Eot Crane Specification x521i
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RRCAT/AMTD 50 MT EOT Crane Specification.
SPECIFICATION FOR 50 MT DOUBLE GIRDER ELECTRIC OVERHEAD TRAVELLING (EOT) CRANE FOR MAGNET FABRICATION BUILDING (MFB)
S.No.
CONTENTS
PAGE No.
I.
INTRODUCTION
1
II.
GENERAL REQUIREMENTS
2
III.
STRUCTURAL REQUIREMENTS
4
IV.
MECHANICAL REQUIREMENTS
6
V.
ELECTRICAL REQUIREMENTS
8
VI.
INSPECTION, ERECTION, COMMISSIONING AND PROVING TESTS
12
VII.
NOTE TO THE CRANE MANUFACTURERS / SUPPLIERS
14
VIII.
DELIVERY SCHEDULE
15
Annexure-I : - End view of MFB High bay with crane. Annexure-II : - Guaranteed Technical Particulars (Technical data) of offered crane to be submitted.
RRCAT/AMTD 50 MT EOT Crane Specification.
SPECIFICATION FOR 50 MT DOUBLE GIRDER ELECTRIC OVERHEAD TRAVELLING (EOT) CRANE FOR MAGNET FABRICATION BUILDING I. INTRODUCTION Raja Ramanna Centre for Advanced Technology (RRCAT), Indore. M.P. requires a 50 MT EOT crane, to be installed and commissioned at their new up-coming Magnet Fabrication Building (MFB). This Centre is situated at a distance of 14 km from Indore Railway Station. Indore is situated at an altitude of 553 metres above sea level on the Malwa plateau and falls in seismic zone - III. The crane is intended for handling of large size electro-magnets. The specifications of this electric overhead traveling crane are given below. The end view of high bay with crane is shown in Annexure-I. Table.1: Data Sheet of 50 MT Double Girder EOT Crane. 1)
Designation
50 MT EOT crane.
2) 3) 4)
Duty Class of Crane (As per IS: 807-2006) Quantity Location
M7 (class III). 01 No. Indoor (MFL building, RRCAT, Indore).
5) 6) 7)
Crane Classification as per IS: 13834 Mechanical & Electrical Type Type of Girder
M7 Electric Overhead Travelling (EOT) Double
8) 9) 10)
Capacity Main Hoist Span Longitudinal Travel
50 MT. 11.50 meters. 50 meters.
11)
Lifting Range Main Hoist
8.5 meters (Hook height FFL).
12)
Type of Hook Main Hook
Ram shorn type with swiveling.
13) 14) 15)
Speeds with VVVF drive Main Hoist Long Travel Cross Travel
Full speed / creep speed [meter /min ] 2.0 / 0.2 15.0 / 1.5 10.0 / 1.0
16)
Operating Mode Pendant
Push button trailing type & Wireless remote control. [1]
RRCAT/AMTD 50 MT EOT Crane Specification.
II.
GENERAL REQUIREMENTS: 1. Scope of supply The scope of supply shall include the design, manufacturing, transportation, erection, commissioning and testing of 50 MT EOT crane as specified in table 1 and complete with all electrical and other standard accessories. The crane must be rugged, robust and smooth in operation without any jerks. Also, the scope of supply shall include the following along with necessary fittings, fixtures and ancillaries. a. b. c. d. e. f. g. h. i. j.
Bridge structure with platform and hand railing. Rails and track wheels for longitudinal and cross travel. Traveling mechanism for longitudinal and cross travel. Hoisting mechanism. Brake mechanism separately for long travel, cross traverse and hoisting. Trolley. Service Platform. Pendant Control and radio wireless remote operation for all movements. Electrical motors, control gear and equipment. AC controls for all motions of the crane shall be of VVVF drive.
2. Applicable standards: a)
IS: 3177-1999 (latest) - Indian Standard Code of Practice for electric overhead traveling cranes.
b)
IS: 807- 2006 (latest) - Indian Standard Code of Practice for design, manufacture, erection and testing (structural portion) of cranes and hoists.
c)
IS: 13834 for crane classification.
The crane should be designed for a minimum life of 30 years. 3.
Rigidity, Control and Safety: a. The crane should be rigid, robust and of sturdy construction b. No cast iron part should be used on the crane except for electrical equipment . Similarly wood / combustible material and bush bearing should not be used in any part of the crane. Open gears should not be used in any drive/motion. c. The crane controls should be conveniently located. The various controls should be suitably interlocked to prevent accidental movement of the crane. d. Suitable limit switches for long, cross travel and main hoist should be provided to stop the crane and prevent over-travel of various moving parts of the crane. In addition, gravity type back up limit switch shall be provided for hoisting motion. e. Suitable buffers should be provided to prevent over travel of the crane mechanism in both longitudinal and cross traverse directions. f. All machinery or equipment included in this specification must be provided with safety devices and clearances as per standards and purchaser's requirements. g. Suitable guards or enclosures should be provided on the crane to prevent inadvertent with down shop leads (DSL) or any other exposed electrical conductors and cables. [2]
RRCAT/AMTD 50 MT EOT Crane Specification.
h. i.
j.
k. l.
Suitable isolation switches and stop buttons should be provided to isolate the electric supply for maintenance or in the event of an emergency. A safety hand railing of tubular construction shall be provided on bridge footwalls, end carriages, trolley and any other places where access has been provided. Railings should not be less than 1000 mm high with an intermediate member at a height of 500mm. All sheaves should be provided with rigid guards to retain the ropes in the grooves. Guard should fit close to flange and should have a clearance between the sheaves and inside the guard of not more than 3 mm or 1/4th of rope diameter, whichever is less. The crane should comply with the relevant safety regulations under the Factories Act, Indian Electricity Rules and other statutory regulations as applicable. All cables should be clamped individually. All trailing cables should be clamped with PVC or non-metallic clamps.
4. Maintainability:
5.
a.
Safe accesses of maintenance and removal of all mechanical, electrical and structural components must be ensured. All parts requiring replacement, inspection and lubrication should be easily accessible without the need of dismantling other equipment or structures. Arrangements for access to important components must include a cradle for inspection and maintenance of DSL, such cradle being conveniently accessible.
b.
All electrical cables should be so laid that they are not liable to damage and can be easily inspected and maintained.
c.
All Access walkways of min. 750 mm clear inside width with hand railings on both sides of girders for the full span length for inspection & maintenance of the crane shall be provided. The walkways shall be attached with crane girders at a height of 1800 mm from the beam bottom of building roof. Walkways shall be of chequered plate or nonslip steel surface of minimum 6mm thick, shall be of rigid construction and designed to sustain a distributed live load of 3 kN/m2 (min).
d.
Materials used for equipment and structural should be free from cracks, blow holes, laminations, pitting etc. Except for areas where a superior grade of materials is required, steel class should be as per IS: 2062 (latest).
e.
A tool box containing all tools required for the maintenance of the crane should be supplied along with the crane.
f.
Fasteners for pedestal blocks, gear boxes, etc., should be easily removable from the top of the platform.
Painting and Colour: The crane should be epoxy painted (golden yellow colour) after obtaining surface finish better than or equal to SA 1½. All motors, brakes and s should also be epoxy painted. The following points should be noted. a. b. c.
All parts of the crane shall be thoroughly cleaned of all loose mill scales, rust or foreign matter. All parts inaccessible after assembly shall be painted before assembly. The interior of all gear box housings shall be painted with two coats of oil resistant enamel paint. [3]
RRCAT/AMTD 50 MT EOT Crane Specification.
III. STRUCTURAL REQUIREMENTS: 1. The following points are applicable for design and manufacturing of structural . a.
The crane bridge should comprise of double girders of plate box type.
b.
In the main bridge girders, in addition to the required full length diaphragms, short diaphragms should be inserted wherever required to transmit the trolley wheel load to the web plates and to limit the maximum stress in the trolley rail to safe permissible limits. All diaphragms must bear against the top flange. Steel plates used for bridge girders and diaphragms should be as per IS: 2062 (latest).
c.
All fasters should be hot dip galvanized.
d.
The bridge girders should be connected to the end carriages by large gusset plates. Ground tight fit bolts in reamed holes should be used for bolted connections.
e.
The calculated strength of ts made by High Strength Friction Grip (HSFG) bolts should not be less than calculated net strength of the member. The calculated strength of other bolted ts in structural should not be less than the net strength of the member plus 25%.
f.
All butt welds on structural of bridge girders subject to tension should be radio graphically tested. All other welds should be subjected to Magna flux or Dye Penetration Test.
g.
The box girders should be so constructed as to eliminate any possibility of accumulation of water or oil inside them.
2. End carriages: a.
The crane bridge should be carried on end trolleys with double flanged solid forged wheels. The minimum end clearance on each side of the long travel wheels should be 10mm. The wheels should be mounted on fixed axle or suitable anti-friction spherical roller bearings which can be conveniently removed for maintenance.
b.
End carriages should be designed to be strong enough to resist all stresses likely to be imposed upon them under varied service conditions, including collision with stops. The length of the end carriages should be such that no other part of the crane is damaged in the event of a collision.
c.
End carriages should be fabricated from rolled steel sections or plates, welded together to form a box. Suitable stiffening diaphragms should be provided wherever required. The material used should be steel as per IS: 2062 (latest).
d.
Suitable jacking pads should be provided on each end carriage for jacking up the crane while changing track wheels. These jacking pads should not interfere with replacement of track wheels.
e.
The end carriages should be fitted with suitable safety stops to prevent the crane from falling more than 25mm in the event of breakage of track wheel, bogie or axle. These safety stops should not interfere with the removal of track wheels. [4]
RRCAT/AMTD 50 MT EOT Crane Specification.
3. Bridge rails: The bridge rails shall be CR-80 RAIL of suitable size (min. 105 lbs/yd) of length 52 metres on both sides of the girder to be supplied & installed by crane manufacturer. 4. Trolley frame: a. The trolley frame should be welded rolled steel box section, designed to transmit the load to the bridge rails without undue deflection. It should be made rigid by providing suitable diaphragms. The material used should be steel as per IS: 2062 (latest). b. The drum bearings and s for upper sheaves should be located so as to equalize the load on the trolley wheels as nearly as possible. c. The trolley wheels should be double flanged with axle bearings of spherical roller type. The bearing housing should be designed for easy removal of wheels and bearings for maintenance. The wheel assembly should be fitted in L-type housing for the same. d. All the mechanical and electrical equipment should be placed above the trolley top plate as far as practicable. The access for maintenance, repairs and replacement should be provided for any part placed below the trolley top plate. The trolley should be fitted with substantial safety stops to prevent the trolley from falling more than 25mm in the event of breakage of a track wheel, bogies or an axle. This safety stops should not interfere with removal of wheels. The trolley should be provided with lifting pads for jacking up the trolley on all four corners for wheel removal. Details of the arrangement should be explained in the offer. e. A canopy over crab assembly shall be fixed on the trolley platform for safety during maintenance of crab. It shall be made from thin corrugulated sheet, fixed with pillars. 5. Rail /Track wheels: a. The rail wheels shall be double-flanged with straight tread. b. These wheels shall be manufactured from medium carbon alloy steels and shall be solid forged & heat treated to have minimum hardness of 36HRC (341 BHN) on the tread and flanges to a depth of not less than 10 mm. The wheels should be shrink-fit on the axles. 6. Rope drums: a. The rope drum shall be designed to withstand the compressive stresses caused by the wound of wire rope and the bending stress due to beam action of the drum. b. Seamless pipes will be an acceptable alternative. The steel used shall be to IS: 2062 1984 (latest) quality. T-ts of drum shall be radio graphically checked and stress relieved in case of fabricated rope drum. c. The drum with flanges on both ends, shall be designed to take the entire length of the rope in a single layer. Free extra turns as specified in IS: 3177 shall also be provided. The drum shall be designed with number of ropes having 16 falls. 7. Wire ropes: Wire rope in the crane should be galvanized and of reputed make. The wire ropes preferably of “Hyflex” type should be used. If it is conventional type, then it will be 6 x 36 construction made from best plough steel of tensile strength 180kg/mm2. [5]
RRCAT/AMTD 50 MT EOT Crane Specification.
8. Rope sheaves: All sheaves should be of forged steel. They should be identical, with the exception of the equalizer sheave. The equalizer sheave should be mounted above the trolley floor and should be easily accessible and removable from the trolley floor level. The sheave grooves should be smooth finished for getting increased rope life. The supplier should further ensure that wire ropes are parallel with each other. IV. MECHANICAL REQUIREMENTS: The following features are required in addition to those specified in relevant standards. 1. Drive mechanisms: The drive mechanisms should have provision for two speeds i.e. rated full and creep speeds as specified in table.1. a. Long travel (LT) drive: Total no. of wheels (min. 4 Nos.) shall be decided by the manufacturer. The LT Drive should be with two-motor drive, driving not less than 50% of wheels provided. One brake for each drive should be provided. If anyone motor fails, the other motor should be able to operate the crane at reduced speed. All parts of the LT drive should be located at proper place, easy accessible for inspection and maintenance. b. Cross travel (CT) Drive: Total no. of wheels should not be more than four. The CT Drive should be with two corner drive and either of the drives should be capable of operating the trolley movement in case of failure of the other drive. One brake for each drive should be provided. c. Hoist: Total no. of falls should not be more than 16. The hoist should have twin motor drive through VVVF drive. Two brakes should be provided. Ramshorn hook with swiveling should be suspended from a balancing beam. 2. Gearing system: Only helical gears should be used for all motions. The gearing in all motions should be of suitable case carburizing low carbon alloy steels and should conform to relevant Indian/International standards. They shall be in accordance with IS: 4460-1967(or latest). All gears should be with machine cut teeth, hardened and profile ground for longer life and silent operation. The min. surface hardness of pinions & gears should be in the range of 55-60 HRC. The hardness of gears should be at least 2 - 3 HRC less than that of pinion. 3. Gear boxes: a. All gear boxes shall be of completely enclosed splash lubricated type. All gear boxes shall be oil tight and sealed with neoprene ‘O’ rings of suitable section. All gear shafts shall be ed in bearings mounted in the gear boxes. Gear boxes shall be made of graded C.I/M.S fabricated. All gear boxes shall be stress relieved and the method of doing so shall be explained in detail in the offer. Gear boxes shall be provided with breather vents, easily accessible drain plugs, and a suitable oil level indicator such as a dip stick. Adequate radial clearances between the gear box inner surface and outside diameter of the gears shall be ensured and clearance proposed to be provided shall be indicated in the offer. [6]
RRCAT/AMTD 50 MT EOT Crane Specification.
The facial clearance between the inner surface of the gear box and the face of the nearest gear/pinions shall be at least 10mm. b. All gear boxes should have drip pans to avoid oil falling on shop floor. c. LT/CT gear boxes-- These should be of a modular, integral design. The motors may be either flange-mounted or foot mounted, or a combination of the two. 4. Bearings: a. Ball and roller anti-friction bearings shall be of reputed make. The acceptable makes will be NBC, SKF, FAG, NORMA, NRB, NTN and KOYO. b. For long and cross traverse wheels, spherical roller bearings shall be used. Bush bearings should not be used at any location. 5. Couplings: a. Motor shafts should be connected to gear extension shafts through flexible shock absorbing couplings. Geared or universal couplings should be used between gear box output shaft and intermediate shaft and wheel axle. b. Any other special coupling, which can give better and more reliable service, may be used after obtaining specific approval of the purchaser. Pin Bush coupling should not be used. 6. Brakes: a. Double shoe brakes should be provided for each drive. All the brakes shall be provided with fail-safe D.C. Disc brakes of reputed make. Additional hoisting brake shall be of DCEM shoe type of BCH make. b. The maximum braking torque to arrest LT and CT motions should not less than 100% of full load torque for each brake. For hoist motion and the braking torque for each brake should not be less than 125% of full load torque. One of the two hoist brakes shall be applied with a time lag of 3 seconds in relation to the first. 7. Lifting hook: Standard shank Ram shorn hook for the hoist should be used. The hook should conform to the latest edition of BS:3017 and IS:3815 or any other relevant Indian / International standard. Safety latches on hook shall be provided with closing fingers to prevent slippage of wire ropes/load. 8. Buffers: Spring loaded or other suitable buffers should be fitted on the four corners of the crane also at the four ends of the bridge girders. Buffers should be rigidly bolted in place, preferably along the centre line of the crane rail or trolley rail as the case may be. All buffers should have sufficient energy absorbing capacity to stop the bridge or trolley in either direction when traveling at a speed of least 40% full load rated speed. Bridge buffers should have a surface of not less than 125mm diameter. 9. Lubrication: a. All gears and bearings enclosed inside gear boxes should be splash lubricated. Bottom blocks and pedestal bearings should have independent greasing points. [7]
RRCAT/AMTD 50 MT EOT Crane Specification.
b. A lubricating chart should be provided in the manual, indicating all lubrication points, the type of lubricants required and the recommended frequency of lubrication. These details should be repeated, and amplified if necessary, in the Maintenance Manual to be supplied along with the crane minimum three nos. of hard copies. V. ELECTRICAL REQUIREMENTS: All accessories and auxiliary electrical equipment including drive motors, electrically operated brakes, controllers, AC variable frequency controls, conductors, protective devices, operating devices, cables, conduits etc. are necessary for the safe and satisfactory operation and maintenance of the crane shall be included in the Vendor’s scope of supply. Electrical equipment shall be adequately rated to permit simultaneous operation of any combination of motions of the crane for its duty service. 1. The scope of supply relating to electrical requirements should include the following. a.
Copper shrouded down shop leads (DSL).
b.
2 Nos. of main current Collectors (one in forward and another in rear).
c.
Power disconnecting switch on the crane bridge walk way, to be provided, immediately after the main current collection gears.
d.
Motors (ABB/Siemens/Crompton Greaves/BBL/Kirloskar/LHP make with IP 55 protections).
e.
Protective Switch gears.
f.
Motor control s.
g.
Squirrel cage motors with variable frequency drive for all LT, CT & hoist motions.
h.
DC disc brakes for all motions and DCEM shoe type of BCH make for hoisting as a second brake.
i.
Limit Switches.
j.
Socket outlets.
k.
CT motion cables, power and control cables should run in cable drag chain.
l.
Drag link cable system of reputed make like IGUS.
m.
Indicating lamps.
n.
Double step push buttons on Telemechanique make pendent and wireless remote control.
o.
Only MCBs should be used in the crane in lieu of HRC fuses.
p.
Earth wire on crane portion.
q.
The control pendent should have separate movement in CT direction independently from trolley.
r.
Shrouded bus bar copper conductor along with Isolator switch at the ground level. Cabling from the Isolator to the shrouded bus bar should be in vendor’s scope.
[8]
RRCAT/AMTD 50 MT EOT Crane Specification.
s.
Lighting fixtures shall be metal halide lamps 250W x 4 nos. under arm type operable from pendant as well as from the wireless remote control.
t.
All sundry erection material required for installation and connecting up of electrical equipment with cable laying and fixing accessories shall be included in the price of the crane.
2. Power supply conditions: The power shall be available at 415 ± 10% volts, 3 phase, 50 ± 3% Hz. 3. Specifications for shrouded bus bar conductor: The shrouded bus bar conductor shall conform to the following: a. The conductor system shall be finger safe to IP-21 with necessary ing technical evidence of the same and the conductor material shall be of suitable metal (Copper) insulated by a high impact gloss finish VR 935/2 PVC compound which shall have a step/groove shrouded all along its length for effective molding of the conductor system. b. The conductor shall be in minimum of 4 metres length to be ted with molded t of the same material. c. The conductors shall be ed by way of a single piece molding, four pole hangers with single bolt fixing. d. The current collector arm should be aluminum die cast, totally insulated and the connection cable shall be fully enclosed and double insulated within the collector arm with a proven performance. Two sets of current collectors should be used, one in forward and another on rear, on DSL. e. The shrouded bus bar conductor of M/s. STROMAG or safe track brand of M/s. Sushi Engg. Corporation, Mumbai, or any other equivalent reputed make shall be used. 4. Motors: a. All crane motors shall be totally enclosed, fan cooled, squirrel cage type. All the motors offered should be suitable for heavy- duty reversible crane service. b. All motors should preferably be with class 'F' insulation and the maximum permissible temperature shall be limited to class B. c. The pull out torque of the motors at rated voltage and frequency should be not less than 2.75 times of the nominal torque 5. Crane controls: The following crane controls should be provided. a. Pendant push button control for long travel, cross travel and hoist motions. For switching ON and OFF the motor of a particular motion, the supply voltage to the pendant control shall be 55V/110V AC/DC which shall be obtained through a suitable transformer. Necessary flexible multi core cable with sufficient length shall be supplied to enable the crane to be operated from floor level. Pendant shall be moving type and the movement of pendant will be independent of trolley via a separate track along girder length. On all the motions, the circuit shall be so designed that brakes come into operation immediately in the event of tripping of motor main circuit breaker. [9]
RRCAT/AMTD 50 MT EOT Crane Specification.
b. The pendant control shall be capable of withstanding rough handling without being damaged. The cover shall be firmly secured. c. The mass of the pendant shall be ed independently of the electric cable by means of wire rope/chain. The pendant should be Telemechanique make and the push buttons should be of double step type. d. All crane’s safety means shall be provided on pendant to prevent inadvertent operation from floor while maintenance work is being carried out on the crane. e. Adequate guards shall be provided to prevent accidental of pendant ropes or holding wire rope/chain with cross traverse. f. Along with the push button pendant, wireless remote control of a reputed make should also be offered for LT, CT and hoist motions. g. Wireless remote control should have two transmitters and one receiver. The wireless remote control transmitter should be impact resistant. h. Selector switch on pendant for pendant operation or remote control operation. i. AC variable frequency controls: AC variable frequency control of adequate capacity of L&T / SIEMENS / TOSHIBA/ABB/ Group Schneider make shall be used for all motions. Independent AC variable frequency control for hoist, CT and LT shall be used by using independent variable voltage, variable frequency drives. However, common controller for both the motors of LT may be used. The tenderer shall submit necessary technical details of the offered model. Brake release should be dependent on motor torque. The brake should be released only if 100% torque is developed in the motor. 6. ors: a. All ors shall be of AC 4 Class of duty with rating sufficiently higher than the full load current of the respective motors at the specified duty cycle. The directional ors of all motions shall be suitably interlocked for correct sequence of operation. b. The ors shall have high reliability. c. All ors shall be of ABB, Siemens, L&T, Gourp Schneider, Telmechnique and Cutler Hammer make. 7. Circuit protective switch gear: a. Push button operated or shall be provided for circuit protection of the crane. b. Each control circuit branch to every or shall be provided with facility for isolation and protection against short circuits and sustained high overloads by means of appropriately rated miniature circuit breaker. 8. Limit switches and locks: a.All hoist motions shall be provided with limit switches to prevent crane from over hoisting and over lowering. Two limit switches shall be provided for proper back up protection. The limit switch shall act in the event of over hoisting and over lowering. [10]
RRCAT/AMTD 50 MT EOT Crane Specification.
The switch shall be of snap action/pin type with self resetting feature and incorporated in the control circuit of respective drive motor. b. Any other limit switches viz. for slewing, skewing of crane etc. shall be provided, if required. c. All Limit switches for hoist cross and long travel motions shall be supplied, installed and wired by the manufacturer. d. Audio & Visual Alarm for all the limit switches should be provided. e.Safety latch and swiveling lock should be provided for hook. 9. Emergency stop push buttons: Safety switches of sustained type shall be provided at each end of crane bridge, so that, under any emergency conditions, by operating anyone of the switches, the incoming circuit breaker is tripped, thus, cutting power to all motions. One number of emergency stop push button should also be provided on pendant. 10. Control (IP 55 class protection): a.
All power and auxiliary ors shall be mounted in sheet steel cubical with lockable hinged doors. The door hinges shall be of such type that during the repair work inside the , the entire door can be lifted out and placed away, enabling better access inside the . Each motion shall have its individual . However, common with separate compartments for each motion shall be acceptable.
b.
s shall be front wired with readily accessible terminal blocks for making connections in the external equipment. s shall be pre wired into terminal strip. Single core, copper conductor shall be used for control circuit wiring in the .
c.
All ors etc. shall be mounted securely in a vertical arrangement with the consideration of the vibrations encountered in the operation of cranes. The bottom most row of the equipment mounted inside the except terminals strips shall be at least 150 mm above the bottom cover to facilitate inspection and repairs.
d.
All the equipments shall be so mounted in as to enable its easy removal/replacement from the front.
e.
The terminal strips shall be fixed inside the preferably in a horizontal manner leaving enough space underneath the strip for termination of cables in a convenient manner. Power and control terminals shall be segregated. Power terminals blocks shall be separated from each other by means of replaceable insulated spacers. Terminal block shall have adequate clearance to avoid tracking. A minimum of 20% spare terminals block shall be provided in terminals strips.
f.
All equipments inside the shall have permanent identification labels in accordance with circuit diagram as also the power and control terminals. Terminal blocks shall be of robust and of such construction as to preclude possibility of cable connections getting loose during vibration on crane.
g.
Sheet steel used for fabrication of s shall have a minimum thickness of 2.0 mm. s shall be mounted such that bottom of is at least 150 mm above the floor. [11]
RRCAT/AMTD 50 MT EOT Crane Specification.
h.
or s shall be well braced to the crane structure and each shall be provided with adequate number of lifting lugs.
i. The control may be preferably Rittal / Elsteel / BCH make only. 11. Cabling work: a. All wiring for power control circuit shall be carried out with 1.1 KV grade Flame Retardant Low Smoke (FRLS) PVC insulated copper cables as per IS 694 and IS 1554 Pt. I with smoke index and typical index corresponding to ASTM-2843 & IEC332-I. b. Minimum size of cables shall be 4 mm2 for power and 2.5 mm2 for controls. c. All cables shall be systematically laid on G.I. trays or in cable drags of suitable type. d. All cables shall be of reputed make and approved ISI brands. e. CT cables of the crane shall run on cable drag chain. 12. Identification of circuit components: Labels of permanent nature shall be provided on s of all switches, fuses, ors, relays etc., to facilitate identification of circuits and their replacement. All s, controllers etc. shall be properly marked for each motion. All power control cables and other cables shall be ferruled at both ends as per cable numbers indicated in the supplier’s drawing. All equipment terminals shall also to be marked likewise. 13. Earthing of crane: Earthing to the crane shall be effected through track rails and crane structure. As such, all the electrical equipments mounted on crane shall be connected to the crane structure by means of earthing links. Equipments fed by flexible cables shall be earthed by means of spare core provided in the flexible cable. 14. Two numbers of fluorescent lamps of suitable rating shall be provided below the crane girder for lighting purpose during crane operation. VI. INSPECTION, ERECTION, COMMISSIONING AND PROVING TESTS (Acceptance Creteria): The crane shall be inspected & accepted as per this specification and other applicable standards. a. Inspection & tests shall be done on the crane during different stages of its manufacture, starting from raw-materials till its completion, by the Purchaser or his authorized representative at the supplier’s or his sub-supplier’s works. However, the purchaser or his authorized representative is free to institute any further checks, if he so desires. b. All electrical and mechanical equipment shall be tested in accordance with the appropriate Indian Standard at either the crane maker’s or equipment manufacturer’s works and test certificates provided if required by the Purchaser or his representative. c. The following points should be noted during erection and commissioning of the crane. 1. The contractor shall arrange erection and commissioning of the cranes. Adequate number of teams of technical experts will be made available so that erection and commissioning delays are eliminated. Such personnel will be required to be present immediately as soon as we call upon for erection after receipt of crane at our site and site preparedness. [12]
RRCAT/AMTD 50 MT EOT Crane Specification.
2. The contractor or his agent shall commission the crane within 60 days from the date of intimation by the consignee in respect of readiness of site/gantry etc. 3. The following items of work shall be performed by the Contractor. i. Fixing of rails on gantry girder at RRCAT site and checking the alignment of the same at site. ii. Installing of the crane structure and associated machinery in position. iii. Complete fitting and wiring of all electrical items. iv. Fixing of down shop leads. v. Commissioning of the equipment. The crane performance shall be demonstrated after successful commissioning. d.
Purchaser’s obligation with regard to erection & commissioning will be limited to the following: i. Unloading, transporting materials free of cost from the destination station at RRCAT to the work site at RRCAT and storing until taken over by the supplier for erection. ii. The following will be provided free of cost at the site of work. 1.
Electricity required for the purpose of erection/ lighting.
2.
Test loads with slings and tackles for performing the load tests.
3.
A stair case with railing with at least 3 landings for going up the gantry rails at RRCAT site (MFL building, near shutter) shall be provided.
e. The supplier shall transport major crane equipment in assembled modules (crab assembly, gear box assembly etc.) to RRCAT site for early errection & commissioning of the crane. f. Tests on Purchaser’s Premises: 1. The contractor shall carry out the start up and trial operation tests (commissioning test) on receipt of authorization from the Purchaser. In addition to tests indicated in IS: 3177(latest), the following shall also be carried out: i. The earthing of the crane and control equipment, to be tested as per Indian Electricity Rules. ii. The operation of brakes on LT, CT and hoisting motions with rated loads & speeds. iii. Inching control and speed as specified in table-1. iv. There is no skewness in crane during long travel and cross travel motions, presence of vibrations and unusual noise in operation. 2. The trials shall be carried out initially under no load conditions and on satisfactory completion of these, trials shall be repeated for various loads until the full rated load and operating speed range are covered. 3. During the trial operation, all necessary adjustments shall be made so as to ensure compliance with the operating characteristics of the complete equipment as stipulated in the technical specifications. [13]
RRCAT/AMTD 50 MT EOT Crane Specification.
4. Overload Test: All motions of the crane should be tested with 25% overload in which case the geared speeds need not be attained but the crane should show itself capable of dealing with the overload without any difficulty. 5. Deflection test: The deflection of the crane with maximum working load at rest and with the crab in central position, should be checked as per the applicable standard specification (latest IS 807 & 3177). VII. NOTE TO THE CRANE MANUFACTURERS / SUPPLIERS: 1. The quotations are invited and accepted only from crane manufacturers with ISO-9001- 2008 certification. The tenderer should provide satisfactory evidence, acceptable to the Purchaser, to prove that he is a licensed manufacturer and has adequate plant and manufacturing capacity /facilities and has a quality assurance programme. He should furnish a statement giving a list of similar EOT cranes of 40 MT capacities and above with min. 12 metre span and above supplied by him during the last 5 years, along with the Purchaser’s name and address, order number, date and quantity supplied, comments on their performance, and whether the supplies were made within the delivery period. In the absence of the above information, the tender is liable to be rejected. 2. The following should accompany the offer: a. General Arrangement (GA) drawing to scale (showing elevation, cross-section and plan of the crane) indicating clearances, hook approaches, lift, location and direction of view of operator, wheel base, wheel loads etc. of the crane being offered along with the quotation. Offer with generalized details is liable to be rejected. b. Submission of duly filled ‘Guaranteed Technical Particulars’ (technical data sheet) as per Annexure - II. c. Deviations from this specification, if any, with a comparative statement. d. The offer shall include all the transportation expenses of crane. e. The validity of offer shall be at least 3 months from the date of opening of tender. 3. Successful tenderer should furnish the following prior to manufacture of the crane for Purchaser’s approval. a. The GA drawings containing all information as described above clause 2.a. b. General layout drawing of the trolley. c. Assembly drawing -inclusive of gearbox details, individual drives like hoist, long travel and cross travel. d. Pendant controls with functional details. e. Circuit diagrams showing the wiring for the complete crane. f. Final design calculations for all motions, structure etc., and selection of bought out items should be submitted at the time of approval of GA drawings. g. Submission of a detailed quality assurance programme indicating QAP applicable at various stages of crane fabrication starting from raw material to final crane testing. [14]
RRCAT/AMTD 50 MT EOT Crane Specification.
4. The following should be provided. A CD containing all the documents / information recorded on it should also be supplied at the time of erection and commissioning of the crane. a. All the drawings approved by the purchaser along with all workshop drawings for structural, mechanical & electrical items containing full information such as assembly drawings/diagram showing the placement of components/parts along with make, rating & specification etc. b. Electrical circuit diagrams and catalogues of all electrical equipment. c. Operation & Maintenance manuals- 3 Sets. d. Maintenance schedule and lubricating charts. 5. The supplier should furnish material test certificates for all electrical equipment, cables, parts used in handling loads (e.g. wire ropes, chains, hooks etc.), structural steel, mechanical components such as couplings, gears boxes, rope drums, pulleys, shafts, wheels etc. 6. Spares: To be quoted separately for two years of maintenance. 7. Guarantee shall be provided for 24 months from the date of commissioning of crane. If during the guarantee period, the supplied equipment are found not manufactured to the specification and does not confirm to the standard of reliability, then the item shall be replaced/rectified by the supplier at his risk and cost within the reasonable period. 8. Pre-Dispatch inspection: The crane shall be inspected and tested at the manufacturer’s works. The material shall be dispatched only after approval and issue of shipping release. 9. Performance bond Bank guarantee: The supplier shall furnish a performance bond in the form of a Bank guarantee as per the format of Purchaser for 10% of the total value of the crane towards satisfactory performance of the same. The Bank guarantee should be valid till the expiry of the guarantee/warranty period and shall be submitted by the supplier before the shipment of the items to the Purchaser for scrutiny and to convey the acceptance to the supplier. 10. Training: Technical experts of the manufacturer during erection & commissioning of cranes will fully and adequately train operators / maintenance staff nominated by the Purchaser. VIII. DELIVERY SCHEDULE: The total completion period will be 12 months from the date of release of purchase order (P.O) and it includes the following milestones: S.No. Activity Completion date 1. General Arrangement drawing with complete details, design 2 months from the date calculations and approval from the Purchaser. of release of P.O. 2. Manufacturing, inspection and testing at manufacturer’s site 9 months from the date as per the specification and final delivery to RRCAT, Indore. of release of P.O. 3. Erection and performance testing of the crane at new 12 months from the date magnet fabrication building, RRCAT, Indore. of release of P.O. The accepted crane with all accessories will be delivered to: The Stores officer, IRP&SU, Raja Ramanna Centre for Advanced Technology (RRCAT), Indore – 452013, M.P., India. Encl.: Annexure I & II.
[15]
RRCAT/AMTD 50 MT EOT Crane Specification.
ANNEXURE - I.
W1
W1
C3
5800x11800
G-21
QP MEASUREMENT HORMONIC BENCH
1000 C/C
C3
A.H.U. ROOM
C2
W1
W1
W1
C3
C3
W1
W1
1050
1000 C/C
G-23
1000 C/C
D1
1000 C/C
C3
C3
G-20
5750
C4
C3
CMM BENCH
ROOM FOR CLEANING
4700
200 C/C
G-22
4550
W1
200 C/C
BEAM
1000 C/C
D1
1000 C/C
3500
200 C/C
PROPOSED 50T EOT CRANE
NO OBSTRUCTION ZONE
W1
W1 D1
C2
1200
C2
C4
C3
CMM BENCH
W1
A.H.U. ROOM
C2
C4
C3
350
G-19 W1
W1
11500 10800
700
D1
630 C2
C4
12200
D1
700
W1
W1 11800x5800
C2
C4
C3
B
G-18
B
W1
W1
1500
1500
C2
C4
C3
F-23
CORRIDOR
G-18
2000
6000
W1
W1
CORRIDOR
D1 C2
C4
1500
D6
D6
C4
C3
C2
C4
W1
W1
C3
8500
C3
C3 D6
C3
AL1 GATE
8500
V1
V1
V1
V1
W1
G-17
9700
D1
W1 7800x5800
D5
D5
C3
C3
C3
C3
C2
AL1
W1
C3
C3
C2
C4
C3 3800x5800
W1
W1
G-27 D1
MS COLLAPSABLE GATE
AL1 C3
C2
C4 D1 7800x5800
G-26
4800
C4
C3
C2
C4
W1
W1
C3
WIDE ROAD 3700mm
1000
W1
W1
W2
C1 C2
C1
13000
ALL DIMENSIONS ARE IN MM. SECTION `B-B'
N
RRCAT/AMTD 50 MT EOT Crane Specification.
ANNEXURE -II.
Guaranteed Technical Particulars (Technical data sheet to be submitted with the tender by manufacturer)
S.No.
Description
Unit
1.0.0
GENERAL
1.1.0
Manufacturer
1.2.0
Type/ Model
1.3.0
Quantity
1.4.0
Design according to standard service class/ load class
1.5.0
Nominal load carrying capacity (SWL)
1.6.0
Span
M
1.7.0
Highest position of hook
M
1.8.0
Lowest position of hook
M
1.9.0
Lifting Sling length
M
2.0.0
SPEEDS
2.1.0
Long travelling speed
2.2.0 2.3.0
MT
Main Creep
M/min M/min
Main Creep
M/min M/min
Main Creep
M/min M/min
Cross travelling speed Hoisting speed
3.0.0
Location (Indoor/ Outdoor)
4.0.0
Clearances and Hook approaches as per Tender (If no, specify)
Data
RRCAT/AMTD 50 MT EOT Crane Specification.
S.No.
Description
Unit
5.0.0
Type of control proposed
6.0.0
Gantry Rail Size
7.0.0
CONSTRUCTIONAL FEATURES
7.1.0
Weight of complete crane unladen
MT
7.2.0
Wt. of Trolley/Crab
MT
7.3.0
Weight of hoist unladen
MT
7.4.0
Weight of each end carriage
MT
7.5.0
Weight of girder
MT
7.6.0
Wt. of all electrical
MT
7.7.0
Maximum wheel load
MT
7.8.0
Wheel loading diagram furnished
8.0.0
HOISTING SYSTEM
8.1.0
Rope
8.1.1
Rope diameter mm
8.1.2
Rope construction
8.1.3
Rope quality (material)
8.1.4
Rope strength
8.1.5
Number of rope falls
8.1.6
Factor of safety
8.1.7
Rope drum
8.2.0
Drum diameter and length
8.2.1
Drum material
kg/mm²
mm
[ii]
Data
RRCAT/AMTD 50 MT EOT Crane Specification.
S.No.
Description
Unit
8.2.2
Whether stress relieved
8.2.3
Bearing type/ make
8.3.0
Hook
8.3.1
Hook type
8.3.2
Hook material
8.3.3
Safety latches provided
8.4.0
Sheaves
8.4.1
Lower sheave diameter
8.4.2
Lower sheave material
8.4.3
Equalizing sheave diameter
8.5.0
Hoist Brake
8.5.1
Type
8.5.2
Make
8.5.3
Size
mm
8.5.4
Torque
Nm
8.6.0
Brake Drum
8.6.1
Material
8.6.2
Width
8.6.3
Coupling type
8.6.4
Gear box input
8.6.5
Gear box output
8.6.6
Material of gears
8.6.7
Material of pinions
8.6.8
Type of gears/pinions
mm
mm
mm
[iii]
Data
RRCAT/AMTD 50 MT EOT Crane Specification.
S.No.
Description
Unit
8.7.0
Limit Switch
8.7.1
Numbers
8.7.2
Type
8.7.3
Make
9.0.0
CROSS TRAVEL
9.1.0
CT brake
9.1.1
Type
9.1.2
Make
9.1.3
Size
mm
9.1.4
Torque
Nm
9.2.0
Brake Drum
9.2.1
Material
9.2.2
Width
9.3.0
Coupling type
9.3.1
Gear box
9.3.2
Gear box input
9.3.3
Gear box output
9.3.4
Material of gears
9.3.5
Material of pinion
9.3.6
Type of gears/pinion
9.4.0
Wheels
9.4.1
Materials
9.4.2
Hardness
mm
BHN [iv]
Data
RRCAT/AMTD 50 MT EOT Crane Specification.
S.No.
Description
9.4.3
Type
9.4.4
Diameter
9.4.5
Wheel bearing type/ make
9.5.0
Limit switches
9.5.1
Number
9.5.2
Type
9.5.3
Make
9.6.0
Type of Stoppers
9.7.0
Number of driven wheels
9.8.0
Number of total wheels
10.0.0
LONG TRAVEL
10.1.0
End carriage length
10.2.0
Coupling type
10.2.1
Gear box
10.2.2
Gear box input
10.2.3
Gear box output
10.2.4
Material of gears
10.2.5
Material of pinion
10.2.6
Type of gears/pinion
10.3.0
LT brakes
10.3.1
Type
10.3.2
Make
10.3.3
Size
10.3.4
Torque
Unit
mm
mm
Nm [v]
Data
RRCAT/AMTD 50 MT EOT Crane Specification.
S.No.
Description
10.4.0
Brake Drum
10.4.1
Material
10.4.2
Width
10.5.0
Wheels
10.5.1
Materials
10.5.2
Hardness
10.5.3
Type
10.5.4
Diameter
10.5.5
Wheel bearing type/ make
10.6.0
Limit switches
10.6.1
Number
10.6.2
Type
10.6.3
Make
10.7.0
Type of Stoppers
10.8.0
Number of driven wheels
10.9.0
Number of total wheels
11.0.0
MOTOR (To be filled separately for each main and creep motor)
11.1.0
General
11.1.1
Make
11.1.2
Type
11.1.3
Number
11.2.0
Rating
Unit
Data
mm
BHN
mm
Hoist
Main
[vi]
Creep
Bridge Travel
Trolley Travel
Main
Main
Creep
Creep
RRCAT/AMTD 50 MT EOT Crane Specification.
S.No.
Description
11.2.1
Rating : kW at 50°C Time CDF
11.2.2
Permissible Starts/Hr.
11.2.3
Voltage-phase, frequency
11.2.4
Rated current
11.2.5
Rated torque
Unit
Data
Nm
i) Starting ii) Braking 11.2.6
15% margin for motor ratings considered
12.0.0
CRANE CONTROL
12.1.0
Type
12.2.0
Inching Speed Control
12.2.1
Inching speed in % full load speed
12.2.2
Detailed write-up furnished on inching speed control
12.2.3
Individual control furnished for all crane motions?
12.2.4
Detailed write-up on speed control furnished?
NOTE: If above clauses are found inadequate for furnishing all necessary information of the crane offered, the supplier may append further information separately.
Signature of the Tenderer [vii]
SPECIFICATION FOR 50 MT DOUBLE GIRDER ELECTRIC OVERHEAD TRAVELLING (EOT) CRANE FOR MAGNET FABRICATION BUILDING (MFB)
S.No.
CONTENTS
PAGE No.
I.
INTRODUCTION
1
II.
GENERAL REQUIREMENTS
2
III.
STRUCTURAL REQUIREMENTS
4
IV.
MECHANICAL REQUIREMENTS
6
V.
ELECTRICAL REQUIREMENTS
8
VI.
INSPECTION, ERECTION, COMMISSIONING AND PROVING TESTS
12
VII.
NOTE TO THE CRANE MANUFACTURERS / SUPPLIERS
14
VIII.
DELIVERY SCHEDULE
15
Annexure-I : - End view of MFB High bay with crane. Annexure-II : - Guaranteed Technical Particulars (Technical data) of offered crane to be submitted.
RRCAT/AMTD 50 MT EOT Crane Specification.
SPECIFICATION FOR 50 MT DOUBLE GIRDER ELECTRIC OVERHEAD TRAVELLING (EOT) CRANE FOR MAGNET FABRICATION BUILDING I. INTRODUCTION Raja Ramanna Centre for Advanced Technology (RRCAT), Indore. M.P. requires a 50 MT EOT crane, to be installed and commissioned at their new up-coming Magnet Fabrication Building (MFB). This Centre is situated at a distance of 14 km from Indore Railway Station. Indore is situated at an altitude of 553 metres above sea level on the Malwa plateau and falls in seismic zone - III. The crane is intended for handling of large size electro-magnets. The specifications of this electric overhead traveling crane are given below. The end view of high bay with crane is shown in Annexure-I. Table.1: Data Sheet of 50 MT Double Girder EOT Crane. 1)
Designation
50 MT EOT crane.
2) 3) 4)
Duty Class of Crane (As per IS: 807-2006) Quantity Location
M7 (class III). 01 No. Indoor (MFL building, RRCAT, Indore).
5) 6) 7)
Crane Classification as per IS: 13834 Mechanical & Electrical Type Type of Girder
M7 Electric Overhead Travelling (EOT) Double
8) 9) 10)
Capacity Main Hoist Span Longitudinal Travel
50 MT. 11.50 meters. 50 meters.
11)
Lifting Range Main Hoist
8.5 meters (Hook height FFL).
12)
Type of Hook Main Hook
Ram shorn type with swiveling.
13) 14) 15)
Speeds with VVVF drive Main Hoist Long Travel Cross Travel
Full speed / creep speed [meter /min ] 2.0 / 0.2 15.0 / 1.5 10.0 / 1.0
16)
Operating Mode Pendant
Push button trailing type & Wireless remote control. [1]
RRCAT/AMTD 50 MT EOT Crane Specification.
II.
GENERAL REQUIREMENTS: 1. Scope of supply The scope of supply shall include the design, manufacturing, transportation, erection, commissioning and testing of 50 MT EOT crane as specified in table 1 and complete with all electrical and other standard accessories. The crane must be rugged, robust and smooth in operation without any jerks. Also, the scope of supply shall include the following along with necessary fittings, fixtures and ancillaries. a. b. c. d. e. f. g. h. i. j.
Bridge structure with platform and hand railing. Rails and track wheels for longitudinal and cross travel. Traveling mechanism for longitudinal and cross travel. Hoisting mechanism. Brake mechanism separately for long travel, cross traverse and hoisting. Trolley. Service Platform. Pendant Control and radio wireless remote operation for all movements. Electrical motors, control gear and equipment. AC controls for all motions of the crane shall be of VVVF drive.
2. Applicable standards: a)
IS: 3177-1999 (latest) - Indian Standard Code of Practice for electric overhead traveling cranes.
b)
IS: 807- 2006 (latest) - Indian Standard Code of Practice for design, manufacture, erection and testing (structural portion) of cranes and hoists.
c)
IS: 13834 for crane classification.
The crane should be designed for a minimum life of 30 years. 3.
Rigidity, Control and Safety: a. The crane should be rigid, robust and of sturdy construction b. No cast iron part should be used on the crane except for electrical equipment . Similarly wood / combustible material and bush bearing should not be used in any part of the crane. Open gears should not be used in any drive/motion. c. The crane controls should be conveniently located. The various controls should be suitably interlocked to prevent accidental movement of the crane. d. Suitable limit switches for long, cross travel and main hoist should be provided to stop the crane and prevent over-travel of various moving parts of the crane. In addition, gravity type back up limit switch shall be provided for hoisting motion. e. Suitable buffers should be provided to prevent over travel of the crane mechanism in both longitudinal and cross traverse directions. f. All machinery or equipment included in this specification must be provided with safety devices and clearances as per standards and purchaser's requirements. g. Suitable guards or enclosures should be provided on the crane to prevent inadvertent with down shop leads (DSL) or any other exposed electrical conductors and cables. [2]
RRCAT/AMTD 50 MT EOT Crane Specification.
h. i.
j.
k. l.
Suitable isolation switches and stop buttons should be provided to isolate the electric supply for maintenance or in the event of an emergency. A safety hand railing of tubular construction shall be provided on bridge footwalls, end carriages, trolley and any other places where access has been provided. Railings should not be less than 1000 mm high with an intermediate member at a height of 500mm. All sheaves should be provided with rigid guards to retain the ropes in the grooves. Guard should fit close to flange and should have a clearance between the sheaves and inside the guard of not more than 3 mm or 1/4th of rope diameter, whichever is less. The crane should comply with the relevant safety regulations under the Factories Act, Indian Electricity Rules and other statutory regulations as applicable. All cables should be clamped individually. All trailing cables should be clamped with PVC or non-metallic clamps.
4. Maintainability:
5.
a.
Safe accesses of maintenance and removal of all mechanical, electrical and structural components must be ensured. All parts requiring replacement, inspection and lubrication should be easily accessible without the need of dismantling other equipment or structures. Arrangements for access to important components must include a cradle for inspection and maintenance of DSL, such cradle being conveniently accessible.
b.
All electrical cables should be so laid that they are not liable to damage and can be easily inspected and maintained.
c.
All Access walkways of min. 750 mm clear inside width with hand railings on both sides of girders for the full span length for inspection & maintenance of the crane shall be provided. The walkways shall be attached with crane girders at a height of 1800 mm from the beam bottom of building roof. Walkways shall be of chequered plate or nonslip steel surface of minimum 6mm thick, shall be of rigid construction and designed to sustain a distributed live load of 3 kN/m2 (min).
d.
Materials used for equipment and structural should be free from cracks, blow holes, laminations, pitting etc. Except for areas where a superior grade of materials is required, steel class should be as per IS: 2062 (latest).
e.
A tool box containing all tools required for the maintenance of the crane should be supplied along with the crane.
f.
Fasteners for pedestal blocks, gear boxes, etc., should be easily removable from the top of the platform.
Painting and Colour: The crane should be epoxy painted (golden yellow colour) after obtaining surface finish better than or equal to SA 1½. All motors, brakes and s should also be epoxy painted. The following points should be noted. a. b. c.
All parts of the crane shall be thoroughly cleaned of all loose mill scales, rust or foreign matter. All parts inaccessible after assembly shall be painted before assembly. The interior of all gear box housings shall be painted with two coats of oil resistant enamel paint. [3]
RRCAT/AMTD 50 MT EOT Crane Specification.
III. STRUCTURAL REQUIREMENTS: 1. The following points are applicable for design and manufacturing of structural . a.
The crane bridge should comprise of double girders of plate box type.
b.
In the main bridge girders, in addition to the required full length diaphragms, short diaphragms should be inserted wherever required to transmit the trolley wheel load to the web plates and to limit the maximum stress in the trolley rail to safe permissible limits. All diaphragms must bear against the top flange. Steel plates used for bridge girders and diaphragms should be as per IS: 2062 (latest).
c.
All fasters should be hot dip galvanized.
d.
The bridge girders should be connected to the end carriages by large gusset plates. Ground tight fit bolts in reamed holes should be used for bolted connections.
e.
The calculated strength of ts made by High Strength Friction Grip (HSFG) bolts should not be less than calculated net strength of the member. The calculated strength of other bolted ts in structural should not be less than the net strength of the member plus 25%.
f.
All butt welds on structural of bridge girders subject to tension should be radio graphically tested. All other welds should be subjected to Magna flux or Dye Penetration Test.
g.
The box girders should be so constructed as to eliminate any possibility of accumulation of water or oil inside them.
2. End carriages: a.
The crane bridge should be carried on end trolleys with double flanged solid forged wheels. The minimum end clearance on each side of the long travel wheels should be 10mm. The wheels should be mounted on fixed axle or suitable anti-friction spherical roller bearings which can be conveniently removed for maintenance.
b.
End carriages should be designed to be strong enough to resist all stresses likely to be imposed upon them under varied service conditions, including collision with stops. The length of the end carriages should be such that no other part of the crane is damaged in the event of a collision.
c.
End carriages should be fabricated from rolled steel sections or plates, welded together to form a box. Suitable stiffening diaphragms should be provided wherever required. The material used should be steel as per IS: 2062 (latest).
d.
Suitable jacking pads should be provided on each end carriage for jacking up the crane while changing track wheels. These jacking pads should not interfere with replacement of track wheels.
e.
The end carriages should be fitted with suitable safety stops to prevent the crane from falling more than 25mm in the event of breakage of track wheel, bogie or axle. These safety stops should not interfere with the removal of track wheels. [4]
RRCAT/AMTD 50 MT EOT Crane Specification.
3. Bridge rails: The bridge rails shall be CR-80 RAIL of suitable size (min. 105 lbs/yd) of length 52 metres on both sides of the girder to be supplied & installed by crane manufacturer. 4. Trolley frame: a. The trolley frame should be welded rolled steel box section, designed to transmit the load to the bridge rails without undue deflection. It should be made rigid by providing suitable diaphragms. The material used should be steel as per IS: 2062 (latest). b. The drum bearings and s for upper sheaves should be located so as to equalize the load on the trolley wheels as nearly as possible. c. The trolley wheels should be double flanged with axle bearings of spherical roller type. The bearing housing should be designed for easy removal of wheels and bearings for maintenance. The wheel assembly should be fitted in L-type housing for the same. d. All the mechanical and electrical equipment should be placed above the trolley top plate as far as practicable. The access for maintenance, repairs and replacement should be provided for any part placed below the trolley top plate. The trolley should be fitted with substantial safety stops to prevent the trolley from falling more than 25mm in the event of breakage of a track wheel, bogies or an axle. This safety stops should not interfere with removal of wheels. The trolley should be provided with lifting pads for jacking up the trolley on all four corners for wheel removal. Details of the arrangement should be explained in the offer. e. A canopy over crab assembly shall be fixed on the trolley platform for safety during maintenance of crab. It shall be made from thin corrugulated sheet, fixed with pillars. 5. Rail /Track wheels: a. The rail wheels shall be double-flanged with straight tread. b. These wheels shall be manufactured from medium carbon alloy steels and shall be solid forged & heat treated to have minimum hardness of 36HRC (341 BHN) on the tread and flanges to a depth of not less than 10 mm. The wheels should be shrink-fit on the axles. 6. Rope drums: a. The rope drum shall be designed to withstand the compressive stresses caused by the wound of wire rope and the bending stress due to beam action of the drum. b. Seamless pipes will be an acceptable alternative. The steel used shall be to IS: 2062 1984 (latest) quality. T-ts of drum shall be radio graphically checked and stress relieved in case of fabricated rope drum. c. The drum with flanges on both ends, shall be designed to take the entire length of the rope in a single layer. Free extra turns as specified in IS: 3177 shall also be provided. The drum shall be designed with number of ropes having 16 falls. 7. Wire ropes: Wire rope in the crane should be galvanized and of reputed make. The wire ropes preferably of “Hyflex” type should be used. If it is conventional type, then it will be 6 x 36 construction made from best plough steel of tensile strength 180kg/mm2. [5]
RRCAT/AMTD 50 MT EOT Crane Specification.
8. Rope sheaves: All sheaves should be of forged steel. They should be identical, with the exception of the equalizer sheave. The equalizer sheave should be mounted above the trolley floor and should be easily accessible and removable from the trolley floor level. The sheave grooves should be smooth finished for getting increased rope life. The supplier should further ensure that wire ropes are parallel with each other. IV. MECHANICAL REQUIREMENTS: The following features are required in addition to those specified in relevant standards. 1. Drive mechanisms: The drive mechanisms should have provision for two speeds i.e. rated full and creep speeds as specified in table.1. a. Long travel (LT) drive: Total no. of wheels (min. 4 Nos.) shall be decided by the manufacturer. The LT Drive should be with two-motor drive, driving not less than 50% of wheels provided. One brake for each drive should be provided. If anyone motor fails, the other motor should be able to operate the crane at reduced speed. All parts of the LT drive should be located at proper place, easy accessible for inspection and maintenance. b. Cross travel (CT) Drive: Total no. of wheels should not be more than four. The CT Drive should be with two corner drive and either of the drives should be capable of operating the trolley movement in case of failure of the other drive. One brake for each drive should be provided. c. Hoist: Total no. of falls should not be more than 16. The hoist should have twin motor drive through VVVF drive. Two brakes should be provided. Ramshorn hook with swiveling should be suspended from a balancing beam. 2. Gearing system: Only helical gears should be used for all motions. The gearing in all motions should be of suitable case carburizing low carbon alloy steels and should conform to relevant Indian/International standards. They shall be in accordance with IS: 4460-1967(or latest). All gears should be with machine cut teeth, hardened and profile ground for longer life and silent operation. The min. surface hardness of pinions & gears should be in the range of 55-60 HRC. The hardness of gears should be at least 2 - 3 HRC less than that of pinion. 3. Gear boxes: a. All gear boxes shall be of completely enclosed splash lubricated type. All gear boxes shall be oil tight and sealed with neoprene ‘O’ rings of suitable section. All gear shafts shall be ed in bearings mounted in the gear boxes. Gear boxes shall be made of graded C.I/M.S fabricated. All gear boxes shall be stress relieved and the method of doing so shall be explained in detail in the offer. Gear boxes shall be provided with breather vents, easily accessible drain plugs, and a suitable oil level indicator such as a dip stick. Adequate radial clearances between the gear box inner surface and outside diameter of the gears shall be ensured and clearance proposed to be provided shall be indicated in the offer. [6]
RRCAT/AMTD 50 MT EOT Crane Specification.
The facial clearance between the inner surface of the gear box and the face of the nearest gear/pinions shall be at least 10mm. b. All gear boxes should have drip pans to avoid oil falling on shop floor. c. LT/CT gear boxes-- These should be of a modular, integral design. The motors may be either flange-mounted or foot mounted, or a combination of the two. 4. Bearings: a. Ball and roller anti-friction bearings shall be of reputed make. The acceptable makes will be NBC, SKF, FAG, NORMA, NRB, NTN and KOYO. b. For long and cross traverse wheels, spherical roller bearings shall be used. Bush bearings should not be used at any location. 5. Couplings: a. Motor shafts should be connected to gear extension shafts through flexible shock absorbing couplings. Geared or universal couplings should be used between gear box output shaft and intermediate shaft and wheel axle. b. Any other special coupling, which can give better and more reliable service, may be used after obtaining specific approval of the purchaser. Pin Bush coupling should not be used. 6. Brakes: a. Double shoe brakes should be provided for each drive. All the brakes shall be provided with fail-safe D.C. Disc brakes of reputed make. Additional hoisting brake shall be of DCEM shoe type of BCH make. b. The maximum braking torque to arrest LT and CT motions should not less than 100% of full load torque for each brake. For hoist motion and the braking torque for each brake should not be less than 125% of full load torque. One of the two hoist brakes shall be applied with a time lag of 3 seconds in relation to the first. 7. Lifting hook: Standard shank Ram shorn hook for the hoist should be used. The hook should conform to the latest edition of BS:3017 and IS:3815 or any other relevant Indian / International standard. Safety latches on hook shall be provided with closing fingers to prevent slippage of wire ropes/load. 8. Buffers: Spring loaded or other suitable buffers should be fitted on the four corners of the crane also at the four ends of the bridge girders. Buffers should be rigidly bolted in place, preferably along the centre line of the crane rail or trolley rail as the case may be. All buffers should have sufficient energy absorbing capacity to stop the bridge or trolley in either direction when traveling at a speed of least 40% full load rated speed. Bridge buffers should have a surface of not less than 125mm diameter. 9. Lubrication: a. All gears and bearings enclosed inside gear boxes should be splash lubricated. Bottom blocks and pedestal bearings should have independent greasing points. [7]
RRCAT/AMTD 50 MT EOT Crane Specification.
b. A lubricating chart should be provided in the manual, indicating all lubrication points, the type of lubricants required and the recommended frequency of lubrication. These details should be repeated, and amplified if necessary, in the Maintenance Manual to be supplied along with the crane minimum three nos. of hard copies. V. ELECTRICAL REQUIREMENTS: All accessories and auxiliary electrical equipment including drive motors, electrically operated brakes, controllers, AC variable frequency controls, conductors, protective devices, operating devices, cables, conduits etc. are necessary for the safe and satisfactory operation and maintenance of the crane shall be included in the Vendor’s scope of supply. Electrical equipment shall be adequately rated to permit simultaneous operation of any combination of motions of the crane for its duty service. 1. The scope of supply relating to electrical requirements should include the following. a.
Copper shrouded down shop leads (DSL).
b.
2 Nos. of main current Collectors (one in forward and another in rear).
c.
Power disconnecting switch on the crane bridge walk way, to be provided, immediately after the main current collection gears.
d.
Motors (ABB/Siemens/Crompton Greaves/BBL/Kirloskar/LHP make with IP 55 protections).
e.
Protective Switch gears.
f.
Motor control s.
g.
Squirrel cage motors with variable frequency drive for all LT, CT & hoist motions.
h.
DC disc brakes for all motions and DCEM shoe type of BCH make for hoisting as a second brake.
i.
Limit Switches.
j.
Socket outlets.
k.
CT motion cables, power and control cables should run in cable drag chain.
l.
Drag link cable system of reputed make like IGUS.
m.
Indicating lamps.
n.
Double step push buttons on Telemechanique make pendent and wireless remote control.
o.
Only MCBs should be used in the crane in lieu of HRC fuses.
p.
Earth wire on crane portion.
q.
The control pendent should have separate movement in CT direction independently from trolley.
r.
Shrouded bus bar copper conductor along with Isolator switch at the ground level. Cabling from the Isolator to the shrouded bus bar should be in vendor’s scope.
[8]
RRCAT/AMTD 50 MT EOT Crane Specification.
s.
Lighting fixtures shall be metal halide lamps 250W x 4 nos. under arm type operable from pendant as well as from the wireless remote control.
t.
All sundry erection material required for installation and connecting up of electrical equipment with cable laying and fixing accessories shall be included in the price of the crane.
2. Power supply conditions: The power shall be available at 415 ± 10% volts, 3 phase, 50 ± 3% Hz. 3. Specifications for shrouded bus bar conductor: The shrouded bus bar conductor shall conform to the following: a. The conductor system shall be finger safe to IP-21 with necessary ing technical evidence of the same and the conductor material shall be of suitable metal (Copper) insulated by a high impact gloss finish VR 935/2 PVC compound which shall have a step/groove shrouded all along its length for effective molding of the conductor system. b. The conductor shall be in minimum of 4 metres length to be ted with molded t of the same material. c. The conductors shall be ed by way of a single piece molding, four pole hangers with single bolt fixing. d. The current collector arm should be aluminum die cast, totally insulated and the connection cable shall be fully enclosed and double insulated within the collector arm with a proven performance. Two sets of current collectors should be used, one in forward and another on rear, on DSL. e. The shrouded bus bar conductor of M/s. STROMAG or safe track brand of M/s. Sushi Engg. Corporation, Mumbai, or any other equivalent reputed make shall be used. 4. Motors: a. All crane motors shall be totally enclosed, fan cooled, squirrel cage type. All the motors offered should be suitable for heavy- duty reversible crane service. b. All motors should preferably be with class 'F' insulation and the maximum permissible temperature shall be limited to class B. c. The pull out torque of the motors at rated voltage and frequency should be not less than 2.75 times of the nominal torque 5. Crane controls: The following crane controls should be provided. a. Pendant push button control for long travel, cross travel and hoist motions. For switching ON and OFF the motor of a particular motion, the supply voltage to the pendant control shall be 55V/110V AC/DC which shall be obtained through a suitable transformer. Necessary flexible multi core cable with sufficient length shall be supplied to enable the crane to be operated from floor level. Pendant shall be moving type and the movement of pendant will be independent of trolley via a separate track along girder length. On all the motions, the circuit shall be so designed that brakes come into operation immediately in the event of tripping of motor main circuit breaker. [9]
RRCAT/AMTD 50 MT EOT Crane Specification.
b. The pendant control shall be capable of withstanding rough handling without being damaged. The cover shall be firmly secured. c. The mass of the pendant shall be ed independently of the electric cable by means of wire rope/chain. The pendant should be Telemechanique make and the push buttons should be of double step type. d. All crane’s safety means shall be provided on pendant to prevent inadvertent operation from floor while maintenance work is being carried out on the crane. e. Adequate guards shall be provided to prevent accidental of pendant ropes or holding wire rope/chain with cross traverse. f. Along with the push button pendant, wireless remote control of a reputed make should also be offered for LT, CT and hoist motions. g. Wireless remote control should have two transmitters and one receiver. The wireless remote control transmitter should be impact resistant. h. Selector switch on pendant for pendant operation or remote control operation. i. AC variable frequency controls: AC variable frequency control of adequate capacity of L&T / SIEMENS / TOSHIBA/ABB/ Group Schneider make shall be used for all motions. Independent AC variable frequency control for hoist, CT and LT shall be used by using independent variable voltage, variable frequency drives. However, common controller for both the motors of LT may be used. The tenderer shall submit necessary technical details of the offered model. Brake release should be dependent on motor torque. The brake should be released only if 100% torque is developed in the motor. 6. ors: a. All ors shall be of AC 4 Class of duty with rating sufficiently higher than the full load current of the respective motors at the specified duty cycle. The directional ors of all motions shall be suitably interlocked for correct sequence of operation. b. The ors shall have high reliability. c. All ors shall be of ABB, Siemens, L&T, Gourp Schneider, Telmechnique and Cutler Hammer make. 7. Circuit protective switch gear: a. Push button operated or shall be provided for circuit protection of the crane. b. Each control circuit branch to every or shall be provided with facility for isolation and protection against short circuits and sustained high overloads by means of appropriately rated miniature circuit breaker. 8. Limit switches and locks: a.All hoist motions shall be provided with limit switches to prevent crane from over hoisting and over lowering. Two limit switches shall be provided for proper back up protection. The limit switch shall act in the event of over hoisting and over lowering. [10]
RRCAT/AMTD 50 MT EOT Crane Specification.
The switch shall be of snap action/pin type with self resetting feature and incorporated in the control circuit of respective drive motor. b. Any other limit switches viz. for slewing, skewing of crane etc. shall be provided, if required. c. All Limit switches for hoist cross and long travel motions shall be supplied, installed and wired by the manufacturer. d. Audio & Visual Alarm for all the limit switches should be provided. e.Safety latch and swiveling lock should be provided for hook. 9. Emergency stop push buttons: Safety switches of sustained type shall be provided at each end of crane bridge, so that, under any emergency conditions, by operating anyone of the switches, the incoming circuit breaker is tripped, thus, cutting power to all motions. One number of emergency stop push button should also be provided on pendant. 10. Control (IP 55 class protection): a.
All power and auxiliary ors shall be mounted in sheet steel cubical with lockable hinged doors. The door hinges shall be of such type that during the repair work inside the , the entire door can be lifted out and placed away, enabling better access inside the . Each motion shall have its individual . However, common with separate compartments for each motion shall be acceptable.
b.
s shall be front wired with readily accessible terminal blocks for making connections in the external equipment. s shall be pre wired into terminal strip. Single core, copper conductor shall be used for control circuit wiring in the .
c.
All ors etc. shall be mounted securely in a vertical arrangement with the consideration of the vibrations encountered in the operation of cranes. The bottom most row of the equipment mounted inside the except terminals strips shall be at least 150 mm above the bottom cover to facilitate inspection and repairs.
d.
All the equipments shall be so mounted in as to enable its easy removal/replacement from the front.
e.
The terminal strips shall be fixed inside the preferably in a horizontal manner leaving enough space underneath the strip for termination of cables in a convenient manner. Power and control terminals shall be segregated. Power terminals blocks shall be separated from each other by means of replaceable insulated spacers. Terminal block shall have adequate clearance to avoid tracking. A minimum of 20% spare terminals block shall be provided in terminals strips.
f.
All equipments inside the shall have permanent identification labels in accordance with circuit diagram as also the power and control terminals. Terminal blocks shall be of robust and of such construction as to preclude possibility of cable connections getting loose during vibration on crane.
g.
Sheet steel used for fabrication of s shall have a minimum thickness of 2.0 mm. s shall be mounted such that bottom of is at least 150 mm above the floor. [11]
RRCAT/AMTD 50 MT EOT Crane Specification.
h.
or s shall be well braced to the crane structure and each shall be provided with adequate number of lifting lugs.
i. The control may be preferably Rittal / Elsteel / BCH make only. 11. Cabling work: a. All wiring for power control circuit shall be carried out with 1.1 KV grade Flame Retardant Low Smoke (FRLS) PVC insulated copper cables as per IS 694 and IS 1554 Pt. I with smoke index and typical index corresponding to ASTM-2843 & IEC332-I. b. Minimum size of cables shall be 4 mm2 for power and 2.5 mm2 for controls. c. All cables shall be systematically laid on G.I. trays or in cable drags of suitable type. d. All cables shall be of reputed make and approved ISI brands. e. CT cables of the crane shall run on cable drag chain. 12. Identification of circuit components: Labels of permanent nature shall be provided on s of all switches, fuses, ors, relays etc., to facilitate identification of circuits and their replacement. All s, controllers etc. shall be properly marked for each motion. All power control cables and other cables shall be ferruled at both ends as per cable numbers indicated in the supplier’s drawing. All equipment terminals shall also to be marked likewise. 13. Earthing of crane: Earthing to the crane shall be effected through track rails and crane structure. As such, all the electrical equipments mounted on crane shall be connected to the crane structure by means of earthing links. Equipments fed by flexible cables shall be earthed by means of spare core provided in the flexible cable. 14. Two numbers of fluorescent lamps of suitable rating shall be provided below the crane girder for lighting purpose during crane operation. VI. INSPECTION, ERECTION, COMMISSIONING AND PROVING TESTS (Acceptance Creteria): The crane shall be inspected & accepted as per this specification and other applicable standards. a. Inspection & tests shall be done on the crane during different stages of its manufacture, starting from raw-materials till its completion, by the Purchaser or his authorized representative at the supplier’s or his sub-supplier’s works. However, the purchaser or his authorized representative is free to institute any further checks, if he so desires. b. All electrical and mechanical equipment shall be tested in accordance with the appropriate Indian Standard at either the crane maker’s or equipment manufacturer’s works and test certificates provided if required by the Purchaser or his representative. c. The following points should be noted during erection and commissioning of the crane. 1. The contractor shall arrange erection and commissioning of the cranes. Adequate number of teams of technical experts will be made available so that erection and commissioning delays are eliminated. Such personnel will be required to be present immediately as soon as we call upon for erection after receipt of crane at our site and site preparedness. [12]
RRCAT/AMTD 50 MT EOT Crane Specification.
2. The contractor or his agent shall commission the crane within 60 days from the date of intimation by the consignee in respect of readiness of site/gantry etc. 3. The following items of work shall be performed by the Contractor. i. Fixing of rails on gantry girder at RRCAT site and checking the alignment of the same at site. ii. Installing of the crane structure and associated machinery in position. iii. Complete fitting and wiring of all electrical items. iv. Fixing of down shop leads. v. Commissioning of the equipment. The crane performance shall be demonstrated after successful commissioning. d.
Purchaser’s obligation with regard to erection & commissioning will be limited to the following: i. Unloading, transporting materials free of cost from the destination station at RRCAT to the work site at RRCAT and storing until taken over by the supplier for erection. ii. The following will be provided free of cost at the site of work. 1.
Electricity required for the purpose of erection/ lighting.
2.
Test loads with slings and tackles for performing the load tests.
3.
A stair case with railing with at least 3 landings for going up the gantry rails at RRCAT site (MFL building, near shutter) shall be provided.
e. The supplier shall transport major crane equipment in assembled modules (crab assembly, gear box assembly etc.) to RRCAT site for early errection & commissioning of the crane. f. Tests on Purchaser’s Premises: 1. The contractor shall carry out the start up and trial operation tests (commissioning test) on receipt of authorization from the Purchaser. In addition to tests indicated in IS: 3177(latest), the following shall also be carried out: i. The earthing of the crane and control equipment, to be tested as per Indian Electricity Rules. ii. The operation of brakes on LT, CT and hoisting motions with rated loads & speeds. iii. Inching control and speed as specified in table-1. iv. There is no skewness in crane during long travel and cross travel motions, presence of vibrations and unusual noise in operation. 2. The trials shall be carried out initially under no load conditions and on satisfactory completion of these, trials shall be repeated for various loads until the full rated load and operating speed range are covered. 3. During the trial operation, all necessary adjustments shall be made so as to ensure compliance with the operating characteristics of the complete equipment as stipulated in the technical specifications. [13]
RRCAT/AMTD 50 MT EOT Crane Specification.
4. Overload Test: All motions of the crane should be tested with 25% overload in which case the geared speeds need not be attained but the crane should show itself capable of dealing with the overload without any difficulty. 5. Deflection test: The deflection of the crane with maximum working load at rest and with the crab in central position, should be checked as per the applicable standard specification (latest IS 807 & 3177). VII. NOTE TO THE CRANE MANUFACTURERS / SUPPLIERS: 1. The quotations are invited and accepted only from crane manufacturers with ISO-9001- 2008 certification. The tenderer should provide satisfactory evidence, acceptable to the Purchaser, to prove that he is a licensed manufacturer and has adequate plant and manufacturing capacity /facilities and has a quality assurance programme. He should furnish a statement giving a list of similar EOT cranes of 40 MT capacities and above with min. 12 metre span and above supplied by him during the last 5 years, along with the Purchaser’s name and address, order number, date and quantity supplied, comments on their performance, and whether the supplies were made within the delivery period. In the absence of the above information, the tender is liable to be rejected. 2. The following should accompany the offer: a. General Arrangement (GA) drawing to scale (showing elevation, cross-section and plan of the crane) indicating clearances, hook approaches, lift, location and direction of view of operator, wheel base, wheel loads etc. of the crane being offered along with the quotation. Offer with generalized details is liable to be rejected. b. Submission of duly filled ‘Guaranteed Technical Particulars’ (technical data sheet) as per Annexure - II. c. Deviations from this specification, if any, with a comparative statement. d. The offer shall include all the transportation expenses of crane. e. The validity of offer shall be at least 3 months from the date of opening of tender. 3. Successful tenderer should furnish the following prior to manufacture of the crane for Purchaser’s approval. a. The GA drawings containing all information as described above clause 2.a. b. General layout drawing of the trolley. c. Assembly drawing -inclusive of gearbox details, individual drives like hoist, long travel and cross travel. d. Pendant controls with functional details. e. Circuit diagrams showing the wiring for the complete crane. f. Final design calculations for all motions, structure etc., and selection of bought out items should be submitted at the time of approval of GA drawings. g. Submission of a detailed quality assurance programme indicating QAP applicable at various stages of crane fabrication starting from raw material to final crane testing. [14]
RRCAT/AMTD 50 MT EOT Crane Specification.
4. The following should be provided. A CD containing all the documents / information recorded on it should also be supplied at the time of erection and commissioning of the crane. a. All the drawings approved by the purchaser along with all workshop drawings for structural, mechanical & electrical items containing full information such as assembly drawings/diagram showing the placement of components/parts along with make, rating & specification etc. b. Electrical circuit diagrams and catalogues of all electrical equipment. c. Operation & Maintenance manuals- 3 Sets. d. Maintenance schedule and lubricating charts. 5. The supplier should furnish material test certificates for all electrical equipment, cables, parts used in handling loads (e.g. wire ropes, chains, hooks etc.), structural steel, mechanical components such as couplings, gears boxes, rope drums, pulleys, shafts, wheels etc. 6. Spares: To be quoted separately for two years of maintenance. 7. Guarantee shall be provided for 24 months from the date of commissioning of crane. If during the guarantee period, the supplied equipment are found not manufactured to the specification and does not confirm to the standard of reliability, then the item shall be replaced/rectified by the supplier at his risk and cost within the reasonable period. 8. Pre-Dispatch inspection: The crane shall be inspected and tested at the manufacturer’s works. The material shall be dispatched only after approval and issue of shipping release. 9. Performance bond Bank guarantee: The supplier shall furnish a performance bond in the form of a Bank guarantee as per the format of Purchaser for 10% of the total value of the crane towards satisfactory performance of the same. The Bank guarantee should be valid till the expiry of the guarantee/warranty period and shall be submitted by the supplier before the shipment of the items to the Purchaser for scrutiny and to convey the acceptance to the supplier. 10. Training: Technical experts of the manufacturer during erection & commissioning of cranes will fully and adequately train operators / maintenance staff nominated by the Purchaser. VIII. DELIVERY SCHEDULE: The total completion period will be 12 months from the date of release of purchase order (P.O) and it includes the following milestones: S.No. Activity Completion date 1. General Arrangement drawing with complete details, design 2 months from the date calculations and approval from the Purchaser. of release of P.O. 2. Manufacturing, inspection and testing at manufacturer’s site 9 months from the date as per the specification and final delivery to RRCAT, Indore. of release of P.O. 3. Erection and performance testing of the crane at new 12 months from the date magnet fabrication building, RRCAT, Indore. of release of P.O. The accepted crane with all accessories will be delivered to: The Stores officer, IRP&SU, Raja Ramanna Centre for Advanced Technology (RRCAT), Indore – 452013, M.P., India. Encl.: Annexure I & II.
[15]
RRCAT/AMTD 50 MT EOT Crane Specification.
ANNEXURE - I.
W1
W1
C3
5800x11800
G-21
QP MEASUREMENT HORMONIC BENCH
1000 C/C
C3
A.H.U. ROOM
C2
W1
W1
W1
C3
C3
W1
W1
1050
1000 C/C
G-23
1000 C/C
D1
1000 C/C
C3
C3
G-20
5750
C4
C3
CMM BENCH
ROOM FOR CLEANING
4700
200 C/C
G-22
4550
W1
200 C/C
BEAM
1000 C/C
D1
1000 C/C
3500
200 C/C
PROPOSED 50T EOT CRANE
NO OBSTRUCTION ZONE
W1
W1 D1
C2
1200
C2
C4
C3
CMM BENCH
W1
A.H.U. ROOM
C2
C4
C3
350
G-19 W1
W1
11500 10800
700
D1
630 C2
C4
12200
D1
700
W1
W1 11800x5800
C2
C4
C3
B
G-18
B
W1
W1
1500
1500
C2
C4
C3
F-23
CORRIDOR
G-18
2000
6000
W1
W1
CORRIDOR
D1 C2
C4
1500
D6
D6
C4
C3
C2
C4
W1
W1
C3
8500
C3
C3 D6
C3
AL1 GATE
8500
V1
V1
V1
V1
W1
G-17
9700
D1
W1 7800x5800
D5
D5
C3
C3
C3
C3
C2
AL1
W1
C3
C3
C2
C4
C3 3800x5800
W1
W1
G-27 D1
MS COLLAPSABLE GATE
AL1 C3
C2
C4 D1 7800x5800
G-26
4800
C4
C3
C2
C4
W1
W1
C3
WIDE ROAD 3700mm
1000
W1
W1
W2
C1 C2
C1
13000
ALL DIMENSIONS ARE IN MM. SECTION `B-B'
N
RRCAT/AMTD 50 MT EOT Crane Specification.
ANNEXURE -II.
Guaranteed Technical Particulars (Technical data sheet to be submitted with the tender by manufacturer)
S.No.
Description
Unit
1.0.0
GENERAL
1.1.0
Manufacturer
1.2.0
Type/ Model
1.3.0
Quantity
1.4.0
Design according to standard service class/ load class
1.5.0
Nominal load carrying capacity (SWL)
1.6.0
Span
M
1.7.0
Highest position of hook
M
1.8.0
Lowest position of hook
M
1.9.0
Lifting Sling length
M
2.0.0
SPEEDS
2.1.0
Long travelling speed
2.2.0 2.3.0
MT
Main Creep
M/min M/min
Main Creep
M/min M/min
Main Creep
M/min M/min
Cross travelling speed Hoisting speed
3.0.0
Location (Indoor/ Outdoor)
4.0.0
Clearances and Hook approaches as per Tender (If no, specify)
Data
RRCAT/AMTD 50 MT EOT Crane Specification.
S.No.
Description
Unit
5.0.0
Type of control proposed
6.0.0
Gantry Rail Size
7.0.0
CONSTRUCTIONAL FEATURES
7.1.0
Weight of complete crane unladen
MT
7.2.0
Wt. of Trolley/Crab
MT
7.3.0
Weight of hoist unladen
MT
7.4.0
Weight of each end carriage
MT
7.5.0
Weight of girder
MT
7.6.0
Wt. of all electrical
MT
7.7.0
Maximum wheel load
MT
7.8.0
Wheel loading diagram furnished
8.0.0
HOISTING SYSTEM
8.1.0
Rope
8.1.1
Rope diameter mm
8.1.2
Rope construction
8.1.3
Rope quality (material)
8.1.4
Rope strength
8.1.5
Number of rope falls
8.1.6
Factor of safety
8.1.7
Rope drum
8.2.0
Drum diameter and length
8.2.1
Drum material
kg/mm²
mm
[ii]
Data
RRCAT/AMTD 50 MT EOT Crane Specification.
S.No.
Description
Unit
8.2.2
Whether stress relieved
8.2.3
Bearing type/ make
8.3.0
Hook
8.3.1
Hook type
8.3.2
Hook material
8.3.3
Safety latches provided
8.4.0
Sheaves
8.4.1
Lower sheave diameter
8.4.2
Lower sheave material
8.4.3
Equalizing sheave diameter
8.5.0
Hoist Brake
8.5.1
Type
8.5.2
Make
8.5.3
Size
mm
8.5.4
Torque
Nm
8.6.0
Brake Drum
8.6.1
Material
8.6.2
Width
8.6.3
Coupling type
8.6.4
Gear box input
8.6.5
Gear box output
8.6.6
Material of gears
8.6.7
Material of pinions
8.6.8
Type of gears/pinions
mm
mm
mm
[iii]
Data
RRCAT/AMTD 50 MT EOT Crane Specification.
S.No.
Description
Unit
8.7.0
Limit Switch
8.7.1
Numbers
8.7.2
Type
8.7.3
Make
9.0.0
CROSS TRAVEL
9.1.0
CT brake
9.1.1
Type
9.1.2
Make
9.1.3
Size
mm
9.1.4
Torque
Nm
9.2.0
Brake Drum
9.2.1
Material
9.2.2
Width
9.3.0
Coupling type
9.3.1
Gear box
9.3.2
Gear box input
9.3.3
Gear box output
9.3.4
Material of gears
9.3.5
Material of pinion
9.3.6
Type of gears/pinion
9.4.0
Wheels
9.4.1
Materials
9.4.2
Hardness
mm
BHN [iv]
Data
RRCAT/AMTD 50 MT EOT Crane Specification.
S.No.
Description
9.4.3
Type
9.4.4
Diameter
9.4.5
Wheel bearing type/ make
9.5.0
Limit switches
9.5.1
Number
9.5.2
Type
9.5.3
Make
9.6.0
Type of Stoppers
9.7.0
Number of driven wheels
9.8.0
Number of total wheels
10.0.0
LONG TRAVEL
10.1.0
End carriage length
10.2.0
Coupling type
10.2.1
Gear box
10.2.2
Gear box input
10.2.3
Gear box output
10.2.4
Material of gears
10.2.5
Material of pinion
10.2.6
Type of gears/pinion
10.3.0
LT brakes
10.3.1
Type
10.3.2
Make
10.3.3
Size
10.3.4
Torque
Unit
mm
mm
Nm [v]
Data
RRCAT/AMTD 50 MT EOT Crane Specification.
S.No.
Description
10.4.0
Brake Drum
10.4.1
Material
10.4.2
Width
10.5.0
Wheels
10.5.1
Materials
10.5.2
Hardness
10.5.3
Type
10.5.4
Diameter
10.5.5
Wheel bearing type/ make
10.6.0
Limit switches
10.6.1
Number
10.6.2
Type
10.6.3
Make
10.7.0
Type of Stoppers
10.8.0
Number of driven wheels
10.9.0
Number of total wheels
11.0.0
MOTOR (To be filled separately for each main and creep motor)
11.1.0
General
11.1.1
Make
11.1.2
Type
11.1.3
Number
11.2.0
Rating
Unit
Data
mm
BHN
mm
Hoist
Main
[vi]
Creep
Bridge Travel
Trolley Travel
Main
Main
Creep
Creep
RRCAT/AMTD 50 MT EOT Crane Specification.
S.No.
Description
11.2.1
Rating : kW at 50°C Time CDF
11.2.2
Permissible Starts/Hr.
11.2.3
Voltage-phase, frequency
11.2.4
Rated current
11.2.5
Rated torque
Unit
Data
Nm
i) Starting ii) Braking 11.2.6
15% margin for motor ratings considered
12.0.0
CRANE CONTROL
12.1.0
Type
12.2.0
Inching Speed Control
12.2.1
Inching speed in % full load speed
12.2.2
Detailed write-up furnished on inching speed control
12.2.3
Individual control furnished for all crane motions?
12.2.4
Detailed write-up on speed control furnished?
NOTE: If above clauses are found inadequate for furnishing all necessary information of the crane offered, the supplier may append further information separately.
Signature of the Tenderer [vii]
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