annexure – a item: 1 ps2/gs2 12t eot crane · 2015-08-13 · annexure – a item: 1 ps2/gs2 12t...

Annexure – A

ITEM: 1 PS2/GS2 12T EOT CRANE

TECHNICAL SPECIFICATION FOR 12T CAPACITY DG EOT CRA NE WITH GANTRY GIRDER & RAIL:

Sl. No Description Specification

01 Safe Working Load (t) 12t

02 Type Double girder plate fusion welded box type EOT cran e

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, PS2/GS2 Integration Bldg

05 Ambient temperature 30-40 degree centigrade

07 Area classification Normal Area

08 Span 24.0m (Appx)

09 Height of lift 22.0m

10 Bay length 41.18 m (Appx)

11 Nearest position of hook to the centre of gantry rail(CT)

950mm left side & 950mm right side

12 Gantry Girder with Rail

Steel Gantry Girder for bay length of 41.18m consists of composite girder fabricated from standard ISMB & ISMC and same to be fixed by welding over the RC columns base plate already provided by Dept. The centre to centre distance between the bracket is 4.58m max fo r 12T crane . Long travel rail in bright square bar but not less than 50mm size to be welded over ISMC top of the gantry girder for bay length of 41.18m.

Annexure – B

ITEM: 2 PS2/GS2 3T MONORAIL

TECHNICAL SPECIFICATION FOR 3T CAPACITY ELECTRICALL Y OPERATED UNDERSLUNG MONORAIL:



02 Type Electrically operated under slung trolley with wire rope Monorail crane


04 Location Indoor, PS2/GS2 Integration Bldg Airlock Room



07 Height of lift 6m

08 Bay length 8m (Appx)

09 Main Operating speed(m/min)

Hoist 3.0 m/min(Main Speed) – 0.30m/min(Micro Speed) LT 6.0 m/min(Main Speed) – 0.60m/min(Micro Speed)

10 I - Beam Steel beam construction , the centre to centre distance between the brackets is 4.24m max .

11 Type of hook Standard forged single point “ C” hook with spring loaded safety latch, thruster bearing, free swivel with lock confirming to IS: 3815

12 a)Wire rope 4 fall with Hot dip galvanized.6x37/ 6x36, IWRC

b) Factor of safety 6.0

13 Brakes

The torque capacity of brakes shall be 2 times the rated full torque of the selected motor for main hoist and for LT the torque capacity of brakes shall be 1.5 times the rated full torque of the selected motor 1 No. each EM for Hoist & LT operations of approved makes only.

14 Gear box

Totally enclosed type and oil bath lubricated. Gear and pinions shall be forged steel and machine cut. IS 3681 for tooth form & module and IS 4460 for rating of gears.

15 Couplings The coupling shall meet the requirement of IS 3177

16 Motor

IP 55, class F insulation, squirrel cage crane duty induction motors in TEFC enclosure as per IS: 325 shall be provided for all the motions. The motor shall be suitable for operation with VVVF Drives. 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.

17 Limit switches One gravity type & one rotary type limit switches for hoist motion. Two way lever shunt type limit switch for LT.

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

19 Control supply 24V AC power supply

20 Pendent Control

Operation from floor through light weight SS pendent moveable along the bridge girder on four wheeled cable trolleys with anti-friction ball bearing running on a separate track with 24V AC confirming to IS: 5780 and push button station to be self ignited.

21 Speed Control The speed & brake control shall b e through VVVF Drives for Hoist & LT operations.

22 DSL

Festoon cable arrangement, PVC sheathed, flexible cables with multi strand copper conductors cable SS chain in `T ` track system.

23 Pendent

Pendent cable (single cable with multi core) shall be on independent “T” track. SS chain for holding self weight of cable & pendant. Pendant consists of Power ON/OFF bush button, Power indicator, Lockable ON with key, bush button with contactor for hoist & LT normal speed & micro speed

24 Control panel Electrical panel to be provided on beam.

25 Buffer Rubber buffers for LT.

26 Painting

The entire crane structure shall be provided with one or more coat of zinc primer and one coat of synthetic enamel golden yellow finish paint before dispatch and at site one more coat of synthetic enamel golden yellow finish paint after crane erection at site.

1. MAJOR PARTS OF THE CRANE : The crane assembly shall include, but not limited to the following for safe and efficient operation of the crane. The crane is suitable for vertical loading shall comprise the following.

- I-Beam and drives - Hoist with anti swing - Rope drums, sheaves, wire rope and lifting hook - Motors with gear box - V3F drive for all the two motions with software - Rubber buffers for LT - EM brakes - Limit switches (Gravity &Roller for Hoist, two way lever for LT) - Incoming power supply with TPN MCB - Festoon cable arrangement `T ` track DSL system - Movable Pendant push button control from floor

2. DESIGN:

- The design of the monorail shall be indoor and generally comply with latest

revision of all relevant Indian standards and generally confirms to IS226, 325, 800, 807, 1030, 1181,2068, 2266, 3177, 4460, 5780 & 8239

- In the design of components on the basis of strength, factor of safety shall not be less than five (5) based on ultimate strength, impact, fatigue, wear and stress concentration factors shall be taken into account, wherever applicable.

- Design shall provide for easy maintenance of all parts. Necessary safe and

sufficient working space shall be provided all around the sub systems for easy maintenance.

- The total maximum vertical deflection of the beam for the live load and not

including impact or dead load of the beam shall not exceed limit of span/750.

- No wood or other combustible material shall be used.

- Maximum use shall be made of shop fabricated sub-assemblies. Sub-assemblies shall be finalized so as to facilitate easy transportation and erection at site considering clearances and approaches available inside respective facilities.

- All materials shall be of tested quality and shall confirm to the specification requirements and standards mentioned.

- Where welding is not practicable, turned and fitted bolts shall be used.

- Minimum number of turned and fitted bolts in a connection shall not be less than two.

- Black bolts shall not be used in main structures and high tensile bolts shall not be used unless approved. Bolts shall be preferably be not used in tension.

- Where bolts pass through sections having tapered flanges, tapered flats shall be welded to inside of the flanges. Tapered washers shall not be used.

- Traverse fillet welds on load carrying members shall be avoided. If side fillets are used in end connections, the length of each side fillet should not be less than the edge distance between the fillets.

- Butt welds on structural members under tensile stress shall be checked by radiographic examination.

- Two limit switches shall be provided for main hoist motion with gravity & rotary

type and two-way lever type limit switches for LT motion.

- Receiving system shall be so designed that the rope will not slip out of the pulleys or foul with any part of the devices.

- Failsafe EM brakes for Hoist and LT shall be provided.

- The monorail should be able to position the load in any desired height with a

reasonable accuracy.

- Factor of safety for wire rope shall be 6 on nominal breaking strength and size selection of wire ropes in general shall be section 8.3 of IS3177 & IS 13870-Part 1.

- The wire rope used in the crane shall be made out of galvanized steel (with steel

core) and tensile designation 1770 N/mm² and shall be non lubricated pre-stretched core 6x36/ 6x37 construction, regular right hand lay performed and non rotating type as per IS 2266 and core shall be IWRC.

- All finished wires shall be well and cleanly drawn to the required dimensions. The

wire shall be sound, free from splits, surface laws rough, jagged and imperfect edges and other harmful surface defects. No joint shall be used for any of the ropes under this specification. Kinks are not allowed on any part of wire rope.

- Rubber buffers & stoppers shall be provided on LT motion and minimum

hardness of the rubber shall be 90BHN.

- V3F drives shall be provided in each motion of the cranes, i.e LT & Hoist and driver impedance shall be matched with gear box motor & brakes. All brakes are to be interlocked by control wiring with respective V3F drives.

Rope Drum : - The drum shall be fabricated of cast steel and designed for single layer of ropes

and fabricated rope drum 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 provided with flanges at both ends. Design of rope drum in all other aspects shall be as per IS3177 & IS6938

- Rope drum support structure shall be so designed that the bearings are mounted under compression to minimize potential for failure of bearings increase the probability of maintaining the mesh between the drum gear and drive in case of bearing failure.

Sheaves :

- The sheaves shall be of forged steel and shall be provided with anti-friction ball bearings. 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 bearing and not on ball bearings. The design shall confirm to IS3177.

Shafts : - Shafts shall be of EN8 material confirming to IS970

- Wherever components of considerable amount of inertia are directly mounted on

the high speed shaft (eg. Brake drum, couplings, etc) they shall be balanced dynamically to minimize vibrations.

- Design of shaft is to minimize stress concentration at the changes of diameter,

and hence shall be provided with chambers, fillet, radii or relief grooves as applicable. Wherever practicable keys and keyways and splines shall confirm to the relevant Indian standards.

- Provision shall be made so as to prevent the sliding of the keys from their respective keyway during operation. Wherever feasible head keys shall be used.

- All shafts, including gear box output shafts shall be of EN8/EN9 steel with

minimum hardness of 200BHN. Wheels : - Design of wheels shall conform to the requirements of IS 3177 as applicable. The

face width of the wheels is determined on the basis of rail size and possible lateral displacement of wheel during operation.

- All wheels shall be of forged type and shall be machined/ ground to equal diameter in pairs. Material of construction of the wheels shall be of forged steel of EN 8, BS 970 or equivalent. Wheel axles shall be with L-type bearing support with rotating axles. The hardness of wheel shall be between 275 to 300 BHN. The long travel and cross travel wheels shall be 55+ MN75 materials confirming to BS-970 & IS 1570.

- Wheel mounting shall be designed for easy removal for maintenance. Gear Boxes : - Gearing shall be as per IS: 3177 and also as for the following:

- Gear boxes shall be totally enclosed type and oil bath lubricated. Reputed make

gear boxes as approved by Dept only to be used. - Gears and pinions shall be of forged steel and machine cut. Gear and pinion

teeth shall be treated for resistance to wear. All gears and pinions shall be of ground type so as to reduce noise levels to the minimum. The permissible noise level is 75dB at 1m distance from the gear box.

- Gears shall have tooth form and modules as recommended in IS: 3681 and they

shall be adequately to withstand shock load and vibration and shall not be excessively noisy in operation. The ratings of gears shall be established as per IS: 4460.

- Spur and helical gears only shall be used for reduction gearings.

- The creep motion shall be through VVVF control.

- Sheaves shall be arranged on the trolley that rope receiving arrangement resulting in lifting of the load almost in a vertical line with minimum of swing or side movement.

Lifting Hook :

- Hook shall be single shank ‘’C’’ type forged steel confirming to IS3815 and shall be supported on thrust bearing for free swiveling on the hook. The hook shall be tested to 200% to SWL. The lifting hook shall confirm to the requirement of IS3177.

- Swivel lock and safety latch is to be provided for the crane hook with anti sway.

Materials :

- A material for main girder is mild steel of SAIL/ VIZAG and as per IS2062.

Brakes : - Brake design shall confirm IS: 3177 as applicable.

- Fail safe EM brakes shall be provided for Hoist & LT motion.

- Each rated for 2.0 times of motor rated torque/ suitable capacity shall be

provided for hoist motion. Brake for hoist motion shall be adequately sized to arrest and hold any load up to and including test load at any position of the lift.

- Brake drum shall be positively locked in position so as not to prevent lateral movement by means of retainer plates or any other means.

- All brakes shall have smooth braking capability to decelerate in safe manner to avoid any derailment even when applied at maximum speed. The braking action of hoist motion shall be such that there shall not be any jerks for the objects being lifted at main speed.

Lubrication :

- Bearings shall be enclosed in suitable housing with proper holes and plugs to prevent any ingress of drift and to permit easy lubrication of the bearing.

- Lubricating chart shall be provided indicating all lubricating points, type of lubricant and recommended frequency of lubrication.

Power Supply : - Power: 415V, 3phase, 50Hz, four wire system with double earthing. - Control: Control supply shall be 24V. The supply to the circuit shall be from the

secondary winding of isolating transformer and rectifier. One pole of this supply shall be earthed.

- Main incoming TPN MCB, interlocking with door panel.

- Power wiring shall be XLPE armored aluminium/ copper conductor cable.

- Control wiring shall be PVC insulated flexible copper conductor cable.

- Individual single phasing preventor shall be provided to all the motors or V3F drive shall have provision of single phase control.

- Cable glands to be provided for all cables with necessary crimping &

interconnections in an approved manner.

Motors :

- The motors shall be selected to take care of the loading conditions and to suit the duty of the mechanism in which it is used. The motors shall be suitable for frequent acceleration, frequent reversing and braking.

- All crane motors shall be totally enclosed, fan cooled type and shall conform to IS 325. The enclosure shall suit the specified service conditions.

- The motors shall be of squirrel cage and shall be capable of producing maximum torque required to produce motion in the most unfavorable loading conditions. The motors shall be easily accessible for inspection and maintenance.

- Voltage 415 ± 5%, 3phase, 50Hz,

- Insulation class `F’ for motor winding

- Duty: To match the class as per IS807, with duty cycle of 40% CDF.

- Resistance: The resistance if provided shall be designed as per IS1822 and shall

be air cooled, restless, unbreakable grid type rated for minimum 10 minutes. Suitable sheet steel housing with ventilated side cover.

Controls & Protection Panels :

- The method of control of the crane shall be pendant control. An electro magnetically operated contact with inherent under voltage protection and manually operated circuit for each motor. The circuit breaker of the main contactor shall be rated to carry at least the combined full load currents of two motors having the largest wattage.

- For pendant control system, the controller shall consist of forward/ reverse push

button with contactor for individual motions like normal & creep speed. The bush button shall be spring returned to off in case of emergency. Start and stop push buttons are to be provided with self illuminated in green & red and to make and break the main contactor/ circuit breaker. Hooter switch is to be provided in the pendant and hooter to be fixed at crane. The pendant shall have mushroom type emergency switch and indication lamp for main ON/OFF.

- All reversing contacts shall be electrically and mechanically interlocked, connections for the pendant controller shall be taken through braided cable ( with necessary earth wire inside). Support the pendant controller in such a way that its weight does not appear on the cables by providing SS type chain to hold the pendant.

- The panel shall be painted with 2 coat of synthetic enamel paint externally and 2coat of fire retardant paint internally and up to 1.5 mtr length of each cable from panel to be painted with fire retardant paint.

- All cables entries in the panel shall be from bottom and shall be provided with

cable glands and earthing

- Control of the monorail shall be from floor through moveable pendent push button stations. The pendent movement along the span should be festoon type running in a four wheel trolley on a separate track.

LIMIT SWITCHES:

One gravity type and one rotary type limit switches shall be provided for hoist motion. Two ways lever shunt type limit switches shall be provided for LT.

CURRENT COLLECTION SYSTEMS:

For taking power to the monorail by Festoon cable arrangement, PVC sheathed, flexible cables with multi strand copper conductors cable SS chain in `T ` track system.

EARTHING:

- The crane structure, motor frames, metal enclosures of all electrical equipments, shall be effectively grounded in accordance with Indian Electricity Rules.

- Copper conductors of required size shall be used for grounding purpose.

- Double earthing to be provided to all electrical equipment of crane.

ELECTRICAL TESTS:

- All electrical installation work shall be carried out through electrical contractor holding valid license issued by Electricity board.

- All tests applicable as per relevant standards shall be conducted on all electrical before dispatch from the manufactures’ works.

- After erection, but before the cranes is connected to the supply, installation of the electrical equipments shall be tested by a suitable instrument and any defects revealed shall be rectified.

- After the power supply has been connected, the following test to be carried out

i. The satisfactory operation of each controller, switch contactor, relay and other control devices and in particular the current operation of all limit switches under the most and favorable condition.

ii. The correctness of all circuits and inter-locks and sequence of operation

iii. The satisfactory operation of all fool proof devices

iv. The satisfactory operation of each motion of the crane. 3. Make of the approved bought out components and r aw materials:

Sl.No Item Make

1. Motor Kirloskar/Bharat Bijlee/Crompton Greaves/ABB/

GE/Seimens 2. Brakes Storm-Kraft/ Pethe/ Speed-O-Control/ BCH/

Speed-N-System/ KMM/ MAG Co 3. Limit switches ESSEN / STROM KRAFT / SPEED O

CONTROL / AR / BAUMEN / BCH / EPC / SEW

4. Wire ropes (All galvanized)

USHA MARTIN

5. Contactors SIEMENS/ L&T/ TELEMECHANIQUE

6. Switch gear SIEMENS / L&T / TELEMECHANIQUE

7. MCB LEGRAND (MDS) / HAVELLS / VERSATRIP/ GE /SIEMENS / SCHNEIDER / ABB / STANDARD

8. Cable trays(PVC,FRP,GI)

Profab/Sintex/Indiana/Patny System / L&T / Cablofil(Legrand)/OBO Bettermann

9. Push buttons SIEMENS / L&T

10. Flexible cable GLOSTER / PARAGON / ICC / STANDARD / SPENCER

11. Gear boxes

Radicon(Premiem)/ Elecon/ Shanthi/ Allenberry

12. Transformer SIMHA / UNIT SERVICE TRANSTECH SYSTEM

13. Lifting hook ESSOFAIL/ ESMAILJI / KARACHIWALA & CO

14. PVC wires ANCHOR / FINOLEX / HAVELLS / RR KABEL

15. TPN switches SIEMENS / L&T / GE / CRE / STANDARD / ABB

16. Armoured LT power cable (both PVC or XLPE)

HINDUSTAN / GLOSTER / POLYCAB / FINOLEX / CCI / RPG / HAVELLS / UNIVERSAL / RALLISON

17. 18. 19. 20.

Variable speed drives (V3F) Steel(I-Beam) Relays Paints

ABB/ Siemens/L&T SAIL/ VIZAG L&T/ SIEMENS/BCH Asian/ Berger/ Nerolac/ Dulux

Material Specification : 1. Main beam: Fabricated out of rolled steel beam construction 2. Gears and pinions EN8 – IS: 1570/61 3. Wire rope IS: 2266 4. Hook Forged steel – IS: 3815 5. Rope drum Seamless pipe as per IS 3177 6. Wheel and shaft EN8 – IS 1570/61 7. Rope sheave Cast steel

4. PAINTING:

- All the parts of the crane shall be thoroughly cleaned of all loose mills

scales, rust or foreign matter and then painted as specified.

- The entire surface of all the fabricated material is to be sand blasted as per standard. Immediately after sand blasting, one coat of metal primer shall be applied to a Dry Film thickness (DFT) of 75microns (min). An intermediate coating of synthetic golden yellow enamel paint to a dry film thickness of 80microns shall be applied. Then a final coat of 40microns shall be applied.

- All damage to the paint shall be corrected and made good by the contractor after assembly of the crane at site.

- The equipment shall be suitably protected in respective packing for the shipping

distance and the weather conditions involved.

5. INSPECTION:

The monorail shall be designed, drawn, fabricated and tested under a quality control Engineer of the company. The scope of inspection includes design verification & approval, shop drawings approval, material acceptance, verification of test certificates of bought out components, fabrication dimensional inspection & welding joints, load test and speed verification test at supplier`s work station. Monorail shall be brought to purchaser’s site only after final inspection at supplier premises by purchaser, however, such approval shall not absolve supplier from his obligations to comply with purchase order.

6. TESTING: The monorail shall be tested subject to full load of SWL and over load of 125% and speed verification in load and no load conditions as per Indian standard at supplier’s premises in presence of purchaser.

Components using such as motor, limit switches, wire ropes, crane hooks, gear boxes, drive system etc shall be subjected to routine test at sub supplier/manufactures works and test certificates shall be furnished at the time of inspection.

The monorail after erection at site shall be tested as given below in the presence of purchaser.

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, interlocks etc.

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.

Speed test : All the motions of the crane shall be tested with rated load and the rated speeds shall be attained within the tolerance limits indicated below.

Travelling & traversing +10%-5% of specified speed. Hoisting +10%-5% of specified speed. Lowering +20%-5% of specified speed.

All the motions of the crane shall be tested with 25% overload of SWL in such case the rated speed may not be reached but the crane must be capable of handling such overhead without difficulty. The cranes shall be tested with rated load for performance of hoists, long travel and cross travel motions with VVVF controls from maximum to minimum speeds.

7. ERECTION & COMMISIOING AT SITE:

The monorail shall be brought by the supplier to the purchaser’s site for erection & commissioning. Erection of the monorail with I-Beam, DSL, etc shall be carried out by the supplier at IPRC, ISRO, Mahendragiri. Mahendragiri is located near Nagercoil, Tamilnadu and elevation is 157m above MSL. Ambient temp is 40deg.cel max and RH80%.

Monorail to be tested & commissioned as per approved specifications / code at our site shall include tests for no load, full load, overload, speed and deflection. Unloading of the crane at site, all skilled / unskilled labors, supervisor, tools, tackles, machineries like welding machines slings and consumable etc shall be arranged by the supplier.

Electric power required for the erection work will be provided by the purchaser free of charges. However the supplier shall comply with the purchaser’s regulations such as safety permit, work permit, Power board cable, etc are to be brought by the supplier.

Safe storage and handling of all components till the crane is erected, tested satisfactorily and handed over to the purchaser, including insurance for workers against death & accidents.

Prior to start fabrication of the monorail, supplier has to take actual measurements at site IPRC, ISRO, Mahendragiri.

8. INFORMATION AND DOCUMENTS TO BE FURNISHED: Along with Tender (Quotation) :

i. GA drawing with dimensions for mechanical & schematic diagram for electrical.

ii. Bill of materials being used for monorail & Technical specifications for components / equipments.

Within two weeks after receipt of Purchase Order :

- Prepare the detailed design for structural like main girder, trolley, rope drum, wire rope, gear box, hook etc and mechanical design like motors, brakes etc.

- After design calculations detailed drawings to be prepared for all the

components Submitting Design & Drawings to Department to accor d fabrication Approval :

- All design & drawings to be submitted to Dept within 10days after receipt of Purchase Order to accord fabrication approval.

- Prior to start fabrication of the crane actual measurements shall be taken at site by supplier.

- Monorail fabrication shall be completed as per Department fabrication

approval within 20days and final inspection of the crane by Department also shall be completed in the 3weeks time.

At the time of inspection by purchaser’s representa tive:

i. Reports of inspection agency as per Inspection clause No.5 ii. Dimensional inspection report verified by QC

iii. Test report of all items to be verified by QC iv. Purchaser shall witness load test in rated SWL & 125% over load, speed

verification in load & no load condition at supplier premises in the presence of inspection agency.

Along with dispatch of crane:

i. Operation and maintenance manual in duplicate. ii. Guarantee & test certificates for monorail. iii. 6 sets of as built drawing and soft copy of all the drawings, operation and

maintenance manual and wiring diagrams in the CD

9. GUARANRTEE: All the items shall be guaranteed against faulty design, use of defective material and bad workmanship for a period of min 12months from the date of acceptance by Purchaser. Any defect noticed during this period shall be rectified by the supplier to the purchaser’s satisfaction free of cost.

10. STANDARD AND REGULATIONS: The electrical of the crane shall confirm to the latest edition of the relevant IS 226 & 2148 and to the Indian electricity rules and regulations also to the relevant class of factories. The electrical of the crane shall be suitable for indoor arrangement. All equipments shall be of tropical design according to Indian / International standards.

Annexure – C

ITEM: 3 STRUCTURAL TEST FACILITY 20T EOT CRANE




02 Type Double girder plate fusion welded box type EOT crane


04 Location Indoor, Structural Test Bay



08 Span 24m (Appx)






Steel Gantry Girder for bay length of 32m consists of composite girder fabricated from standard ISMB & ISMC and same to be fixed by welding over the RCC column base plate already provided by Dept. The centre to centre distance between the brackets is 5.37m max for 20T crane . Long travel rail in bright square bar but not less than 50mm size to be welded over ISMC top for the bay length of 32m

Annexure – D

ITEM: 4 HARDWARE PREPARATION 20T EOT CRANE




02 Type Double girder plate fusion welded box type EOT cran e


04 Location Indoor, Hardware Preparation Storage Bldg.



08 Span 24m (Appx)






Steel Gantry Girder for bay length of 40m consists of composite girder fabricated from standard ISMB & ISMC and same to be fixed by welding over the RCC column base plate already provided by Dept. The centre to centre distance between the brackets is 5.25m max for 20T crane . Long travel rail in bright square bar but not less than 50mm size to be welded over ISMC top for the bay length of 40m

COMMON SPECIFICATIONS FOR 12T & 20T DG EOT CRANE(It em No.1,3&4):

1 Main Operating speed(m/min)

Hoist 3.0 m/min(Main Speed) – 0.30m/min(Micro Speed)

LT 6.0 m/min(Main Speed) – 0.60m/min(Micro Speed)

CT 6.0 m/min (Main Speed) – 0.60m/min(Micro Speed)

2 Bridge girder Fabricated out of plate fusion welded box type construction

3 Type of hook Standard forged single point “ C” hook with spring loaded safety latch, thruster bearing, free swivel with lock confirming to IS: 3815

4 Type of wheel Double flanged wheels machined out of EN -8 forging, hardened as per IS: 3177 and mounted on ‘L” type bearings housings.

5 a)Wire rope Hot dip galvanized.6x37/ 6x36, IWRC

b) Factor of safety 6.0

6 Brakes

The torque capacity of brakes shall be 2 times the rated full torque of the selected motor for main hoist and for LT and CT the torque capacity of brakes shall be 1.5 times the rated full torque of the selected motor 2Nos. EHT brakes for main hoist & LT and 1 No. EM for CT operations of approved makes only.

7 Rail Bright square bar for LT & CT motion

8 Bearings Anti friction ball roller bearings shall be provide d

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

10 Gear box

Totally enclosed type and oil bath lubricated. Gear and pinions shall be forged steel and machine cut. IS 3681 for tooth form & module and IS 4460 for rating of gears.

11 Couplings The coupling shall meet the requirement of IS 3177

12 Motor

IP 55, class F insulation, squirrel cage crane duty induction motors in TEFC enclosure as per IS: 325 shall be provided for all the motions. The motor shall be suitable for operation with VVVF Drives. 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.

13 Limit switches One gravity type & one rotary type limit switches

for hoist motion. Two way lever shunt type limit switches for LT & CT.

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

15 Control supply 24V AC power supply

16 Pendent Control

Operation from floor through light weight SS pendent moveable along the bridge girder on four wheeled cable trolleys with anti-friction ball bearing running on a separate track with 24V AC confirming to IS: 5780 and push button station to be self ignited.

17 Speed Control The speed & brake control shall b e through VVVF Drives for Hoist, LT &CT operations.

18 DSL

Single Shrouded Bus bar type (Power duct) consists of 3phase, 1nuetral & 2earth in copper conductor with moving contact. (one spare moving contact also to be supplied)

19 Cross Travel cable arrangement

PVC sheathed, flexible cables with multi strand copper conductors with SS chain in `T ` track system

20 Power feed arrangement for the hoist

PVC sheathed, flexible cables with multi strand copper conductors mounted on cable trolleys.

21 Pendent Pendent cable (single cable with multi core) shall be on independent “T” track. SS chain for holding self weight of cable & pendant.

22 Control panel Electrical panel to be provided on LT platform with maintenance space in front of panel in the platform

23 Buffer Rubber buffers for LT(100mm) & CT(60mm)

24 Painting

The entire crane structure shall be provided with one or more coat of zinc primer and one coat of synthetic enamel golden yellow finish paint for main girders & grey paint for gantry girder before dispatch and at site one more coat of synthetic enamel golden yellow finish & grey paint after crane erection at site.

25 Bridge platform Full l ength chequrred plate platform for both sides of the bridge girder

26 Other points after placing Purchase Order

1. After receipt of purchase order supplier shall prepare detailed drawings & Design for entire system within 20days and same to be submitted to Dept approved Third Party Inspection agency for vetting & approval of drawings and design. This process to be completed within 20days. The drawings & design approved by TPI agency shall be

submitted to Department for according fabrication approval.

2. Prior to start fabrication actual measurement shall be taken at site.

3. Supplier shall submit test certificates for all the bought out items.

4. The crane shall be load tested for full load and 125% over load test prior to dispatch and also at site.

5. The noise level shall not be more than 75 dbA when the crane is operated at full load and measured at 1m distance from the crane gear box.

6. The crane shall be guaranteed for a period of min 12 months from the date of commissioning.

2. MAJOR PARTS OF THE CRANE : The crane assembly shall include, but not limited to the following for safe and efficient operation of the crane. The crane is suitable for vertical loading shall comprise the following.

- Bridge and trolley drives - Hoist with anti sway - Rope drums, sheaves, wire rope and lifting hook - End carriages - Track wheels - Motors with gear box - V3F drive for all the three motions with software - Rubber buffers for LT & CT - EHT & EM brakes - Limit switches (Gravity &Roller for Hoist, two way lever for LT & CT) - All safety guards and controls - Incoming power supply with TPN MCB/ MCCB - Single shrouded bus bar type DSL - Double earthing for all electrical items - Movable Pendant push button control from floor - Necessary chequerred platforms forming part of the crane

3. DESIGN:

- The design of the crane shall be indoor and generally comply with latest revision

of all relevant Indian standards and generally confirms to IS226, 325, 800, 807, 1030, 1181,2068, 2266, 3177, 4460, 5780 & 8239

- In the design of components on the basis of strengt h, factor of safety shall not be less than five (5) based on ultimate strengt h, impact, fatigue, wear and stress concentration factors shall be taken int o account, wherever applicable.

- Design shall provide for easy maintenance of all parts particularly the wheel

bearings on end trucks. Necessary safe and sufficient working space shall be provided all around the sub systems for easy maintenance. Repair cages to be provided to access LT wheels.

- The crane girder shall be box type and robust construction free from obstructing high wind force and non vibration, design to reduce vibration damping period less than 15seconds. The exterior surface of the girder shall be smooth and free from projections to minimize the dust collection.

- A full length chequrred plate 6mm thick platform of minimum 750mm width shall

be provided for both the bridge girders in order to have access to long travel drive, current collectors, trolley etc. All panels shall be mounted on platform with sufficient space for door opening & maintenance.

- For load carrying members the component plates, bars, angles and other rolled sections the minimum thickness shall be 4.9mm (6SWG). For unsealed tubes the minimum thickness shall be 8mm.

- Three tire hand railing of 1.2m height made out of tubular construction shall be

provided on platform, crab and trolley.

- In bridge girder strength calculation, the trolley rails and chequrred plates shall not be considered as load carrying members.

- For compression members, the slenderness ratio shal l not exceed 150. In

case of other load carrying member and subsidiary m embers the slenderness ratio shall not exceed 240.

- The value of maximum span to depth ratio-18 (for pl ate girders) shall be

adopted.

- The total maximum vertical deflection of the girders for the live load plus trolley and not including impact or dead load of the girder shall not exceed limit of span/1000

- The girders shall be cambered by an amount equal to the max deflection due to

dead load plus one half the live load and trolley.

- No wood or other combustible material shall be used.

- Maximum use shall be made of shop fabricated sub-assemblies. Sub-assemblies shall be finalized so as to facilitate easy transportation and erection at site considering clearances and approaches available inside respective facilities.

- All materials shall be of tested quality and shall confirm to the specification requirements and standards mentioned.

- Where welding is not practicable, turned and fitted bolts shall be used. Connection between End carriages and main girders shall be by means of machined bolts fitted in reamed holes.

- Minimum number of turned and fitted bolts in a connection shall not be less than two.

- Black bolts shall not be used in main structures and high tensile bolts shall not be used unless approved. Bolts shall be preferably be not used in tension.

- Where bolts pass through sections having tapered flanges, tapered flats shall be welded to inside of the flanges. Tapered washers shall not be used.

- Traverse fillet welds on load carrying members shall be avoided. If side fillets are used in end connections, the length of each side fillet should not be less than the edge distance between the fillets.

- Butt welds on structural members under tensile stre ss shall be checked by radiographic examination.

- The box girder shall be designed for suitable size taking into account of the following proportions:

a) l/ h shall not exceed 25 l = span of the cra ne in mm b) l/ b shall not exceed 60 h = depth of the gir der in mm c) b/ c shall not exceed 60 b = width of the gird er in mm c = thickness of the top cover plates in mm

- The ratio of crane span to end carriage wheel base shall be as detailed

below: • For cranes up to and including 20m span not less th an one-sixth

of the span. • For cranes over 21m span and up to 24.5m, not less than 3.5m of

the span. • For cranes over 24.5m span not less than one-sevent h of the

span.

- The following tolerances shall be maintained: Over all depth of crane girders ±2mm

Span over LT wheels ±4mm max for span upto 19.5m Diagonal on wheels ±5mm max LT wheel alignment ±1mm max Tilt of wheels or balance ±1/1000 max (horizontal & vertical) Trolley wheel gauge ±3mm for gauge above 2.5mtr Dif. In height bet. Trolley ±3mm upto 2.5mtr

- Two limit switches shall be provided for main hoist motion with gravity & rotary type and two-way lever type limit switches for LT & CT motion.

- Receiving system shall be so designed that the rope will not slip out of the pulleys or foul with any part of the devices.

- Dual Thruster brakes for Hoist, failsafe EM brakes for CT and LT shall be

provided.

- The crane should be able to position the load in any desired height with a reasonable accuracy.

- Factor of safety for wire rope shall be 6 on nominal breaking strength and size

selection of wire ropes in general shall be section 8.3 of IS3177 & IS 13870-Part 1.

- The wire rope used in the crane shall be made out of galvanized steel (with steel

core) and tensile designation 1770 N/mm² and shall be non lubricated pre-stretched core 6x36/ 6x37 construction, regular right hand lay performed and non rotating type as per IS 2266 and core shall be IWRC.

- All finished wires shall be well and cleanly drawn to the required dimensions. The

wire shall be sound, free from splits, surface laws rough, jagged and imperfect edges and other harmful surface defects. No joint shall be used for any of the ropes under this specification. Kinks are not allowed on any part of wire rope.

- Rubber buffers & stoppers shall be provided on all motions and minimum hardness of the rubber shall be 90BHN.

- V3F drives shall be provided in each motion of the cranes, i.e LT, CT & Hoist and

driver impedance shall be matched with gear box motor & brakes. All brakes are to be interlocked by control wiring with respective V3F drives.

Rope Drum : - The drum shall be fabricated of cast steel and designed for single layer of ropes

and fabricated rope drum 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 provided with flanges at both ends. Design of rope drum in all other aspects shall be as per IS3177 & IS6938

- Rope drum support structure shall be so designed that the bearings are mounted under compression to minimize potential for failure of bearings increase the probability of maintaining the mesh between the drum gear and drive in case of bearing failure.

Sheaves :

- The sheaves shall be of forged steel and shall be provided with anti-friction ball bearings. 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 bearing and not on ball bearings. The design shall confirm to IS3177.

Bearings : - All bearings of the gearing shall be anti-friction type. Angular contact ball or taper

roller bearings shall be used wherever necessary. The bearings shall correctly locate the shafts while allowing for thermal expansion of the shafts.

- Provisions shall be made for service lubrication of all bearings. Bearing enclosure shall be designed to exclude dirt and prevent leakage of oil or grease.

- All bearings used shall be self aligning ball/ roller bearings sealed type of SKF/

FAG/ NBC makes.

Couplings : - All couplings shall be of steel or a cast steel of grade 25 of IS210-1970 and shall

be designed to suit the maximum torque that may be developed.

- Wherever necessary gear couplings shall be used between connecting shafts. Positive locking by means of gib headed keys or end stopper plates shall be provided. To prevent axial displacement for all couplings keys they shall be so fitted and screwed such that they cannot work loose in service.

Shafts : - Shafts shall be of EN8 material confirming to IS970

- Wherever components of considerable amount of inertia are directly mounted on

the high speed shaft (eg. Brake drum, couplings, etc) they shall be balanced dynamically to minimize vibrations.

- Design of shaft is to minimize stress concentration at the changes of diameter,

and hence shall be provided with chambers, fillet, radii or relief grooves as applicable. Wherever practicable keys and keyways and splines shall confirm to the relevant Indian standards.

- Provision shall be made so as to prevent the sliding of the keys from their respective keyway during operation. Wherever feasible head keys shall be used.

- All shafts, including gear box output shafts shall be of EN8/EN9 steel with

minimum hardness of 200BHN. Wheels : - Design of wheels shall conform to the requirements of IS 3177 as applicable. The

face width of the wheels is determined on the basis of rail size and possible lateral displacement of wheel during operation.

- All wheels shall be of forged type double flanged and shall be machined/ ground to equal diameter in pairs. Material of construction of the wheels shall be of forged steel of EN 8, BS 970 or equivalent. Wheel axles shall be with L-type bearing support with rotating axles. The hardness of wheel shall be between 275 to 300 BHN. The long travel and cross travel wheels shall be 55+ MN75 materials confirming to BS-970 & IS 1570.

- Design and construction of the wheels and rails shall match the requirements of the driven mechanism and shall be properly coordinated with parameters of the drive system being supplied.

- Wheel mounting shall be designed for easy removal for maintenance.

Gear Boxes : - Gearing shall be as per IS: 3177 and also as for the following:

- Gear boxes shall be totally enclosed type and oil bath lubricated. Reputed make

gear boxes as approved by Dept only to be used. - Gears and pinions shall be of forged steel and machine cut. Gear and pinion

teeth shall be treated for resistance to wear. All gears and pinions shall be of ground type so as to reduce noise levels to the minimum. The permissible noise level is 75dB at 1m distance from the gear box.

- Gears shall have tooth form and modules as recommended in IS: 3681 and they

shall be adequately to withstand shock load and vibration and shall not be excessively noisy in operation. The ratings of gears shall be established as per IS: 4460.

- Spur and helical gears only shall be used for reduction gearings.

- The creep motion shall be through VVVF control.

Bridge Drive and End Carriage : - For bridge travel (LT) central drive is preferred so as to avoid the skew and have

a smooth, jerk-free LT motion. The torsional rigidity of LT drive shaft shall be such that hunting/jerks are avoided when crane is moving or at the time of stopping. Torsional limit shall be limited to 0.10 degree/m length. If central drive is not feasible and independent corner drives are selected, suitable control system shall be provided to apply equal driving effort at each drive wheel of bridge to prevent one end travelling faster than the other. However the shaft at each corner shall be designed with sufficient margin, so that individual drive shaft can take full load.

- For bridge drive the torsional deflection in the cross travel drive shaft shall be

limited to safe value as per applicable code.

- Angular deflection of the line shaft at torque corresponding to 1 1/3 motor torque during acceleration shall not exceed 0.10 deg/m of shaft length. In case of LT 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 crane bridge shall be connected on end carriage of suitable design. Each

end truck shall be built up from steel plates welded together to form a closed box section with opening at each end to receive the wheels. Steel sections shall be welded to trucks to form bearings for the axes and the drive shaft and bumper. They shall also be provided with suitable jacking pads for maintenance of the wheel and bearings. The location of the jacking pads shall be such that it will not interfere with the maintenance of the wheels and its bearings.

- Where more than two bridge wheels are used per end truck, the end truck shall be split into two sections, each carrying one bridge independent of other. Two sections of the end truck shall be joined by suitable joining device that will ensure uniform wheel loading. Steel pads shall be welded on the top of end truck where the girder rests and shall be machined to receive the girder ends.

- End trucks shall be equipped with spring/ rubber buffers and rail sweep for bridge

travel. The rail sweep shall be such that it can brush away any object they may fall on the runway. The buffers shall be substantial design and suitable for engaging the stops at the end of runway.

Trolley : - Trolley drive shall be achieved by single increased safety motor in which the

motor shall drive a common output shaft through proper gearbox. No open reduction gear is to be used. The torsional rigidity of CT drive shaft shall be that jerks are avoided where trolley is moving or stopping.

- Angular deflection of the line shaft at torque corresponding to 1 1/3 motor torque during acceleration shall not exceed 0.10deg/m of shaft length. In case of CT

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.

- Equalizer sheaves shall be mounted on the trolley frame in such a manner the

deflection resulting from the force on the sheaves is not directly transmitted to the hoisting mechanism.

- Sheaves shall be arranged on the trolley that rope receiving arrangement resulting in lifting of the load almost in a vertical line with minimum of swing or side movement.

Guarding :

- Guard of an approved design, which will push forward or off the rail track any object (such as a person`s foot or arm placed across it) shall be attached to each of the end carriage both for LT & CT.

- Protective guards to live electrical wiring/ conductors shall be provided. However trailing cable arrangement with cable trolleys are only preferred.

- Suitable guards to all revolving shafts and couplings, LT & CT shafts gear etc. shall be provided.

- The sheaves of the hook block shall be guarded to prevent trapping of a hand/ fingers between a sheave and the running ropes.

- Effective means of guarding the wire ropes over the sheaves shall be provided wherever required, so as to prevent dismounting of ropes from the grooves even when a slack rope condition is developed.

- All openings in foot walk flooring, for access of bottom chord platform, if any and to other inspection platforms shall be provided with covers having suitable locking means to avoid any accidental opening.

Lifting Hook :

- Hook shall be single shank ‘’C’’ type forged steel confirming to IS3815 and shall be supported on thrust bearing for free swiveling on the hook. The hook shall be tested to 200% to SWL. The lifting hook shall confirm to the requirement of IS3177.

- Swivel lock and safety latch is to be provided for the crane hook with anti sway.

Materials :

- Materials for main girder, end carriage, Gantry girder, rail etc are mild steel of SAIL/ VIZAG and as per IS2062.

Brakes : - Brake design shall confirm IS: 3177 as applicable.

- Hydraulic thruster brakes of suitable rating to stop the crane within a very short

distance and in a safe and smooth manner. They should be equally effective in both directions. The thruster brakes shall be operated by Electro Hydraulic Thrusters. The brakes shall apply automatically when power to drive motor is cut-off or fails.

- Two brakes each rated for 2.0 times of motor rated torque/ suitable capacity shall be provided for hoist motion. Brake for hoist motion shall be adequately sized to arrest and hold any load up to and including test load at any position of the lift.

- Brake drum shall be positively locked in position so as not to prevent lateral movement by means of retainer plates or any other means.

- All brakes shall have smooth braking capability to decelerate in safe manner to avoid any derailment even when applied at maximum speed. The braking action of hoist motion shall be such that there shall not be any jerks for the objects being lifted at main speed.

Lubrication :

- Bearings shall be enclosed in suitable housing with proper holes and plugs to prevent any ingress of drift and to permit easy lubrication of the bearing.

- Lubricating chart shall be provided indicating all lubricating points, type of lubricant and recommended frequency of lubrication.

- Splash type lubrication shall be incorporated and adequate lubrication of the gears shall be ensured. Oil level required in the housing shall be clearly marked. A large oil filter cum breather shall be provided together with a drain plug. No oil should be leaked from any part of the crane.

- Suitable drip pans shall be provided as required to collect oil and grease which may drop from opening parts. All drip pans shall be accessible for draining and cleaning.

Power Supply : - Power: 415V, 3phase, 50Hz, four wire system with double earthing. - Control: Control supply shall be 24V. The supply to the circuit shall be from the

secondary winding of isolating transformer and rectifier. One pole of this supply shall be earthed.

- Main incoming TPN MCB, interlocking with door panel.

- Power wiring shall be XLPE armored aluminium/ copper conductor cable.

- Control wiring shall be PVC insulated flexible copper conductor cable.

- Individual single phasing preventor shall be provided to all the motors or V3F

drive shall have provision of single phase control.

- An isolator shall be provided at gantry level apart from panel i.e near gage ladder and copper wire of suitable size shall be laid for this isolator from Dept power source available at 1.2mtr from ground. These wires shall be taken through conduit already available at site.

- Cable glands to be provided for all cables with necessary crimping &

interconnections in an approved manner. Motors :

- The motors shall be selected to take care of the loading conditions and to suit the duty of the mechanism in which it is used. The motors shall be suitable for frequent acceleration, frequent reversing and braking.

- All crane motors shall be totally enclosed, fan cooled type and shall conform to IS 325. The enclosure shall suit the specified service conditions.

- The motors shall be of squirrel cage and shall be capable of producing maximum torque required to produce motion in the most unfavorable loading conditions. The motors shall be easily accessible for inspection and maintenance.

- Voltage 415 ± 5%, 3phase, 50Hz,

- Insulation class `F’ for motor winding

- Duty: To match the class as per IS807, with duty cycle of 40% CDF. - Resistance: The resistance if provided shall be designed as per IS1822 and shall

be air cooled, restless, unbreakable grid type rated for minimum 10 minutes. Suitable sheet steel housing with ventilated side cover.

Controls & Protection Panels :

- The method of control of the crane shall be pendant control. An electro magnetically operated contact with inherent under voltage protection and manually operated circuit for each motor. The circuit breaker of the main contactor shall be rated to carry at least the combined full load currents of two motors having the largest wattage.

- For pendant control system, the controller shall consist of forward/ reverse push button with contactor for individual motions like normal & creep speed. The bush button shall be spring returned to off in case of emergency. Start and stop push buttons are to be provided with self illuminated in green & red and to make and break the main contactor/ circuit breaker. Hooter switch is to be provided in the pendant and hooter to be fixed at crane. The pendant shall have mushroom type emergency switch and indication lamp for main ON/OFF.

- All reversing contacts shall be electrically and mechanically interlocked, connections for the pendant controller shall be taken through braided cable ( with necessary earth wire inside). Support the pendant controller in such a way that its weight does not appear on the cables by providing SS type chain to hold the pendant.

- The individual protective panel shall be painted with 2 coat of synthetic enamel paint externally and 2coat of fire retardant paint internally and up to 1.5 mtr length of each cable from panel to be painted with fire retardant paint.

- The panel and motor shall be mounted on a platform with sufficient space so as to attend maintenance works. Triple pole thermal overload relays for individual motors. MCB to be provided for low voltage transformer and all controls instead HRC fuse.

- Plug and socket with earth, neutral & lamp 2Nos. with 5m length wire shall be provided at crane level to connect the inspection hand lamp.

- All cables entries in the panel shall be from bottom and shall be provided with cable glands and earthing

- Control of the crane shall be from floor through moveable pendent push button

stations. The pendent movement along the span should be festoon type running in a four wheel trolley on a separate track and the movement should be independent of CT.

LIMIT SWITCHES:

One gravity type and one rotary type limit switches shall be provided for hoist motion. Two ways lever shunt type limit switches shall be provided for CT & LT.

CURRENT COLLECTION SYSTEMS:

For taking power to the EOT cranes by single shrouded bus bar type DSL. The single shrouded consists of three phases, two earths and one neutral in copper conductor. The shroud shall be strong enough and resist with high insulated value. Bus duct shall be suitably fixed in the crane to avoid vibration while current collector moving on the copper conductor.

EARTHING:

- The crane rails, structure, motor frames, metal enclosures of all electrical equipments, conduct and tray shall be effectively grounded in accordance with Indian Electricity Rules.

- Copper flats/ conductors of required size shall be used for grounding purpose.

- Bonding of structures and crane rails shall be provided as required to ensure

electrical continuity.

- The crane grounding system shall be connected to main grounding system at the ground level.

- Double earthing to be provided to all electrical equipment of crane.

- All electrical installation work shall comply with provisions of Indian Electricity act and Indian Electricity rules as amended up to date.

- All electrical equipment shall be laid out so that they are readily accessible for inspection and maintenance.

ELECTRICAL TESTS:

- All electrical installation work shall be carried out through electrical contractor holding valid license issued by Electricity board.

- All tests applicable as per relevant standards shall be conducted on all electrical before dispatch from the manufactures’ works.

- After erection, but before the cranes is connected to the supply, installation of the electrical equipments shall be tested by a suitable instrument and any defects revealed shall be rectified.

- After the power supply has been connected, the following test to be carried out

v. The satisfactory operation of each controller, switch contactor, relay and other control devices and in particular the current operation of all limit switches under the most and favorable condition.

vi. The correctness of all circuits and inter-locks and sequence of operation

vii. The satisfactory operation of all fool proof devices

viii. The satisfactory operation of each motion of the crane.

4. Make of the approved bought out components and r aw materials: Sl.No Item Make

1. Motor Kirloskar/Bharat Bijlee/Crompton Greaves/ABB/

GE/Seimens 2. Resistance boxes PATHE/STROM-KRAFT/SPEED O

CONTROL/PANSET SYSTEM 3. Brakes Storm-Kraft/ Pethe/ Speed-O-Control/ BCH/

Speed-N-System/ KMM/ MAG Co 4. Limit switches ESSEN / STROM KRAFT / SPEED O

CONTROL / AR / BAUMEN / BCH / EPC / SEW

5. Wire ropes (All galvanized)

USHA MARTIN

6. Contactors SIEMENS/ L&T/ TELEMECHANIQUE

7. Switch gear SIEMENS / L&T / TELEMECHANIQUE

8. MCBS LEGRAND (MDS) / HAVELLS / VERSATRIP/ GE /SIEMENS / SCHNEIDER / ABB / STANDARD

9. Cable trays(PVC,FRP,GI)

Profab/Sintex/Indiana/Patny System / L&T / Cablofil(Legrand)/OBO Bettermann

10. Push buttons SIEMENS / L&T

11. Isolating switch STANDARDS/ CROMPTON/ SPEED-O-CONTROL

12. Bearings SKF / FAG /NBC

13. Over current relay SIEMENS / L&T / BCH

14. Flexible cable GLOSTER / PARAGON / ICC / STANDARD / SPENCER

15. Socket outlet CROMPTON

16. Gear boxes

Radicon(Premiem)/ Elecon/ Shanthi/ Allenberry

17. Transformer SIMHA / UNIT SERVICE TRANSTECH SYSTEM

18. Lifting hook ESSOFAIL/ ESMAILJI / KARACHIWALA & CO

19. Wheel assembly ON L TYPE BRACKET BEARING HOUSING (REPUTED MAKE / FABRICTED)

20. Geared coupling. FENNER / HAMMER TECH / ELECON

21. Plummer block K-NAL / MASTA / UAS

22. PVC wires ANCHOR / FINOLEX / HAVELLS / RR KABEL

23. TPN switches /Isolators

SIEMENS / L&T / GE / CRE / STANDARD / ABB

24. Armoured LT power cable (both PVC or XLPE)

HINDUSTAN / GLOSTER / POLYCAB / FINOLEX / CCI / RPG / HAVELLS / UNIVERSAL / RALLISON

25. 26. 27. 28.

Variable speed drives (V3F) Steel Relays Paints

ABB/ Siemens/L&T SAIL/ VIZAG L&T/ SIEMENS/BCH Asian/ Berger/ Nerolac/ Dulux

Material Specification : 1. Main girder, end carriage MS fabricated – IS 2062

LT platform 2. Gears and pinions EN8 – IS: 1570/61 3. Wire rope IS: 2266 4. Hook Forged steel – IS: 3815 5. Rope drum Seamless pipe as per IS 3177 6. Wheel and shaft EN8 – IS 1570/61 7. Rope sheave Cast steel

5. PAINTING:

- All the parts of the crane shall be thoroughly cleaned of all loose mills

scales, rust or foreign matter and then painted as specified.

- The entire surface of all the fabricated material is to be sand blasted as per standard. Immediately after sand blasting, one coat of metal primer shall be applied to a Dry Film thickness (DFT) of 75microns (min). An intermediate coating of synthetic golden yellow enamel paint to a dry film thickness of 80microns shall be applied. Then a final coat of 40microns shall be applied.

- All damage to the paint shall be corrected and made good by the contractor after assembly of the crane at site.

- The equipment shall be suitably protected in respective packing for the shipping

distance and the weather conditions involved. 6. INSPECTION:

The cranes shall be designed, drawn, fabricated and tested under a

reputed Third Party Inspection agency (TPI) Lloyds, BVQI, TUV and DNV. The scope of inspection includes design verification & approval, shop drawings approval, material acceptance, verification of test certificates of bought out components, fabrication dimensional inspection & welding joints, witness of DP test, radiography test, load test and speed verification test at supplier`s work station. It is the responsibility of the supplier to arrange for and coordinate with the TPI. Crane shall be brought to purchaser’s site only after final inspection with TPI representative and approval done at supplier premises by purchaser, however, such approval shall not absolve supplier from his obligations to comply with purchase order.

7. TESTING: The crane shall be tested subject to full load of SWL and over load of 125% and speed verification in load and no load conditions as per Indian standard at supplier’s premises in the presence of TPI and purchaser. Radiography and DP test to be conducted on all load bearing weld joints at manufacturers work and the result witnessed by third party inspection agency to be produced at the time of inspection carried out by purchaser.

Components using such as motor, limit switches, wire ropes, crane hooks, gear boxes, drive system etc shall be subjected to routine test at sub supplier/manufactures works and test certificates should by vetted by TPI.

The crane after erection at site shall be tested as given below in the presence of purchaser.

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, interlocks etc.

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.

Speed test : All the motions of the crane shall be tested with rated load and the rated speeds shall be attained within the tolerance limits indicated below.

Travelling & traversing +10%-5% of specified speed. Hoisting +10%-5% of specified speed. Lowering +20%-5% of specified speed.

All the motions of the crane shall be tested with 25% overload of SWL in such case the rated speed may not be reached but the crane must be capable of handling such overhead without difficulty. The cranes shall be tested with rated load for performance of hoists, long travel and cross travel motions with VVVF controls from maximum to minimum speeds. Brake tests : The hoist brake shall be capable of braking the movement under conditions 1 & 2 of speed tests, however the braking path with rated load shall not exceed the value given in the table below. Class of the crane

Braking coefficient Braking path in m

2 1.50 S/150

The long travel and cross travel brakes shall be capable of arresting the motion within a distance in m equal to 10% of the speed in m/min and the retardation due to braking shall not exceed the values given in the table below. Working condition Retardation according to percentage number of

driving wheels in m/sec2 Indoor 100% 50% 25% 1.5 0.75 0.45 Refer section 8.12 of IS : 3177-1999 Minimum diameter of EHT brakes for CT and LT drives shall be minimum 160mm.The supplier shall be responsible for compiling the record of various test and preparation and presentation of final test certificates to the purchaser. Test after assembly at site to check all the required functional features of full load and overload.

8. ERECTION & COMMISIOING AT SITE:

The crane, gantry girder, long travel rail, spares etc shall be brought by the supplier to the purchaser’s site for erection & commissioning. Erection of the crane, gantry girder, DSL, etc shall be carried out by the supplier at IPRC, ISRO, Mahendragiri. Mahendragiri is located near Nagercoil, Tamilnadu and elevation is 157m above MSL. Ambient temp is 40deg.cel max and RH80%.

Crane to be tested & commissioned as per approved specifications / code at our site shall include tests for no load, full load, overload, speed and deflection. Unloading of the crane at site, all skilled / unskilled labors, supervisor, tools, tackles, machineries like welding machines slings and consumable etc shall be arranged by the supplier.

Electric power required for the erection work will be provided by the purchaser free of charges. However the supplier shall comply with the purchaser’s regulations such as safety permit, work permit etc Power board cable, etc is to be brought by the supplier.

Safe storage and handling of all components till the crane is erected, tested satisfactorily and handed over to the purchaser, including insurance for workers against death & accidents.

Prior to start fabrication of the crane, supplier has to take actual measurements at site IPRC, ISRO, Mahendragiri.

9. TOOLS:

Special tools required for trouble free operation of the crane shall be

supplied. The Tool box containing grease gun, oil can, spanners including DE & ring (1set), screw drivers (1set), grease buckets and hydraulic jacks for LT & CT wheels.

10. INFORMATION AND DOCUMENTS TO BE FURNISHED: Along with Tender (Quotation) :

i. GA drawing with dimensions for mechanical & schematic diagram for electrical.

ii. Bill of materials being used for cranes & Technical specifications for components / equipments.

Within two weeks after receipt of Purchase Order :

- Prepare the detailed design for structural like main girder, end carriage, wheels, trolley, rope drum, wire rope, gear box, gantry girder, hook etc and mechanical design like motors, brakes etc.

- After design calculations detailed drawings to be prepared for all the components

Submitting Design & Drawings to TPI agency for vett ing & Approval :

- All design & drawings to be submitted to approved Third Party Inspection agency and same to be vetted & approved by TPI agency. This action to be completed with TPI agency within 20days.

Submitting approved Design & drawings to Department for approval :

- Three sets of hard copy design calculations & drawings duly vetted & approved by TPI shall be submitted to Department to accord approval for fabrication of the crane.

- Prior to start fabrication of the crane actual measurements shall be taken at site by supplier.

- Crane fabrication shall be completed as per Department fabrication

approval within 4weeks and final inspection of the crane by Department with TPI also shall be completed in the 4weeks time.

At the time of inspection by purchaser’s representa tive :

i. Reports of third party inspection agency as per Inspection clause No.6 ii. Dimensional inspection report vetted by TPI iii. Stress relieving chart indicating all features shall be provided for each gear

box separately vetted by TPI. iv. Test report of all items to be vetted by TPI. v. Purchaser shall witness load test in rated SWL & 125% over load, speed

verification in load & no load condition at supplier premises in the presence of third party inspection agency.

Along with dispatch of crane :

i. Operation and maintenance manual in duplicate. ii. Special tools required for trouble free operation of the crane shall be supplied. iii. Lubrication schedule giving recommended grade, frequency of

lubrication, point of application and quantity required etc. iv. Guarantee & test certificates for crane. v. Oil pans wherever necessary shall be provided to avoid oil dripping from

the gear box. vi. 6 sets of as built drawing and soft copy of all the drawings, operation and

maintenance manual and wiring diagrams in the CD

11. GUARANRTEE: All the items shall be guaranteed against faulty design, use of defective material and bad workmanship for a period of min12months from the date of acceptance by Purchaser. Any defect noticed during this period shall be rectified by the supplier to the purchaser’s satisfaction free of cost.

12. STANDARD AND REGULATIONS:

The electrical of the crane shall confirm to the latest edition of the relevant IS 226 & 2148 and to the Indian electricity rules and regulations also to the relevant class of factories. The electrical of the crane shall be suitable for indoor arrangement. All equipments shall be of tropical design according to Indian / International standards.

13 IS CODES FOR STANDARDS:

The design, manufacture and testing of the crane shall confirm to the

latest editions of the following codes and standards as applicable.

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

IS 807 Code for practicing for design, Manufacture, erection and testing of cranes and hoists.

IS 3177 Code of practice for design of over head travelling cranes and gantry cranes other than steel works cranes

IS 4137 Torsional rigidity of the shaft.

IS 3681 Gears tooth form and modules.

IS 1835 Steel wires for rope

IS 6594 Technical supply conditions for steel wire ropes and strands. IS 2266 Steel wire ropes for general engineering purposes

IS 2363 Glossary of terms relating to wire ropes.

IS 3973 Selection, installation, maintenance and technical supply

conditions of wire ropes.

IS 3443 Crane rail sections

IS 816 Code of practice for use of metal arc welding for general construction in mild steel.

IS 823 Code for practice use of metal arc welding of mild steel.

IS 1181 Qualifying tests metal arc welders (Engaged in welding structures other than pipes)

IS1323 Code of practice for oxy acetylene welding for structural work in mild steel

IS 325 Three phase induction motors.

IS 4029 IS 8544

Guide for testing three phase induction motor. Motor starters for voltages not exceeding 1000V

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

IS 5571 Guide of selection of electrical equipments for hazardous area

IS 5572 Classification of hazardous areas (other than mines) for electrical installations.

IS 2148 1981 flame proof enclosures for electrical apparatus.

IS 8239 Classification of maximum surface temperature of electrical equipments for use in explosive atmosphere.

IS 2206 Flame proof electric light fittings.

IS 1554 PVC Insulated (Heavy duty) Electrical Cables

IS 2208 HRC cartridge fuses links up to 650V

IS 2959 Contactors for voltage not exceeding 1000V AC or 1200V DC

IS 4064 Air brake switches air brake dis-connector, air brake switch dis-connector and fuse combination for voltages not exceeding 100V AC or 1200V DC

IS 4237 General requirements of switch gear and control gears for voltage not exceeding 1000V AC

IS 8623 Factory built assemblies of switch gears and control gears for voltages not exceeding 1000V or 1200V DC

IS 2062 Steel for general structural purpose.

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 standards worms and helical gear boxes.

IS 5749 Forged Ramshorn hooks.

IS 8610 Point hooks with shanks for general Engineering purpose.

IS 3815 1969 specification for point hooks with general engineering purpose.

IS 5780 Intrinsically safe electrical apparatus and circuits.

IS 6294 1971 specification for point hooks with shank (for capacities 63 T to 160T)

IS 13947 Part 4: Sec 1: 1993 / IEC pub 947-4-1 1990 specification for low voltage switcher gear and control gear Part 1 to Part 5 contactors and motor starters.

IS 4460

The rating of gears.

ANSI/AWS D14.1 Structural welding code of welding practice for mill cranes and other material handling equipments.

ANSI B30.2.0 Safety codes for overhead and gantry cranes.

annexure – a item: 1 ps2/gs2 12t eot crane · 2015-08-13 · annexure – a item: 1 ps2/gs2 12t...

Documents