested with 25% overload in which case the

rated speeds may not be attained but the crane shall show itself capable of dealing with the over load without difficulty.

d) Brake Tests:

� The hoists brakes shall be capable of braking the movement under conditions (1) & (2) of speed tests, however the braking path with rated load shall not exceed value given in the table No.1 under brakes (clause 13 of section IV: Mechanical details).

� The long travel and cross travel brakes shall be capable of arresting the motion within a distance in meters equal to 10% of the speed in metres/min and the retardation due to braking shall not exceed the values as given in the Table No.2 under brakes (clause 13 of section IV: Mechanical details)

e) Insulation and other tests shall also be carried out.

2.10 Dimensions of all parts used on crane shall confirm to metric standards. 2.11 All the electrical equipment shall be of proven quality as regards to their performance. 2.12 The transfer of title to the purchaser will take place only after satisfactory erection, testing

and commissioning of the crane by the contractor and acceptance by the purchaser. Hence, any insurance charges are to be borne by the contractor.

2.13 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. If the loads are not in acceptable limits of civil structure, supplier shall plan different arrangement.

2.14 During the erection, testing and commissioning of the crane at site in Sriharikota, the

contractor

has to make his own arrangements for boarding, lodging, transportation of his men and materials. However, hostel accommodation may be provided by the purchaser on chargeable basis, if available.

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

Commissioning of the crane at the site. 2.16 Initial filling of lubricants required for commissioning at site shall be provided by the

supplier. 2.17 Before starting the site work, the contractor has to insure all his personnel working at site

in Sriharikota against accidents.

II ) TECHNICAL SPECIFICATIONS :

II A. DESIGN STANDARDS & OTHER DETAILS:

01. The crane shall be designed in accordance with the latest editions of IS:3177-1999 for class M5 duty and any other standards referred to therein and subject to any modification and requirement specified herein after. 02. All the Electrical equipment in flame proof cranes shall be of flame proof type suitable to

use in hazardous area Zone1, Group IIA/IIB, T4 as per IS5572 / IEC60079. The control for pendent push button station and limit switches shall be intrinsically safe as per IS: 5780

03. 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. All electrical cables shall be so laid that they are not liable to be damaged and can be easily inspected and maintained.

04. For welded construction such as that of bridge girders and carriages, trolley frames, rope

drums, gearboxes etc., all steel plates shall conform to IS-2062 or its equivalent. 05. No cast iron parts shall be used on cranes except for electrical equipments. Similarly, no

wood or other combustible material shall be used in any part of the crane.

06. Full length chequered plate platform shall be provided for both the bridge girders in order to have access to long travel drive, current collectors, trolley etc., The chequered plate platform shall cover the full width between main and auxiliary girders. Where the platforms are bracketed out from the bridge girders, the width of the chequered plate covering shall not be less than 750 mm. The walkway platforms both the top and bottom chord levels shall be so arranged that there is a minimum clearance of 2000mm between the top of the platform and the lowest overhead obstruction.

07. Foot walks shall be of sufficient width to give at least 750mm clear passage at all points, except between railing and bridge drive where this clearance may be reduced to not less than 400mm.

08. All opening in foot walk flooring for access to bottom chord platforms and inspecting

platforms, shall be provided with strong hinged covers. Minimum size of hatch openings shall be 600 X 600mm. Any other opening in foot walk or end carriage shall be provided with bolted removable plate covers.

09. Guards of an approved design, which will push forward or off the track any object placed

across it, such as a person’s foot or arm, shall be attached to each end of the end carriage. 10. All wheels, couplings, line shafts etc, shall be provided with covers opening on strong

hinges. These covers shall preferably be made of minimum 5mm thick plates. All heavy covers shall be provided with inspection windows.

11. a) All bolts except those with nylon nuts shall be provided with grip lock nuts or

spring washers.

b) For side alignment of motors strong adjustable screws with lock nuts shall be provided. c) Welded snugs hall be fitted against the feet of all pedestals, gear boxes, etc.,

except motors. Motors shall be provided with alignment screws for side alignment.

d) 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.

e) All bolts, studs, nuts, washers, etc., shall be heavy duty galvanized. All bolts

shall be designed assuring the material as mild steel. High strength bolts can be used only where they cannot be avoided. In case of electro-galvanizing, suitable baking of galvanized bolts as per standards shall be carried out to drive out the Hydrogen in order to avoid hydrogen embrittlement.

12. a) Safety hand railings preferably of tubular construction shall be provided on

bridge foot walks, end carriages, ladders, staircases, trolley and in any other places where access has been provided. Railings shall not be less than 1000mm high with an intermediate member at a height of 500mm

. b) All edges or openings shall be provided with toe guards. Toe angles or bent plates

wherever required shall be 100mm high minimum.

13. Defects in the material like fractures, cracks, blow holes, laminations, pitting, etc., are not allowed. Rectification of any such flaw is permissible only with the approval of the purchaser or inspection agency Engineer.

14. a) All parts of the crane shall be sand blasted to SA 2 ½ cleaned of all loose mill scales, rust or foreign matter and then painted as specified. All parts inaccessible after assembly shall be painted before the assembly. Inner surfaces of box sections shall be painted before closing them.

b) All parts except motors, gears, thrusters, etc., shall be painted with a primer coat of

zinc rich epoxy as per IS and two finishing coats of approved color as described below.

c) Sand blasting: The entire surface of all the fabricated materials is to be sand blasted as per

second quality of BS 4232 or near white quality of Steel Structures Painting Council

(SSPC) standard or SA 2½ of SIS 055900. The surface shall be completely free from contamination by oil, grease, dirt or other mater except that tightly bonded residues

or mill scale rust shall be permissible subject to limit of not more than 5% of whole area.

Surface should be free from girt/sand just before application of primer paint. d) Painting: Immediately after sand blasting, one coat of zinc rich epoxy primer shall be

applied to a Dry Film Thickness (DFT) of 75 microns. An intermediate coat of 80 micron

(DFT) of polyurethane/epoxy painting has to be given. A final coat of polyurethane enamel paint of 40 microns DFT has to be given. Any intermediate cleaning required between successive coats of paint are to be carried out as per the recommendation of paint manufacturers and as per the instruction of the purchaser.

All paint and primer shall be of standard quality and procured from approved manufacturers as prescribed in the list furnished. The contractor shall provide “ Elicometer” to the representative of the purchaser for measurements of thickness

of paint at random locations selected by him to confirm the required minimum DFT.

While painting the new structures, the existing floors and structure shall not be spoiled.

If there is any spillage of paint on the floors or members on the existing structure, the

contractor has to clean and provide the painting on the spoiled areas.

e) Interior of all gear box housings shall be sand blasted and painted with two coats of oil resisting enamel paint.

f) All machine pads, bearing surface on structures or housings shall be painted with white lead.

II B. STRUCTURAL DETAILS 01. GENERAL Crane structures shall be designed in accordance with the latest edition of I.S.807 taking the following additions / deviations as applicable into account: a) Unless otherwise specified, only bolted or welded joints shall be used. b) Not less than two turned fitted bolts or equivalent length of welding at each joint shall be

used for connections. c) Black bolts shall not be used in the main structures of the crane and high tensile steel bolts

shall not be used unless approved by the purchaser. All the bolts, nuts, washers etc., shall be heavy duty galvanized.

d) The calculated strength of riveted joint or joints made by friction grip bolts in structural

members shall be not less than calculated net strength of the member. e) Bolts used in shear shall be fitted into reamed holes. f) Where bolts pass through sections having tapered flanges taper pad shall be welded to the

tapered flange. Taper washers shall not be used. g) Transverse fillet welding on load carrying members shall be avoided. h) All but welds on structural members subject to tensile stress shall be x-rayed. i) Plates, bars, angles and where practicable, other rolled sections used in the load bearing

members of the structure shall be not less than 8 mm thick. Steel tubes, if sealed at the ends shall be not less than 4.9-mm (6 SG) thick and if unsealed, not less than 8 mm thick.

Minimum thickness of checkered plates for platforms shall be 6mm over plain for indoor cranes. Checkered plates shall not be considered for strength calculations of load carrying members.

j) The ratio of the effective length ‘l’ to the least radius of gyration ‘r’ for compression

members shall not exceed 120 for all main members i.e., for both the main and auxiliary girder members and top and bottom plan bracings and 180 for secondary members.

k) No splice joints allow for these cranes.

02. BRIDGE GIRDERS:

The bridge girders shall be of construction with double web plate girders. Girders shall be sufficiently strong and rigid to withstand the most severe combination of loads that may develop under different working conditions. The design of the bridge girder shall be in accordance with the latest edition of IS:807 taking following additions / deviations as applicable, into account.

a) For plate girders, span to depth ratio shall not exceed 18

b) For plate box girders, full length diaphragms shall be provided at bridge drive supports and line shaft bearing pedestals.

c) Equal to that at the end of bridge girder. Gusset plates shall be provided to assist the cranes remain square.

d) Squaring marks shall be provided on each girder to facilitate erection and squaring of the bridge.

03. END CARRIAGES:

End carriage shall be fabricated from rolled steel plates, welded together to form as box, a solid box, except for essential openings which shall be reinforced. If more than two wheels are required per bogie, articulated end carriages shall be used. Wherever possible, the end carriages shall be in two halves. Each half shall be rigidly connected to the respective bridge girder in the fabrication shop. End carriages shall be of ample strength to resist all stresses likely to be imposed on them under service conditions, including collision with other cranes or stops. The length of the end carriages shall be such that no other part of the crane is damaged in collision.

The wheel base shall not be less than 1/5th of span. On the end carriages with more than two wheels, the wheel base shall be taken as the distance between the centers of the outside wheels. The end carriages shall be fitted with substantial safety stops to prevent the crane from falling more than 25mm in the event of breakage of a track wheel, bogie, or axle. These safety stops shall not interfere with the removal of wheels. Suitable jacking pads at a height of 300mm from rail level shall be provided on each end carriage for jacking up the crane when changing track wheels. Jacking pads shall not interfere with the replacement of track wheels.

04. TROLLEY FRAME:

Trolley frame shall be produced in one piece unless there are transport limitations. In the case of splicing of the frame; the design shall be such that one unit of a mechanism mounted on one part of the trolley does not come over the other part. Connection between the two parts of the trolley shall be done by machined bolts. Drum bearings and supports for upper sheaves shall be located so as to equalize the load on the trolley wheels as nearly as possible.

The trolley frame shall be built up of rolled sections and plates to form a rigid structure

capable of withstanding all stresses that will develop during the working of the crane and shall be arranged to afford maximum accessibility to mechanical and electrical parts place on it. It 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. Deviations shall be made only with specific approval of the purchaser.

The top of the trolley frame shall be plated all over except for openings required for the

ropes and flexible cables for bottom block etc., to pass. The openings in the trolley frame shall be such as to keep the ropes of cables at least 75 mm away from any part of the trolley frame or equipment to prevent damages for all positions of the bottom blocks. All the mechanical and electrical equipment shall be placed above trolley top plate as far as practicable. For any parts placed below the trolley top plate, access for maintenance, repair and replacement shall be provided. Handrails shall be provided on all the four sides of the trolley.

The trolley shall be fitted with substantial safety stops to prevent the trolley from falling more than 25 mm in the event of breakage of a track wheel, bogie or an axle. This safety stops shall not interfere with the removal of wheel. The trolley shall be provided with lifting pads for jacking up the trolley in case of wheel removal. The jacking pads shall be at a height of about 300mm from the rail level and shall not interfere with the removal of wheels.

05. TROLLEY RAIL:

Trolley track rails made of rail steel shall be clamped to the girders with double bolt clamping plates spaced not more than 900 mm apart with welded alignment blocks between every two clamps such that the distance of a clamp from any adjacent alignment block shall not be more than 450 mm. Rails shall be prevented from creeping in the longitudinal direction by rail stops, welded. Rails shall be made continuous by welding standard lengths. At splice joints, rails shall be welded at site and as such, edge preparation of the rails shall be done in the shop as per standard practice. For double web box girders, rails shall be fastened by clamps held by studs welded to cover plates, spacing of clamps and alignment blocks being as stated earlier.

06. REPAIR CAGES.

Repair cage shall be provided on the inside of the end carriage for attending to the Drag Chain system and trolleys. Repair cages shall also be provided at the corners of the crane, if required, to facilitate removal of long travel wheels. The repair cages shall be minimum 1000 mm wide and shall be such that two persons can work comfortably in the space provided. The floor of the repair cages shall be about 1500 mm below the L. T wheel centres except the one on which the Drag chain system & pendent cable trolleys are mounted, where it shall be suitably adjusted. The cages shall be of structural steel and shall be made substantially rigid by gusset plates and braces welded or bolted. Repair cages shall be provided with railings on all sides except for the repair cages on the down shop lead side, which shall be provided with easily removable type protection guards on three sides for safety reasons.

II C. MECHANICAL DETAILS 01. DESIGN OF MECHANISMS.

In the design of components on the basis of ultimate strength the value of stress factor used shall be the product of the basic factors and the duty factor for the appropriate mechanism class. The basic stress factor shall not be less than 5 and the duty factor, impact factor, basic stress factor, safety factor etc. shall be in accordance with provisions given in section 20 of IS 3177 – 1999 for group classification M5.

02. ROPE DRUMS:

Rope drums shall be fabricated or of cast steel. All fabricated rope drums shall be stress relieved. The length of the drum shall be sufficient to accommodate in one layer the length of rope requisite for the specified lift and in addition, not fewer than three dead turns at each anchored end and at least one spare groove at the other end. Each rope end shall be clamped with minimum two clamping wedges with at least two numbers of bolts on each clamping. Rope drum shall be designed as specified in section 8.4 of IS 3177 – 1999 in general.

03. STEEL WIRE ROPES

i) The ropes will be regular lay, right hand, as specified in IS: 2266 & IS 3973. .

ii). The wires shall be made of steel with tensile designation 1960 (minimum tensile strength 1960 MPa).

Size selections of wire ropes in general shall be as per section 8.3 of IS: 3177 – 1999 and as per IS 13870: Part 1: 1993 /ISO 4308-1: 1986 Cranes and Lifting Appliances - Selection of Wire Ropes - Part 1: General

iii). The factor of safety shall be 6.0, Core shall be IWRC. 04. ROPE SHEAVES:

All sheaves shall be of forged steel or cast steel. All sheaves shall be identical; however, exception may be made for equalizer sheave. The equalizer sheave / bar shall be mounted where feasible above the trolley floor and shall be easily accessible and removable from the floor of the trolley. Equalizer sheave / bar shall be arranged to turn and swivel in order to maintain proper alignment under all circumstances. All sheaves shall have guards, which fit closed to the flange having a clearance not more than 1/3rd rope diameter between sheave and inside of guard. Equalizer sheave / bar shall be mounted on roller bearings and not on ball bearings. Design of sheaves in general shall be as per section 8.5 of IS:3177 – 1999.

05. RAIL WHEELS:

Rail wheel shall be double flanged with straight tread unless guide rollers on sides, to take up horizontal thrust, are provided. The wheels shall be capable of taking up misalignments in span as specified. Wheels shall be of forged steel. Minimum diameter of wheels for cross travel shall be 250 mm. minimum dia. of long travel wheels for class M5 cranes shall

be 315 mm. Minimum hardness of wheel tread shall be 300 BHN. General design of wheels shall be as per section 8.6 of IS:3177 – 1999.

06. BUFFERS:

Spring loaded case or any other better type buffers shall be fitted on the four corners of the crane and also on the four ends of the bridge girders (and not on the trolley frame) for soft dashing of crane and trolley respectively. Buffers shall be rigidly bolted in place preferably along the Centre line of crane rail or trolley rail as the case may be, such that the bolts are not in direct shear. If the buffers are so located as to required removal when changing wheels or bogies, means shall be provided on the crane itself either by hinges or otherwise for handling the buffers. Buffers shall be designed to absorb the kinetic energy released at 50% of the full load rated travelling sped, the average rate of deceleration not exceeding 5.0m/sec2 at 50% of the rated travelling speed (freely oscillating loads suspended on the load suspension system shall not be taken into consideration) Refer sec. 8.11 of IS: 3177 – 1999.

07. DRIVES:

For class 2 duty cranes not less than 50% of the long travel wheels shall be positively driven unless agreed otherwise by the purchaser. The long travel shafts shall be supported on bearings at approximately 3 m Centre or less. Shaft couplings shall be as near as possible to the bearings. Shafts shall be easily accessible throughout their length and shall be designed as far as practicable inter-changeable lengths, the end and centre sections being as short as possible. Where applicable the driving pinions shall not interfere with the removal of wheels. Angular deflection of the line shaft at torque corresponding to 1.33 motor rated torque during acceleration shall not exceed 0.10 deg./m of shaft length. In case of L.T. drive located at the span Centre, half the above torque, i.e. 2/3 of motor torque shall be taken for each half of the shaft. The L.T. drive shaft minimum diameter shall be not less than 100mm. The offer will be rejected if the L.T. shaft minimum diameter is less than 100mm. All parts of the long travel drive shall preferably be located above the top platform. No part of cross travel drive shall be located below the trolley platform. Refer section 8.2 of IS: 3177 – 1999. Wheel mounted drives can be provided LT drive of cranes that are having spans more than 20meters.

wheel mounted drives can be provided LT and CT for single girder and under running cranes.

08. GEARING: (Standard make gear boxes shall be used in EOT cranes for all drives)

Straight and helical spur gearing shall normally be used for all motions. Worm and bevel gears shall not be used without specific permission from purchaser. First and high-speed reductions shall be through helical gears. All first reduction pinions and also other pinions if feasible shall be integral with shafts. All gears shall be of hardened and tempered alloy or carbon steel with machine cut teeth. Gear teeth shell is preferably cut in metric module system. All gear teeth shall be ground smooth to give less noise while running.

09. GEAR BOXES: (Standard make gear boxes shall be used in EOT cranes for all drives):

All gears shall be completely covered or guarded by covers firmly attached to brackets. All gears shall be enclosed in oil tight casings except where not possible. All gear shafts shall be supported on bearings mounted in gear box unless specifically agreed otherwise. In case of totally enclosed gear boxes splash or automatic lubrication system shall be used. The gearboxes shall be fabricated or of cast steel. Fabricated gearboxes shall be made of minimum 8 mm thick steel plate. All fabricated gearboxes shall be stress relieved. Covered shall be split horizontally at each shaft centre line and fastened and arranged so that the top half can be removed for inspection and repair without disturbing the bottom half. Directly above the mesh line of teeth, there shall be hand-holes with oil tight bolted covers. The gear box shall be provided with breather vents, oil level indicator, dipsticks and easily accessible drain plugs. If the sound level is more than the specified, they are to be replaced with better ones. This is very important for all the gearboxes and any gearbox making more noise is liable to be rejected. No oil leakage is allowed from gearboxes. Standard Gearboxes from reputed manufacturers shall be used in all drives of cranes.

10. BEARINGS:

Ball and roller antifriction bearings of FAG, SKF, TIMKEN make shall be used throughout the drives except where specified otherwise. Rated life of ball and roller bearings shall be not less than total life in working hours given under “01. Design of Mechanism”. Life of bearing shall be calculated in accordance with manufacturer’s recommendations. All bearings housings shall be made of cast or wrought steel bolted to a rigid portion of crane structure by at least 4 bolts except for intermediate line shaft bearing housings which may be bolted by at least 2 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. Refer section 8.7 of IS – 3177 – 1999.

11. COUPLINGS: Motor shafts shall be connected to gear extension shafts through flexible shock absorbing couplings. For driving hoist drum, geared couplings shall be used between hoist rope drum and hoist gearbox out-put shafts. Geared couplings shall be used for connecting intermediate lengths of long travel and cross travel shafts. Geared or universal couplings shall be used between gearbox output shaft and intermediate shaft or end shaft. Between intermediate shaft and end shaft and between end shaft and wheel axle, any other special coupling which can give better and more reliable service may be used after obtaining specific approval of the purchaser. Refer section 8.9 of IS: 3177 – 1999.

12. LIFTING HOOKS:

Standard single shank point hooks shall be used unless otherwise specified. These hooks shall confirm the latest edition of IS. Safety latch should be provided to the hook such that the rope does not slip out of the hook. Refer section 8.1 of IS: 3177 – 1999.

13. BRAKES:

Electro hydraulic thruster brakes shall be used for all drives in crane. Flame proof brakes shall be provided for all drives of flame proof cranes. Brake shall be mounted on the input pinion shaft of the gear train. The brake shoes shall be of hinged type. Brake levers shall be forged or fabricated or cast steel. Hinge pins shall be of hardened alloy steel and shall be lubricated. These hinge pins shall be provided with steel bushes at bearing point. Brake drums shall be forged or of cast steel. Drums shall be completely machined and dynamically balance. Width of the brake drum shall be 5 to10mm more than the width of the brake shoes. Hardness of brake drum shall be 38 – 43 Rc. No oil leakage is allowed from thruster brakes. Braking path shall be calculated as per is 3177.

i. Hoist mechanism shall be provided with two brakes. Each brake shall be designed for a minimum of 200% static moment considering that the full load can be held by one brake alone. This shall also apply to single drive with two brakes. ii. The brakes for long and cross travel motions shall be designed from the following consideration:

a) Braking against travelling shall be capable of arresting the motion within a distance in meters equal to 10% of the speed in m/min. When travelling at rated speed with rated load.

b) The retardation due to braking shall not exceed the values given in the table below to avoid skidding wheels.

Table –2

Retardation, according to percentage number of Working condition Driving wheels in ‘m/sec2 ‘

100% 50% 25%

Indoor (When = 0.1) 1.5 0.75 0.45 Refer section 8.12 of IS: 3177 – 1999. 14. BOLTS AND NUTS: All bolts, nuts, washers, etc. used in this crane shall be galvanized as per IS; 1367 part 13 Refer section 8.10 of IS: 3177 – 1999

II D. ELECTRICAL DETAILS

01. SCOPE OF SUPPLY

The scope of supply shall cover all items of electrical systems motors, brakes, limit switches, power and control cables, socket outlets, lighting fittings with lamps, DSL, Cable drag chain system, Pendent, push button station and equipment earthing. All sundry erection material required for installation and connecting up of electrical equipment with cable laying and fixing accessories shall be included in the scope of supply by the tenderer.

02. HAZARDOUS OPERATING ENVIRONMENT:

The EOT cranes are intended to operate in Hazardous environment as per the hazardous area classification Zone 1 Gas group IIA/IIB, T4 as per IS5572. Hence all the electrical equipment, limit switches and controls offered shall be suitable to operate in the above environment as per relevant Indian standards (IS 5571, IS2148, IS 5780) and IEC standards (IEC 60079). The drive panel will be located in non-Hazardous area and hence, need not comply hazardous area requirements.

Motor lights, junction boxes shall be flame proof and pendent fuse button station & limit switches shall be Intrinsically safe system.

03. CLIMATIC CONDITONS:

The equipment offered shall be suitable for tropical and humid climate. For purpose of equipment selection and specially for derating the capacities of drive motors and power cables, the ambient temperature condition specified in salient features shall be taken as the basis. The design shall consider ambient temp of 500 C and saline atmosphere. The equipment on the crane shall be suitably protected against damage from radiant heat and shall be rendered proof against ingress of dust and vermin.

04. STANDARDS:

The equipment shall be selected, assembled and tested as per guide lines provided in the latest edition of Indian Standard Specification IS: 3177 - 1999 or class M5 duty cranes subject to any modification and requirements specified by the purchaser. Flame proof electrical fittings and controls in the cranes mentioned shall be selected, assembled and tested as per relevant Indian/ IEC standards like IS5571, IS2148, IS5780 and IEC 60079.

05. POWER SUPPLY CONDITIONS

The power, on the bay down-shop leads shall be available at 415 Volts, 3 phase, 4 wire, 50 HZ. The power and control equipment selected shall be suitable for operation on ± 10% variation in the voltage and ± 3% variation in supply frequency.

The following voltage shall be used in the cranes: i) 415 volts, 3 phase, 50 HZ : For drive motors A.C (unearthed system) ii) 110V volts single phase, : Control circuit in VFD panel. 50 HZ, A.C ii) Intrinsically safe circuit : Pendent and limit switch interfacing.

06. CURRENT COLLECTION

a) CABLE DRAG CHAIN SYSTEM

Location of main switch is at 1m height from the ground. Supply and routing of cable through cable drag chain system is included in the scope of supply. Erected on EOT Crane Crab through suitable cable drag chain system. The power supply arrangement shall be provided through cable drag system of IGUS / LAPP make. The cables used in Drag chain system shall be of IGUS /LAPP make only suitable to Drag chain applications. The cable Drag chain system & cable Make shall be same. Party shall submit cable schedules & Drag chain selection criteria for approval by SDSC SHAR.

07. MOTORS

All crane motors shall be Flameproof (Ex-d, Temp classification T4) squirrel cage induction motors. Motors shall have S4 DUTY, 60% CDF, min of with 300 starts per hour. The motor shall be flameproof as per IS: 2148.

a) HORSE POWER

The service factors shall be taken for selection of motors for long and cross travel motions as per Annex-C of is 3177-1999. Motor selected are such that the maximum current drawn with full load should not exceed 80% of the full load rated current of the selected motor.

a) TORQUE The pull out torque of the motors at rated voltage and frequency shall not be less than

2.75 times the nominal torque. b) CLASS OF INSULATION

All motors shall be class F or better insulated with temperature rise limited to class B insulation.

SWITCHING FREQUENCY AND DUTY CYCLE

Motor rating shall take into account the operating frequency of 300starts/hour. Class of duty

08. CRANE CONTROL

Controls in FLP cranes shall be made suitable to operate in hazardous environment Zone1, Group IIA/IIB, T4. In order to control the speed during lowering, mechanical braking shall not be employed. On all motions, the circuit shall be so designed that brakes come into operation immediately in the event of tripping of main circuit breaker. Additionally, the control circuit shall be so designed that following functions are fulfilled.

Hoisting shall take place only when hoisting push button operated. Lowering shall take

place only when hoist lowering push button is operated. Both the push buttons should be interlocked such that only one direction operation is possible at a time. This type of control should be followed for all the motions of the crane.

09. PENDENT CONTROLLERS.

Non flame proof push button station with intrinsic safe barrier Isolation shall be used. The control ON push button shall be of lockable at OFF type (with key) so that power and control supply is cut off when the crane is not in use to prevent inadvertent operation. Selector switch C2 2 position shall be provided for lights ON/OFF. Indicating lamp for control ON shall be provided on the pendent. An emergency stop push button with mushroom Red knob latched type push button with 2 No & 2 Nc shall be provided to switch off Incoming MCCB/ A reset main contactor PB to be common for all drives provided to reset Drive fault. Push button for bell and two no’s of spare push buttons shall be provided. The drive fault indication lamp shall also be provided in pendent. The pendant station shall be suitably supported by means of a SS chain and it shall be ensured that no strain is caused to the pendant cable. A minimum of two spare cores shall be provided in the pendant cable. The pendant station shall move along the bridge girder on four wheeled cable trolleys with antifriction ball bearings running on a separate track. Each trolley shall be provided with buffers to avoid entanglement. Tension coming on the cable due to trolley movement shall be avoided by provided SS chain between trolleys. The Push buttons and indication lamps in pendent to be interfaced with switch gear FLP panel through intrinsic safe isolators and solenoid drivers. The indication lamps make shall be Beka or any other make with approval and shall be intrinsically safe. All IS barriers shall be of P& F make only.

10. CIRCUIT PROTECTIVE SWITCHGEAR

One triple pole MCCB Incomer , rated to carry at least combined full load currents of the two motions on the crane having largest power (KW) shall be provided.

11. LIMIT SWITCHES:

Limit switches shall be heavy duty type with protective enclosure of IP 55 as per IS 2147. limit switches shall be heavy-duty type and of shall be wired in the Intrinsic Safe circuit to operate in hazardous environment Zone 1, Gas group IIA/IIB as mentioned above.

All hoist motions shall be provided with limit switches to prevent the crane hook from

over hoisting and over – lowering. Two limit switches shall be provided for proper back up protection. The first limit switch to act in the event of over hoisting and over lowering. This shall be screw type with self-resetting feature and be incorporated in the control circuit of the respective drive motor. The second one shall be of gravity operated hand resetting type switch

Connected in the trip circuit of the main incoming breaker. The second limit switch shall

act only to prevent over hoisting limit switch incorporated in the motor control circuit shall be made to act first but in case this limit switch fails to operate, the second limit switch connected in the main incoming circuit breaker’s control circuit shall operate and trip the breakers.

12. BRAKES:

All motions of the flame proof cranes shall be provided with Flame proof A.C Electro-

hydraulic thruster brakes to arrest the motion safely. This brake should be provided with brake release mechanism. The Brakes shall be protected with suitable MPCBs.

The torque capacity of brakes shall be 2.0 times the rated full torque of the selected motor for

hoist and for LT and CT the torque capacity of brakes shall be 1.5 times the rated full torque of the selected motor.

13. LIGHTING: Four numbers of under slung flame proof lamps of 250 W HPMV and with shock

absorbing & anti swing suspension shall be provided for uniform floor illumination. Screw cap type holders and lamps shall be used for crane lighting. These light fittings should be provided with wire mesh and glass to avoid free falling of lamp. Lighting transformers shall have 50% reserve capacity. Lighting control ON/OFF shall be possible from pendant station. The light fittings shall be so located that free access for maintenance is possible.

Note: for Single girder cranes lights are not required.

14. CABLING All wiring for power control, lighting etc., shall be carried out with 1.1.K.V grade PVC

flexible/Armored copper conductor cables as possible. All power cables shall be minimum 4sq.mm Cu and control cables minimum 2.5 sq. (cu). Cable cores shall be of stranded construction.

Cable selection and routing on the crane shall form part of the crane design. Selection of cable sizes shall take into account the following factors.

a) Ambient derating factors b) Group rating factor. c) Intermittent duty factor.

Suitable cable trays firmly secured to crane structure shall be provided with due regards to cable weight and vibration encountered. Cables shall be routed so that they do not constitute a safety hazard, pose any obstruction to free movement of personnel, and properly laid to present an orderly appearance. The cables shall have proper cable drag chain system of IGUS make cables & Drag chain except for pendent station.

15. IDENTIFICATION OF CIRCUITS, CABLES ETC.

Labels of permanent nature shall be provided on supports of all switches, fuses,

contactors, relays etc., to facilitate identification of circuits and replacement. All panels are to be properly marked for each motion. All power control cables, lighting and other cables are to be tagged at both ends as per cable number indicated in the supplier‘s drawing. All equipment terminals are also to be marked likewise.

16. EARTHING;

The Earth strip /Cable size shall be minimum 25 X 6 to be used for earthing purpose. The LT rail at both sides to be earthed. All electrical equipment mounted on crane including Mechanical structure to be earthed with double runs. Suitable Bridge Clamp provided on crane for tapping earth points. Along with pendent control cable an additional wire braided flexible copper strip of 12mm wide shall run as a special earth from the control panel up to the pendent station. SDSC will only provide ground riser at 1mtr height inside bay for grounding. Further connection from this riser to EOT system for earthing will be in bidder’s scope. Any specific grounding requirement other than the above power earth may be brought out in the offer.

ANNEXURE – VI B

General & Technical Specifications

Non Flame Proof EOT Cranes

I. General Specifications: 1 SCOPE OF WORK

Scope of work shall include design, detail engineering, manufacture, inspection, shop

testing, supply, erection, site testing & commissioning of EOT Crane required for Solid Propellant

Space Booster Plant of SDSC SHAR, ISRO, SRIHARIKOTA including importation of

equipment/ components (if any), in full & good condition as per the specifications, procedure,

completion schedule and the terms & conditions furnished in this document. The scope of work shall

also include procurement of all materials including components required for completion of the

work, coordinated planning for manufacture, testing, painting, inspection, packing, marking,

loading on Trucks/ Trailers, safe transportation to site, unloading and handling of the work fully

erected, tested, commissioned as per Technical Specifications.

a. The place “Sriharikota” is located 20 km east of Sullurupeta (nearest town) which is

80 km north of Chennai Tamil Nadu and 95km South of Nellore, District head quarter of SPSR Nellore District.

b. SDSC SHAR, Sriharikota is a prohibited place. Hence, no contractor, working personnel will be allowed to stay and they have to be accommodated in Sullurupeta by their own arrangements.

c. The Contractor may have to transport working personnel on day to day basis by his own arrangement. Location of the site is worked out to be 30 km from Sullurupeta. The contractor personnel have to undergo security checks by security force is CISF as per the prevailing guidelines.

d. All the working personnel shall comply with code of conduct during their stay inside the SDSC SHAR campus.

Arranging the third party inspection is in the scope of supplier for the entire scope of work as given above.

2 GENERAL CONDITIONS: 2.1 Tender shall be accompanied with general arrangement drawing showing to scale the

elevation, cross section and plan of the EOT crane which shall indicate the information viz., clearances, construction of bridge structure, hook approaches, lift, wheel base, wheel loads and wheel diameters, motor ratings, speeds, arrangement of all the drives and other equipment installed on the crane. Also the tender shall contain Annexure duly filled up to enable the purchaser to assess the important technical features of the equipment offered. Tenders may be rejected, if compliance with this clause is not ensured. The tenderer shall also clearly specify any request for deviation from technical specification on particular items. Generalized statements like crane shall be manufactured as per IS

standard and our specification etc. are not adequate. The reference number of applicable, standards shall be clearly mentioned.

2.2 After receiving the order, the contractor shall submit design details, calculations and

drawings (three copies each) as mentioned in annexure-IV to the purchaser and third party inspection agency for review, comments and approval prior to commencement of fabrication. a) The general arrangement drawings containing all information as described in para 2.1.

In addition to this, the GA drawing shall clearly show the layout of electrical panels, DBR, etc. All the dimensions and clearances shall be clearly marked on the drawing.

b) Electrical schematic diagrams containing details of components such as make, type,

rating/range, settings etc., are to be marked on the schematic diagram. All contacts and coils of contact shall be numbered/ designated.

c) Detailed structural drawings for the bridge girders, end carriages, repair cages,

inspection platforms, trolley frame etc., with Bill of quantities and material specifications.

2.3.1 All the drawings and calculations required for the approval shall be submitted in stages

within 4 weeks of placement of order to the purchaser and third party inspection agency. 2.3.2 If the drawings and other particulars are returned by the purchaser, because they are

incomplete or faulty, the contractor shall make the necessary correction / modifications and resubmit the drawings and calculations within a reasonable time but in any case should not exceed two weeks from the date of receipt of purchase’s/third party inspection agencies comments.

2.3.3 Tendered shall give the break-up of weights of the cranes as mentioned below during

final design. a. Total weight of crane including electrical equipment. b. Total weight of trolley including electrical equipment. c. Weight of each bridge girder as assembled and ready for erection, with and without

mechanical and electrical components. d. Weight of each end carriage as assembled and ready for erection. e. Weight and name of individual heaviest mechanical components. f. Total weight of structural, mechanical and electrical components separately.

2.3.4 The granting of any approval by SDSC, SHAR shall not absolve the CONTRACTOR

of his responsibilities for the design or the correctness of drawings and specifications. Any such approval by SDSC, SHAR shall not constitute a waiver by SDSC, SHAR of any right.

2.3.5 The following information shall be supplied prior to commissioning of the crane:

a) Four copies of all drawings and data, which have been approved by the purchaser. b) Four copies of the following manuals/ drawings shall be submitted.

2.4 THIRD PARTY INSPECTION:

i. The supplier should engage Third Party Inspection Agency (INSPECTORATE) for carrying out design verification/stage inspection/ final inspection for supply items and for construction, erection and testing at supplier’s works and at SHAR site. Contractor shall extend all necessary help/ equipment/ tools/ measuring instruments as required for carrying out necessary tests/ inspection at works/ site to the representatives of SDSC, SHAR/ INSPECTORATE.

ii. SDSC, SHAR/INSPECTORATE shall have the right of inspection and supervision of

the manufacturing process adopted by the Contractor 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 Contractor will be advised to adopt the correct manufacturing process which will be binding on the Contractor. SDSC, SHAR’s decision regarding the quality of work and its acceptability shall be final and binding on the Contractor.

iii. The Supplier shall give mutually agreeable reasonable time in advance to SDSC,

SHAR/INSPECTORATE for inspection and testing of any equipment on its being ready specifying the period likely to be required for such inspection and testing.

Arrangements shall be made by the contractor 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 INSPECTORATE at the suppliers site as per the following schedule.

a) Design verification b) Raw material identification, components like gears, shafts, keys, keyways sub-

assemblies of drive mechanism mechanical and electrical. c) Motor shaft, gear box shaft, brake unit, etc., proper alignment. d) Proper adjustment of brake shoes for optimum braking. Hoisting motion twin brakes –

each should be adjusted independently to take the full load. e) Measurement of noise level in dBA. f) Paint thickness measurements at various stages like primer, intermediate and final

coats. g) Radiographic / ultrasonic inspections of the critical weld joints of the girders, ropes

drums, end carriages etc. h) Testing and inspection of crane at the works prior to the dispatch. The test shall include

full load, no load, overload, insulation test, speed test, deflection test, etc. The crane shall be tested in all respects in conformity with section 4 of IS 3177-1999 in the presence of the purchaser or his representative before dispatch. The manufacturer shall submit detailed list on the item/tests to inspection agency and shall provide the necessary testing facility for the inspecting engineers during the test.

i) The crane is to be erected, tested and commissioning as per the approved specification

code at our site at Sriharikota in addition to the tests at manufactures’ works.

j) Necessary test loads will be identified by the department in existing buildings where

EOT crane is available. Supplier shall make arrangements for loading and transporting these loads on trucks and trailers to building in which crane is being commissioned, and after completion of satisfactory load testing these loads shall be transported back to respective original location. Trucks and trailers will be provided by department for the transportation of test loads at site. But necessary manpower, tools and tackles shall be arranged by the supplier at his own cost.

2.5. The contractor shall ensure that the cranes shall be manufactured as per the tolerances specified below. a) Span over L.T wheel : ± 4mm upto 19.5 meters maximum b) Diagonal on wheels : ± 5mm maximum. c) Long travel wheel alignment : ± 1mm maximum d) Tilt of wheels or balancer : ± 1mm / 100mm maximum (horizontal & vertical) e) Trolley wheel guage : ± 2mm for gauge up to 2.5m} max ± 3mm for gauge over 2.5m}

f) Difference in height between trolley rails. (H) in relation to the trolley track gauge (S) shall be within the following tolerances. “S” (mm) “H” mm up to 2500 3 above 2500 5

g) Speeds at full rated load, voltage, and frequency shall be as follows: I) Travelling & traversing : +10% -5% of specified speed. II) Hoisting : +10% -5% of specified speed. III) Lowering : +20%-5% of specified speed.

2.6 The contractor shall ensure that only minimum amount of assembly at site is necessary for early commissioning of the crane after delivery. Site welding shall be avoided. The contractor before proceeding with design details shall satisfy him self about the site condition so as to avoid any difficulty in erection due to peculiarity of site condition.

2.7 The tenderer shall also quote separately for erection, transport and unloading at site by their

own men, material, tools and tackles. The crane shall be transported at contractors risk and cost. The purchaser will not pay for any insurance.

2.8 The crane shall be completely assembled including wiring and other fittings in the

contractor’s shop before load testing of the crane. The crane hoist and traverse shall be tested to its rated load and over load at the supplier’s workshop before dispatch to site for erection.

2.9 The crane after erection shall be tested as given below: -

a) No load test:

After completion of erection, crane shall be tested with no load to check the performance of crane speeds, end clearance, hook approaches, height of lift, limit switch operations, no load current of motors, contacts, relays, inter locks etc.,

b) Deflection test: The deflection of the bridge girders shall not exceed L/1000 of span with the fully

loaded trolley stationed at mid-span and the safe working load at rest. The measurement shall not be taken on the first application of load. The datum line for measuring the deflection should be obtained by placing the unloaded trolley on the extreme end of the crane span with smaller hook approach of the largest capacity hook.

c) Speed tests:

1) All the motions of the crane shall be tested with rated load and the rated speeds shall be attained within the tolerance limits indicated under clause 2.5(g).

2) All the motions of the crane shall be tested with 25% overload in which case the rated speeds may not be attained but the crane shall show itself capable of dealing with the over load without difficulty.

d) Brake Tests:

� The hoists brakes shall be capable of braking the movement under conditions (1) & (2) of speed tests, however the braking path with rated load shall not exceed value given in the table No.1 under brakes (clause 13 of section IV: Mechanical details).

� The long travel and cross travel brakes shall be capable of arresting the motion within a distance in meters equal to 10% of the speed in metres/min and the retardation due to braking shall not exceed the values as given in the Table No.2 under brakes (clause 13 of section IV: Mechanical details)

e) Insulation and other tests shall also be carried out.

2.10 Dimensions of all parts used on crane shall confirm to metric standards. 2.11 All the electrical equipment shall be of proven quality as regards to their performance. 2.12 Excise duty exemption will be availed by the purchaser for this crane. Hence the

quotation shall take this into account. 2.13 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. If the loads are not in acceptable limits of civil structure, supplier shall plan different arrangement.

2.14 During the erection, testing and commissioning of the crane at site in Sriharikota, the contractor has to make his own arrangements for boarding, lodging, transportation of his men and materials. However, hostel accommodation may be provided by the purchaser on chargeable basis, if available.

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

Commissioning of the crane at the site. 2.16 Initial filling of lubricants required for commissioning at site shall be provided by the

supplier. 2.17 Before starting the site work, the contractor has to insure all his personnel working at site

in Sriharikota against accidents.

II ) TECHNICAL SPECIFICATIONS :

II A. DESIGN STANDARDS & OTHER DETAILS:

01. The crane shall be designed in accordance with the latest editions of IS:3177-1999 for class M5 duty and any other standards referred to therein and subject to any modification and requirement specified herein after. 02. 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. All electrical cables shall be so laid that they are not liable to be damaged and can be easily inspected and maintained.

03. For welded construction such as that of bridge girders and carriages, trolley frames, rope drums, gearboxes etc., all steel plates shall conform to IS-2062 or its equivalent. 04. No cast iron parts shall be used on cranes except for electrical equipments. Similarly, no wood or other combustible material shall be used in any part of the crane.

05. Full length chequered plate platform shall be provided for both the bridge girders in order to have access to long travel drive, current collectors, trolley etc., The chequered plate platform shall cover the full width between main and auxiliary girders. Where the

platforms are bracketed out from the bridge girders, the width of the chequered plate covering shall not be less than 750 mm. The walkway platforms both the top and bottom chord levels shall be so arranged that there is a minimum clearance of 2000mm between the top of the platform and the lowest overhead obstruction.

06. Foot walks shall be of sufficient width to give at least 750mm clear passage at all points,

except between railing and bridge drive where this clearance may be reduced to not less than 400mm.

07. All opening in foot walk flooring for access to bottom chord platforms and inspecting

platforms, shall be provided with strong hinged covers. Minimum size of hatch openings shall be 600 X 600mm. Any other opening in foot walk or end carriage shall be provided with bolted removable plate covers.

08 Guards of an approved design, which will push forward or off the track any object placed

across it, such as a person’s foot or arm, shall be attached to each end of the end carriage. 09 All wheels, couplings, line shafts etc, shall be provided with covers opening on strong

hinges. These covers shall preferably be made of minimum 5mm thick plates. All heavy covers shall be provided with inspection windows.

17. a) All bolts except those with nylon nuts shall be provided with grip lock nuts or

spring washers.

b) For side alignment of motors strong adjustable screws with lock nuts shall be provided. c) Welded snugs hall be fitted against the feet of all pedestals, gear boxes, etc.,

except motors. Motors shall be provided with alignment screws for side alignment.

d) 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.

e) All bolts, studs, nuts, washers, etc., shall be heavy duty galvanized. All bolts

shall be designed assuring the material as mild steel. High strength bolts can be used only where they cannot be avoided. In case of eletro-galvanizing, suitable baking of galvanized bolts as per standards shall be carried out to drive out the Hydrogen in order to avoid hydrogen embrittlement.

18. a) Safety hand railings preferably of tubular construction shall be provided on

bridge foot walks, end carriages, ladders, staircases, trolley and in any other places where access has been provided. Railings shall not be less than 1000mm high with an intermediate member at a height of 500mm

.b) All edges or openings shall be provided with toe guards. Toe angles or bent plates wherever required shall be 100mm high minimum.

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

not allowed. Rectification of any such flaw is permissible only with the approval of the purchaser or inspection agency Engineer.

20. a) All parts of the crane shall be sand blasted to SA 2 ½ cleaned of all loose mill

scales, rust or foreign matter and then painted as specified. All parts inaccessible after assembly shall be painted before the assembly. Inner surfaces of box sections shall be painted before closing them.

b) All parts except motors, gears, thrustors, etc., shall be painted with a primer coat of

zinc rich epoxy as per IS and two finishing coats of approved colour as described below.

21. Sand blasting:

The entire surface of all the fabricated materials is to be sand blasted as per second quality of BS 4232 or near white quality of Steel Structures Painting Council (SSPC) standard or SA 2½ of SIS 055900. The surface shall be completely free from contamination by oil, grease, dirt or other mater except that tightly bonded residues or

mill scale rust shall be permissible subject to limit of not more than 5% of whole area. Surface should be free from girt/sand just before application of primer paint.

22. Painting:

Immediately after sand blasting, one coat of zinc rich epoxy primer shall be applied to a Dry Film Thickness (DFT) of 75 microns. An intermediate coat of 80 micron (DFT) of polyurethane/epoxy painting has to be given. A final coat of polyurethane enamel paint of 40 microns DFT has to be given. Any intermediate cleaning required between successive coats of paint are to be carried out as per the recommendation of paint manufacturers and as per the instruction of the purchaser.

All paint and primer shall be of standard quality and procured from approved manufacturers as prescribed in the list furnished. The contractor shall provide “ Elicometer” to the representative of the purchaser for measurements of thickness of paint at random locations selected by him to confirm the required minimum DFT. While painting the new structures, the existing floors and structure shall not be spoiled. If there is any spillage of paint on the floors or members on the existing structure, the contractor has to clean and provide the painting on the spoiled areas.

23. Interior of all gear box housings shall be sand blasted and painted with two coats of oil resisting enamel paint.

24. All machine pads, bearing surface on structures or housings shall be painted with white lead.

.

II B. STRUCTURAL DETAILS 01.GENERAL Crane structures shall be designed in accordance with the latest edition of I.S.807 taking the following additions / deviations as applicable into account: a) Unless otherwise specified, only bolted or welded joints shall be used. b) Not less than two turned fitted bolts or equivalent length of welding at each joint shall be used for connections.

c) Black bolts shall not be used in the main structures of the crane and high tensile steel bolts shall not be used unless approved by the purchaser. All the bolts, nuts, washers etc., shall be heavy duty galvanized.

d) The calculated strength of riveted joint or joints made by friction grip bolts in structural

members shall be not less than calculated net strength of the member.

e) Bolts used in shear shall be fitted into reamed holes.

f) Where bolts pass through sections having tapered flanges taper pad shall be welded to the tapered flange. Taper washers shall not be used.

g) Transverse fillet welding on load carrying members shall be avoided.

h) All but welds on structural members subject to tensile stress shall be x-rayed.

i) Plates, bars, angles and where practicable, other rolled sections used in the load bearing

members of the structure shall be not less than 8 mm thick. Steel tubes, if sealed at the ends shall be not less than 4.9-mm (6 SG) thick and if unsealed, not less than 8 mm thick.

Minimum thickness of checkered plates for platforms shall be 6mm over plain for indoor cranes. Checkered plates shall not be considered for strength calculations of load carrying members.

j) The ratio of the effective length ‘l’ to the least radius of gyration ‘r’ for compression

members shall not exceed 120 for all main members i.e., for both the main and auxiliary girder members and top and bottom plan bracings and 180 for secondary members.

k) No splice joints allow for these crane.

02. BRIDGE GIRDERS:

The bridge girders shall be of construction with double web plate girders. Girders shall be sufficiently strong and rigid to withstand the most severe combination of loads that may develop under different working conditions. The design of the bridge girder shall be in accordance with the latest edition of IS:807 taking following additions / deviations as applicable, into account.

a) For plate girders, span to depth ratio shall not exceed 18 b) For plate box girders, full length diaphragms shall be provided at bridge drive supports and

line shaft bearing pedestals.

c) Equal to that at the end of bridge girder. Gusset plates shall be provided to assist the cranes remain square.

d) Squaring marks shall be provided on each girder to facilitate erection and squaring of the

bridge. 03 END CARRIAGES:

End carriage shall be fabricated from rolled steel plates, welded together to form as box, a solid box, except for essential openings which shall be reinforced. If more than two wheels are required per bogie, articulated end carriages shall be used. Wherever possible, the end carriages shall be in two halves. Each half shall be rigidly connected to the respective bridge girder in the fabrication shop. End carriages shall be of ample strength to resist all stresses likely to be imposed on them under service conditions, including collision with other cranes or stops. The length of the end carriages shall be such that no other part of the crane is damaged in collision.

The wheel base shall follow as per IS:807. On the end carriages with more than two wheels, the wheel base shall be taken as the distance between the centers of the outside wheels. The end carriages shall be fitted with substantial safety stops to prevent the crane from falling more than 25mm in the event of breakage of a track wheel, bogie, or axle. These safety stops shall not interfere with the removal of wheels. Suitable jacking pads at a height of 300mm from rail level shall be provided on each end carriage for jacking up the crane when changing track wheels. Jacking pads shall not interfere with the replacement of track wheels.

04 TROLLEY FRAME:

Trolley frame shall be produced in one piece unless there are transport limitations. In the case of splicing of the frame; the design shall be such that one unit of a mechanism mounted on one part of the trolley does not come over the other part. Connection between the two parts of the trolley shall be done by machined bolts. Drum bearings and supports for upper sheaves shall be located so as to equalize the load on the trolley wheels as nearly as possible.

The trolley frame shall be built up of rolled sections and plates to form a rigid structure

capable of withstanding all stresses that will develop during the working of the crane and shall be arranged to afford maximum accessibility to mechanical and electrical parts place on it. It 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. Deviations shall be made only with specific approval of the purchaser.

The top of the trolley frame shall be plated all over except for openings required for the

ropes and flexible cables for bottom block etc., to pass. The openings in the trolley frame shall be such as to keep the ropes of cables at least 75 mm away from any part of the trolley frame or equipment to prevent damages for all positions of the bottom blocks. All the mechanical and electrical equipment shall be placed above trolley top plate as far as practicable. For any parts placed below the trolley top plate, access for maintenance, repair and replacement shall be provided. Handrails shall be provided on all the four sides of the trolley.

The trolley shall be fitted with substantial safety stops to prevent the trolley from falling more than 25 mm in the event of breakage of a track wheel, bogie or an axle. This safety stops shall not interfere with the removal of wheel. The trolley shall be provided with lifting pads for jacking up the trolley in case of wheel removal. The jacking pads shall be at a height of about 300mm from the rail level and shall not interfere with the removal of wheels.

05 TROLLEY RAIL:

Trolley track rails made of rail steel shall be clamped to the girders with double bolt clamping plates spaced not more than 900 mm apart with welded alignment blocks between every two clamps such that the distance of a clamp from any adjacent alignment block shall not be more than 450 mm. Rails shall be prevented from creeping in the longitudinal direction by rail stops, welded. Rails shall be made continuous by welding standard lengths. At splice joints, rails shall be welded at site and as such, edge preparation of the rails shall be done in the shop as per standard practice. For double web box girders, rails shall be fastened by clamps held by studs welded to cover plates, spacing of clamps and alignment blocks being as stated earlier.

06 REPAIR CAGES.

Repair cage shall be provided on the inside of the end carriage for attending to the Drag Chain system and trolleys. Repair cages shall also be provided at the corners of the crane, if required, to facilitate removal of long travel wheels. The repair cages shall be minimum 1000 mm wide and shall be such that two persons can work comfortably in the space

provided. The floor of the repair cages shall be about 1500 mm below the L. T wheel centers except the one on which the Drag chain system & pendent cable trolleys are mounted, where it shall be suitably adjusted. The cages shall be of structural steel and shall be made substantially rigid by gusset plates and braces welded or bolted. Repair cages shall be provided with railings on all sides except for the repair cages on the down shop lead side, which shall be provided with easily removable type protection guards on three sides for safety reasons.

II C. MECHANICAL DETAILS 01 DESIGN OF MECHANISMS.

In the design of components on the basis of ultimate strength the value of stress factor used shall be the product of the basic factors and the duty factor for the appropriate mechanism class. The basic stress factor shall not be less than 5 and the duty factor, impact factor, basic stress factor, safety factor etc. shall be in accordance with provisions given in section 20 of IS 3177 – 1999 for group classification M5.

02. ROPE DRUMS:

Rope drums shall be fabricated or of cast steel. All fabricated rope drums shall be stress relieved. The length of the drum shall be sufficient to accommodate in one layer the length of rope requisite for the specified lift and in addition, not fewer than three dead turns at each anchored end and at least one spare groove at the other end. Each rope end shall be clamped with minimum two clamping wedges with at least two numbers of bolts on each clamping. Rope drum shall be designed as specified in section 8.4 of IS 3177 – 1999 in general.

03. STEEL WIRE ROPES

i) The ropes will be regular lay, right hand, as specified in IS: 2266 & IS 3973. . ii) The wires shall be made of steel with tensile designation 1960 (minimum tensile

strength 1960 MPa). Size selections of wire ropes in general shall be as per section 8.3 of IS: 3177 – 1999

and as per IS 13870: Part 1: 1993 /ISO 4308-1: 1986 Cranes and Lifting Appliances - Selection of Wire Ropes - Part 1: General

iii) The factor of safety shall be 6.0, Core shall be IWRC.

04. ROPE SHEAVES:

All sheaves shall be of forged steel or cast steel. All sheaves shall be identical; however, exception may be made for equalizer sheave. The equalizer sheave / bar shall be mounted where feasible above the trolley floor and shall be easily accessible and removable from

the floor of the trolley. Equalizer sheave / bar shall be arranged to turn and swivel in order to maintain proper alignment under all circumstances. All sheaves shall have guards, which fit closed to the flange having a clearance not more than 1/3rd rope diameter between sheave and inside of guard. Equalizer sheave / bar shall be mounted on roller bearings and not on ball bearings. Design of sheaves in general shall be as per section 8.5 of IS:3177 – 1999.

05. RAIL WHEELS:

Rail wheel shall be double flanged with straight tread unless guide rollers on sides, to take up horizontal thrust, are provided. The wheels shall be capable of taking up misalignments in span as specified. Wheels shall be of forged steel. Minimum diameter of wheels for cross travel shall be 250 mm. minimum dia. of long travel wheels for class M5 cranes shall be 315 mm. Minimum hardness of wheel tread shall be 300 BHN. General design of wheels shall be as per section 8.6 of IS:3177 – 1999.

06 BUFFERS:

Rubber buffers shall be fitted on the four corners of the crane and also on the four ends of the bridge girders (and not on the trolley frame) for soft dashing of crane and trolley respectively. Buffers shall be rigidly bolted in place preferably along the Centre line of crane rail or trolley rail as the case may be, such that the bolts are not in direct shear.

07 DRIVES:

For class 2 duty cranes not less than 50% of the long travel wheels shall be positively driven unless agreed otherwise by the purchaser. The long travel shafts shall be supported on bearings at approximately 3 m Centre or less. Shaft couplings shall be as near as possible to the bearings. Shafts shall be easily accessible throughout their length and shall be designed as far as practicable inter-changeable lengths, the end and centre sections being as short as possible. Where applicable the driving pinions shall not interfere with the removal of wheels. Angular deflection of the line shaft at torque corresponding to 1.33 motor rated torque during acceleration shall not exceed 0.10 deg./m of shaft length. In case of L.T. drive located at the span Centre, half the above torque, i.e. 2/3 of motor torque shall be taken for each half of the shaft. The L.T. drive shaft minimum diameter shall be not less than 100mm. The offer will be rejected if the L.T. shaft minimum diameter is less than 100mm. All parts of the long travel drive shall preferably be located above the top platform. No part of cross travel drive shall be located below the trolley platform. Refer section 8.2 of IS: 3177 – 1999. Wheel mounted drives can be provided LT drive of cranes that are having spans more than 20meters.

wheel mounted drives can be provided LT and CT for single girder and under running cranes.

08 GEARING : (Standard make gear boxes shall be used in EOT cranes for all drives)

Straight and helical spur gearing shall normally be used for all motions. Worm and bevel gears shall not be used without specific permission from purchaser. First and high-speed reductions shall be through helical gears. All first reduction pinions and also other pinions

if feasible shall be integral with shafts. All gears shall be of hardened and tempered alloy or carbon steel with machine cut teeth. Gear teeth shell is preferably cut in metric module system. All gear teeth shall be ground smooth to give less noise while running.

09 GEAR BOXES: (Standard make gear boxes shall be used in EOT cranes for all drives) All gears shall be completely covered or guarded by covers firmly attached to brackets. All gears shall be enclosed in oil tight casings except where not possible. All gear shafts shall be supported on bearings mounted in gear box unless specifically agreed otherwise. In case of totally enclosed gear boxes splash or automatic lubrication system shall be used. The gearboxes shall be fabricated or of cast steel. Fabricated gearboxes shall be made of minimum 8 mm thick steel plate. All fabricated gearboxes shall be stress relieved. Covered shall be split horizontally at each shaft centre line and fastened and arranged so that the top half can be removed for inspection and repair without disturbing the bottom half. Directly above the mesh line of teeth, there shall be hand-holes with oil tight bolted covers. The gear box shall be provided with breather vents, oil level indicator, dipsticks and easily accessible drain plugs. Radial clearance between the gear box inner surface and the outside diameter of the gears shall be at least 1¼ times the depth of the largest gear tooth inside the gear box or 20 mm whichever is higher. The physical clearance between the pinions shall be at least 20mm. No oil leakage is allowed from gearboxes. Standard gearboxes from reputed manufacturers shall be used in all drives of cranes.

10. BEARINGS:

Ball and roller antifriction bearings of FAG, SKF, TIMEN make shall be used throughout the drives except where specified otherwise. Rated life of ball and roller bearings shall be not less than total life in working hours given under “01. Design of Mechanism”. Life of bearing shall be calculated in accordance with manufacturer’s recommendations. All bearings housings shall be made of cast or wrought steel bolted to a rigid portion of crane structure by at least 4 bolts except for intermediate line shaft bearing housings which may be bolted by at least 2 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. Refer section 8.7 of IS – 3177 – 1999.

11. COUPLINGS: As far as possible gear boxes directly mounted with motors (Geared motors) shall be used for all drive motions of cranes. Motor shafts shall be connected to gear extension shafts through flexible shock absorbing couplings. For driving hoist drum, geared couplings shall be used between hoist rope drum and hoist gearbox out-put shafts. Geared couplings shall be used for connecting intermediate lengths of long travel and cross travel shafts. Geared or universal couplings shall be used between gearbox output shaft and intermediate shaft or end shaft. Between intermediate shaft and end shaft and between end shaft and wheel axle, any other special coupling which can give better and more reliable service may be used after obtaining specific approval of the purchaser. Refer section 8.9 of IS: 3177 – 1999.

12. LIFTING HOOKS:

Standard single shank point hooks shall be used unless otherwise specified. These hooks shall confirm the latest edition of IS:3815/15560 or to the relevant Indian standards specification. Safety latch should be provided to the hook such that the rope does not slip out of the hook. Refer section 8.1 of IS: 3177 – 1999.

13. BRAKES:

Electro hydraulic thruster brakes shall be used for all drives in crane. Brakes shall be provided for all drives of cranes. Brake shall be mounted on the input pinion shaft of the gear train. The brake shoes shall be of hinged type. Brake levers shall be forged or fabricated or cast steel. Hinge pins shall be of hardened alloy steel and shall be lubricated. These hinge pins shall be provided with steel bushes at bearing point. Brake drums shall be forged or of cast steel. Drums shall be completely machined and dynamically balance. Width of the brake drum shall be 5 to10mm more than the width of the brake shoes. Hardness of brake drum shall be 38 – 43 Rc. No oil leakage is allowed from thruster brakes. Braking path shall be calculated as per is 3177.

i. Hoist mechanism shall be provided with two brakes. Each brake shall be designed for a minimum of 200% static moment considering that the full load can be held by one brake alone. This shall also apply to single drive with two brakes. ii. The brakes for long and cross travel motions shall be designed from the following consideration:

a) Braking against travelling shall be capable of arresting the motion within a distance in meters

equal to 10% of the speed in m/min. When travelling at rated speed with rated load.

b) The retardation due to braking shall not exceed the values given in the table below to avoid

skidding wheels. Table –2

Retardation, according to percentage number of

Working condition Driving wheels in ‘m/sec2 ‘

100% 50% 25%

Indoor (When = 0.1) 1.5 0.75 0.45 Refer section 8.12 of IS: 3177 – 1999.

14. BOLTS AND NUTS: All bolts, nuts, washers, etc. used in this crane shall be galvanized as per IS; 1367 part 13 Refer section 8.10 of IS: 3177 – 1999

II D. ELECTRICAL DETAILS

01. SCOPE OF SUPPLY

The scope of supply shall cover all items of electrical systems commencing from main cable. Motors, brakes, limit switches, power and control cables, encoder, socket outlets, lighting fittings with lamps, DSL, Cable drag chain system, Pendent, push button station and equipment earthing. All sundry erection material required for installation and connecting up of electrical equipment with cable laying and fixing accessories shall be included in the scope of supply by the tenderer.

02. CLIMATIC CONDITONS:

The equipment offered shall be suitable for tropical and humid climate. For purpose of equipment selection and specially for derating the capacities of drive motors and power cables, the ambient temperature condition specified in salient features shall be taken as the basis. The design shall consider ambient temp of 500 C and saline atmosphere. The equipment on the crane shall be suitably protected against damage from radiant heat and shall be rendered proof against ingress of dust and vermin.

03. STANDARDS:

The equipment shall be selected, assembled and tested as per guide lines provided in the latest edition of Indian Standard Specification IS: 3177 - 1999 or class M5 duty cranes subject to any modification and requirements specified by the purchaser.

04. POWER SUPPLY CONDITIONS

The power, on the bay down-shop leads shall be available at 415 Volts, 3 phase, 4 wire, 50 HZ. The power and control equipment selected shall be suitable for operation on ± 10% variation in the voltage and ± 3% variation in supply frequency.

The following voltage shall be used in the cranes: i) 415 volts, 3 phase, 50 HZ : For drive motors A.C (unearthed system) ii) 110V volts single phase, : Control circuit in VFD panel. 50 HZ, A.C

05. CURRENT COLLECTION a). CABLE DRAG CHAIN SYSTEM

Location of main switch is at Bay 1m height from the ground. Supply and routing of cable through cable drag chain system is included in the scope of supply. The power supply arrangement shall be provided through cable drag system of IGUS / LAPP make. The cables used in Drag chain system shall be of IGUS /LAPP make only suitable to drag chain applications. The cable Drag chain system & cable Make shall be same. party shall submit cable schedules & Drag chain selection criteria for approval by SDSC SHAR.

06. MOTORS

All crane motors shall be non-flameproof squirrel cage induction motors. Motors shall have S4 DUTY, 60% CDF, min of with 300 starts per hour. The motors shall be provided with thermistor embedded in the winding and interfaced with Drive for tripping in case surface temperature exceeds designed safe limit of motor.

a) HORSE POWER

The service factors shall be taken for selection of motors for long and cross travel motions as per Annex-C of is 3177-1999. Motor selected are such that the maximum current drawn with full load should not exceed 80% of the full load rated current of the selected motor. Motors shall have 120% of torque rating over the calculated torque requirement.

b) TORQUE The pull out torque of the motors at rated voltage and frequency shall not be less than

2.75 times the nominal torque.

07. CRANE CONTROL

On all motions, the circuit shall be so designed that brakes come into operation immediately in the event of tripping of main circuit breaker. Additionally, the control circuit shall be so designed that following functions are fulfilled.

Hoisting shall take place only when hoisting push button is pressed in position up to rated

load, lowering shall take place only when hoist lowering push button is pressed in position. Both the push buttons should be interlocked such that only one direction

operation is possible at a time. This type of control should be followed for all the motions of the crane. 08. PENDENT CONTROLLERS.

Normal push button station shall be provided with OFF push button shall be of lockable type (with key) so that power and control supply is cut off when the crane is not in use to prevent inadvertent operation. Push button shall be provided for lights. Indicating lamps for power and control ON, emergency switch shall also be provided on the pendant to cutoff control power supply.

The pendant station shall be suitably supported by means of a SS chain and it shall be ensured that no strain is caused to the pendant cable. A minimum of two spare cores shall be provided in the pendant cable. The pendant station shall move along the bridge girder on four wheeled cable trolleys with antifriction ball bearings running on a separate track. Each trolley shall be provided with buffers to avoid entanglement. Tension coming on the cable due to trolley movement shall be avoided by provided SS chain between trolleys.

09. LIMIT SWITCHES: All hoist motions shall be provided with limit switches to prevent the crane hook from

over hoisting and over – lowering. Two limit switches shall be provided for proper back up protection. The first limit switch to act in the event of over hoisting and over lowering. This shall be screw type with self-resetting feature and be incorporated in the control circuit of the respective drive motor. The second one shall be of gravity operated hand resetting type switch connected in the trip circuit of the main incoming current breaker. The second limit switch shall act only to prevent over hoisting limit switch incorporated in the motor control circuit shall be made to act first but in case this limit switch fails to operate, the second limit switch connected in the main incoming circuit breaker’s control circuit shall operate and trip the breakers.

10. BRAKES:

All motions of the cranes shall be provided with non-Flame proof A.C Electro-hydraulic

thruster brakes to arrest the motion safely. This brake should be provided with brake release mechanism. The Brakes shall be protected with suitable MPCBs. The torque capacity of brakes shall be 2.0 times the rated full torque of the selected motor

for hoist. The torque capacity of brakes for LT, CT shall be 1.5 times the rated full torque of the selected motor..

There shall be Two brakes for Hoist one will act as Main and other one will act as redundant brake. Each brake shall operate two no’s of contactors connected in series. This arrangement will prevent brake opening in case of contactor welding.

LIGHTING: Four numbers of under slung Non flame proof lamps of 250 W HPMV and with shock

absorbing & anti swing suspension shall be provided for uniform floor illumination. Screw cap type holders and lamps shall be used for crane lighting. These light fittings should be provided with wire mesh and glass to avoid free falling of lamp. Lighting transformers shall have 50% reserve capacity. Lighting control ON/OFF shall be possible from pendant station. The light fittings shall be so located that free access for maintenance is possible.

Note: for Single girder and under running cranes lights are not required.

11.CABLING:

All wiring for power control, lighting etc., shall be carried out with 1.1.K.V grade PVC flexible armored copper conductor cables. All power cables shall be minimum 4sq.mm Cu and control cables minimum 2.5 sq. (cu). Cable cores shall be of stranded construction.

Cable selection and routing on the crane shall form part of the crane design. Selection of cable sizes shall take into account the following factors.

a) Ambient derating factors b) Group rating factor. c) Intermittent duty factor.

Suitable cable trays firmly secured to crane structure shall be provided with due regards

to cable weight and vibration encountered. Cables shall be routed so that they do not constitute a safety hazard, pose any obstruction to free movement of personnel, and properly laid to present an orderly appearance.

e) IDENTIFICATION OF CIRCUITS, CABLES ETC.

Labels of permanent nature shall be provided on supports of all switches, fuses, contactors, relays etc., to facilitate identification of circuits and replacement. All panels, are to be properly marked for each motion. All power control cables, lighting and other cables are to be tagged at both ends as per cable number indicated in the supplier ‘s drawing. All equipment terminals are also to be marked likewise.

f) EARTHING: The Earth strip /Cable size shall be minimum 25 X 6 to use for earthing purpose. The

LT Rail at both sides to be earthed. All electrical equipment mounted on crane including Mechanical structure to be earthed with double runs. Suitable Bridge Clamp provided on crane for tapping earth points. Along with pendent control cable an additional wire braided flexible copper strip of 12mm wide shall run as a special earth from the control panel up to the pendent station. SDSC will only provide ground riser at 1mtr height inside bay for grounding. Further connection from this riser to EOT system for earthing will be in bidder’s scope. Any specific grounding requirement other than the above power earth may be brought out in the offer.

Documents

ANNEXURE - I - ISRO · 2018-06-01 · As the crane is intended to be used in hazardous area, the electrical motors, junction boxes, light fittings etc., should be of flame proof in