COMPREHENSIVE REPAIR/ MAINTENANCE OF EOT/HOT CRANES INSTALLED AT SITE E NAD/VAJRAKOSH AN SITE A AND ELECTRICALLY OPERATED HANGER DOORS AND OTHER ALLIED WORKS UNDER GE(SB) KARWAR

Servicing, repairs and maintenance of electrically operated overhead travelling cranes (EOT) and hand operated travelling cranes (HOT), single/double girder type, including electric motors for long travel, cross travel and hoist motions (including creep/micro-speed), electrical control panel with MCCBs/main switches, step-down transformer, contactors, HRC fuses, and complete mechanical system comprising wire rope with drum, brake unit, gear boxes with checking/topping up of oil level, end carriage/lathe works, all electrical control cables and connected accessories, for smooth and trouble-free operation, to be carried out by skilled service engineer/mechanic at intervals of 30 (Thirty) days (minimum once in a month), complete all as specified and as directed by Engineer-in-Charge for the following capacities:-

1 Ton Hand operated crane (total 02 No) installed at Warhead Joint Booster building at Vajrakosh area. & MEWR-motor overhauling sec in NSRY area

2 Ton HOT crane (total 04 No) installed at NSRY area (MEWR, MEWR-General Engine, MEWR-R & AC & MEWR-TTS store)

2 Ton FLP EOT crane (total 05 No) installed at L1 building at Vajrakosh area & 04 cranes in NSRY area ( MEWR-weapons, MEWR-chemical plant, MEWR-motor overhauling sec & Yard utility bldg)

3 Ton Hand operated crane (total 02 Nos) installed at HTL AC & HTL Non AC store buildings at NAD area.

5 Ton Hand operated crane (total 04 Nos) installed at Fuel storage-I & Fuel storage-II buildings at Vajrakosh area & MEWR (GE store) & FAB (Rigger section) buildings in NSRY area

5 Ton FLP EOT crane (total 19 Nos) installed at buildings L3 -02 No's. L4 -2 Nos, L5 -2 Nos, L6 -2 No's. L8 -3 Nos , L10 -01 No at Vajrakosh area , DBM -3,4,5 & 6 in NAD area & YAS , MEWR & Shiplift Main pump house bldg in NSRY area.

6 Ton FLP EOT crane (total 08 No's.) installed at IGLOO-II, IGLOO-IV, DBM-store buildings at NAD and PMS, Technical store, Prep-I, Prep-II, SSM store buildings at Vajrakosh.

10 Ton FLP EOT cranes (total 17 No's.) installed at building No's. L1-02 No's. L2-02 Nos, L7-01 No. L11-01 No, B1 to B6(one No crane in each bldg) at Vajrakosh area , 01 No crane in Material organization bldg & 04 cranes in NSRY area (outfitting dept, FAB dept. MEWR(E) & MEWR(L&W) at Naval Base Karwar.

250 kg mono rail (total 01 No) installed at L9 building at Vajrakosh area.

(e) The monthly servicing shall include, inter alia: (i) Cleaning/dust removal of crane and panel. (ii) Checking hoist (MH), cross travel (CT) and long travel (LT) gear oil level and topping up where required. (iii) Grease topping up for CT/LT mechanisms as required. (iv) Lubrication of bottom block sheaves and wire rope. (v) Checking and setting of MH/CT/LT brakes. (vi) Visual inspection of busbar for bending, damage, looseness or displacement. (vii) Ensuring proper mounting/engagement of current collector. (viii) Checking terminals for loose connections; tightening as required. (ix) Ensuring earthing continuity and that earthing points are not corroded/disconnected. (x) Checking for abnormal noise/vibration and rectification of minor causes. (xi) Checking limit switches for physical damage and proper operation; rectification/adjustment as required. (xii) Removal of foreign objects/obstructions on rails. (xiii) Checking hook rotation and free movement. (xiv) Checking pulleys for free rotation and alignment. (xv) Checking wire rope condition for dirt accumulation, bird-caging, excessive wear and other visible defects; taking necessary action as directed. (f)The contractor shall maintain (i) a monthly maintenance register and (ii) a complaint/breakdown register for each crane, and submit the same to the Engineer-in-Charge by the 3rd working day of each month, without fail.

M&L for conducting load testing of overhead travelling cranes (EOT/HOT) with standard test load up to1.25 times of the safe working load, as required under applicable Factory Rules/approved practice and as directed, including arranging and handling of test weights at site, carrying out load test and functional checks in the presence of the Inspector/Competent Authority, obtaining certification/test certificate from the Department of Factories, Boilers, Industrial Safety & Health, Government of Karnataka (or other competent statutory authority as applicable), and submitting test report/certificate in the prescribed format for each crane, complete all as specified and directed, for the following capacities/locations :-

1 Ton Hand operated crane (total 02 No) installed at Warhead Joint Booster building at Vajrakosh area. & MEWR-motor overhauling sec in NSRY area.

2 Ton HOT crane (total 04 No) installed at NSRY area (MEWR, MEWR-General Engine, MEWR-R & AC & MEWR-TTS store)

2 Ton FLP EOT crane (total 05 No) installed at L1 building at Vajrakosh area & 04 cranes in NSRY area ( MEWR-weapons, MEWR-chemical plant, MEWR-motor overhauling sec & Yard utility bldg)

3 Ton Hand operated crane (total 02 Nos) installed at HTL AC & HTL Non AC store buildings at NAD area.

5 Ton Hand operated crane (total 04 Nos) installed at Fuel storage-I & Fuel storage-II buildings at Vajrakosh area & MEWR (GE store) & FAB (Rigger section) buildings in NSRY area

5 Ton FLP EOT crane (total 19 Nos) installed at buildings L3 -02 No's. L4 -2 Nos, L5 -2 Nos, L6 -2 No's. L8 -3 Nos , L10 -01 No at Vajrakosh area , DBM -3,4,5 & 6 in NAD area & YAS , MEWR & Shiplift Main pump house bldg in NSRY area.

6 Ton FLP EOT crane (total 08 No's.) installed at IGLOO-II, IGLOO-IV, DBM-store buildings at NAD and PMS, Technical store, Prep-I, Prep-II, SSM store buildings at Vajrakosh.

10 Ton FLP EOT cranes (total 17 No's.) installed at building No's. L1-02 No's. L2-02 Nos, L7-01 No. L11-01 No, B1 to B6(one No crane in each bldg) at Vajrakosh area , 01 No crane in Material organization bldg & 04 cranes in NSRY area (outfitting dept, FAB dept. MEWR(E) & MEWR(L&W) at Naval Base Karwar.

250 kg mono rail (total 01 No) installed at L9 building at Vajrakosh area.

Supply and fix in repairs power contactor of 9 to 40 amps with AC coil voltage 110 volts complete all as specified and as directed.

Material & Labour required for alignment cross travel and long travel of EOT crane of capacity upto 10 Ton with the railings and rectification of any misalignment during CT/LT movement of the crane at various locations of the Naval base Karwar complete all as specified and as directed.

Supply and fix in repairs slide liner type copper current collector as per existing capacity (100 - 400 Amps) and as per phase colour coding suitable for EOT Crane shrouded DLS Busbar system of cranes complete as specified and as directed

Supply & fixing in repairs shrouded DLS copper busbar system of as per existing current carrying capacity ,size and as per phase wise colour coding including hanger, joint nut bolt clip with joint cover complete all as specified and directed. The bus bar shoule be properly insulated with high grade insulation for 1100 Volts 3 Phase power supply all as specified and directed.

Material and labour for rewinding of transformer mounted in control panel of existing capacity suitable for EOT crane upto 10 Ton capacity complete all as specified and as directed.

Supply & Fix in repair 90 watts LED round type of aluminium pressure die cast material, IP 55 rating suitable for crane roof capacity complete all as specified and directed.

Material & Labour required for repairs of cable trolley all size/type of 6 Ton capacity crane complete all as specified and as directed.

Supply & Fix in repairs CT limit switch two way lever type, 3 phase, 415 volts, 50Hz for EOT crane of any capacity complete all as specified and directed.

Supply & Fix in repairs LT limit switch two way lever type, 3 phase, 415 volts, 50Hz for EOT crane of any capacity complete all as specified and directed.

Supply & Fix in repairs Rotary gear limit switch of aluminium dia cast body, 3 Phase, 415 volts, 50 Hz, rating of IP 55 confirming to IS: 60529 (2001), adjustable type, suitable for EOT crane of any type and capacity complete all as specified and directed.

Supply & Fix in repairs counter weight/gravity limit switch of aluminium dia cast body, 3 Phase, 415 volts, 50 Hz, rating of IP 55 confirming to IS, adjustable type, suitable for EOT crane of any type and capacity complete all as specified and directed.

Supply and fix in repair LT motion chain guard fixed in between LT shaft and LT motion wheel to prevent the slippage of LT chain from the wheel complete all as specified and directed.

M&L for strip opening of 10 HP, 3-phase, 415V electric motor of any make, thorough cleaning of internal parts, replacement of unserviceable minor parts such as nuts/bolts etc., replacing/servicing bearings and greasing as required, and rewinding with same size and class copper winding wire, including re-insulation with shellac varnish, drying in hot air oven, reassembling and complete testing for continuity and insulation resistance, including electrical disconnection, dismantling, lowering, transportation to workshop and re-installation in position, complete all as specified and as directed. Notes: (i) The unit rate quoted shall be deemed to include electrical disconnection, dismantling, transportation to workshop, repairs and re-installation in position. (ii) Replacement of bush and bearing, if required, shall be measured and paid separately under the relevant item(s) of Schedule.

All as per item No. 15 here in before, but for 7.5 HP motor

All as per item No. 15 here in before, but for 1 to 2 HP motor

M&L for dismantling/removing and taking down the gear box assembly of main hoist for crane of capacity 10 ton, and overhauling the gear box including replacement of worn-out gear wheel/unit complete with new one matching to existing system, replacement of defective bearings, oil seals, gear coupling etc., and thereafter re-assembling, re-fixing and aligning the gear box assembly back to the system, complete all as specified and as directed. Note: Replacement of bush and bearing shall be measured and paid separately under the relevant item(s) of Schedule.

All as per item No.18 here in before, but for crane of 6 tonne capacity

All as per item No.18 here in before, but for crane of 5 tonne capacity.

All as per item No.18 here in before, but for crane of 3 tonne capacity.

All as per item No.18 here in before, but for crane of 2 tonne capacity.

All as per item No.18 here in before, but for crane of 1 tonne capacity.

Supply and fix in repair New VFD drive power module suitable for 5.0 / 7.5 KW motor load for cranes including taking out old unsv VFD drive complete all as specified and as directed.

M&L for dismantling and taking down unserviceable wire rope from single/double girder EOT crane(s) and supply and fix in repairs galvanised steel wire rope, flexible, preformed, multi-strand and fully lubricated, of size and construction as per existing, conforming to relevant IS, including reeving through drum/sheaves, providing and fixing all necessary end terminations and accessories such as thimbles, sockets/ferrules, rope clips/clamps, wedges, pins etc. as applicable, tensioning and aligning, trimming and seizing of rope ends, greasing, testing and commissioning to ensure smooth and safe operation, for EOT crane(s) of capacity up to 10 tonne installed at a height not exceeding 6.0 m above ground level, complete all as specified and as directed, for the following sizes:-

wire rope 8/10 mm dia as per site requirement.

wire rope 12/14 mm dia as per site requirement.

Supply and fix in repair MCCB 100 Amps 3 pole 415 volts 50 Hz, thermal release range 48 to 63 amps breaking capacity complete all as specified and as directed.

Supply & fix in repair of Intrinsically safe unit of 110 V / 12 Volts for Hoist/LT/CT motion of crane of existing make all as specified and as directed.

Supply & fix in repair of Intrinsically safe unit of 110 V / 24 Volts for Hoist/LT/CT motion of crane of existing make all as specified and as directed.

Supply & fix in repairs automatic controlling limit switch/ position switch metal enclosure 1NO/2NC slow action contacts plain plunger suitable for cranes all as specified and as directed

M&L for painting to steel surfaces of HOT cranes of capacity up to 5 ton, including cable trays and crane panel board at NAD/Vajrakosh/MO/NSRY, with one coat of synthetic enamel paint of approved shade by spray gun over existing surfaces, including preparation of surfaces by cleaning/removing dust, dirt and loose matter etc., and including writing nomenclature in block letters, and providing necessary scaffolding/arrangements to reach the crane, complete all as specified and as directed

M&L of painting to steel surfaces of double girder or single girder EOT cranes up to 5 ton capacity including cable trays, panel board of crane at NAD/Vajrakosh/MO/NSRY, with one coat of synthetic enamel paint of approved shade using spray gun as per existing including cleaning/removing, dust, dirt etc including writing in block letter its nomenclature and making arrangements of scaffolding to reach the crane complete all as specified and as directed .

M&L for painting to steel surfaces of single girder/double girder EOT cranes of capacity up to 5 ton, including cable trays and crane panel board at NAD/Vajrakosh/MO/NSRY, with one coat of synthetic enamel paint of approved shade by spray gun over existing surfaces, including preparation of surfaces by cleaning/removing dust, dirt, loose matter etc., and including writing crane nomenclature in block letters, and providing necessary scaffolding/arrangements to reach the crane, complete all as specified and as directed

Supply and fix in repair flexible copper cable 3 core 1.5 sqmm PVC insulated and sheathed of 1100 volts grade multistranded in box girder between control panel to all motors and break cylinders for EOT crane complete all as specified and as directed.

Supply and fix in repair flexible copper cable 4 core 6 sqmm PVC insulated and sheathed of 1100 volts grade multistranded for provide supply from main incoming power supply to control panel box for EOT crane complete all as specified and as directed.

Supply and fix in repair flexible FLP copper cable 4 core 6 sqmm PVC insulated and sheathed of 1100 volts grade multistranded for provide supply from main incoming power supply to control panel box for flame proof EOT crane complete all as specified and as directed.

Supply and fix in repair flexible FLP copper cable 4 core 4 sqmm PVC insulated and sheathed of 1100 volts grade multistranded for provide supply from main incoming power supply to control panel box for flame proof EOT crane complete all as specified and as directed.

Supply and fix in repair flexible copper cable 12 core 1.5 sqmm PVC insulated and sheathed of 1100 volts grade multistranded in box girder between control panel to all motors and break cylinders for EOT crane complete all as specified and as directed.

Supply and fix in repair Metal housing anti collision device of single no set point for EOT crane as per existing make and capacity all as specified and directed.

Supply and fix in repairs electro-hydraulic thrust brake suitable for brake drum diameter 100 mm to 600 mm (as per existing), shoe width 70 mm, thrust 18 kg, stroke as per existing, 3-phase, 400/440 volts, 150 watt, braking torque as per existing, weight 9 Kg (max) and maximum number of operations 360 per hour, complete all as specified and as directed

All as per item No.39.00 above but 34 Kg.

Supply and fix in repairs electro-magnetic brake suitable for brake drum diameter 200 mm/150 mm/100 mm (as per existing), shoe width 70 mm, thrust 18 kg, stroke as per existing, 3-phase, 400/440 volts, 165 watt, thrust limit 2 KVA, and maximum number of operations 240 per hour, complete all as specified and as directed

M&L for Repair of FLP Track Wheel upto 10 Ton capacity FLP EOT crane as per sample passed including transportation charge and repairing cost complete all as per directed.

Supply & fix in repairs 10/12 station pendent non flame/flame proof of EOT crane having push button and rotary switch for light/hooter including power indication lamp metallic body complete all as specified and as directed.

Supply & fix in repairs 16/18 station pendent non flame/flame proof of EOT crane having push button and rotary switch for light/hooter including emergency push button and power indication lamp metallic body complete all as specified and as directed.

Supply & fix in repairs 8 station pendent non flame or flame proof of EOT crane having push button and rotary switch for light/hooter including emergency push button and power indication lamp metallic body complete all as specified and as directed.

Supply and fix in repair LT motion wheel complete suitable upto 10 Ton capacity HOT crane complete all as specified and as directed by Engr-in-charge.

Supply and fix in repair triple spur gear chain pulley block (hand operative) capacity of 1/2 Ton maximum hook 5-6 mtr on from ground travel suitable for operation from floor including test certificate complete all as specified and as directed.

Supply and fix in repair triple spur gear chain pulley block (hand operative) capacity of 3/5 Ton maximum hook 5-6 mtr on from ground travel suitable for operation from floor including test certificate complete all as specified and as directed.

Supply & Fixing in repairs Limit Switch, modular plug-in operating heads and bodies type all as specified and as directed.

Supply & Fixing in repairs SMPS (switched mode power supply), single phase input 100-240 Volts 1.5 Amps, 50/60 Hz & output 24 Volts DC complete all as specified and as directed.

Supply and fixing in repairs safety relay, dual channel main unit, with 2 NO safety outputs and 2 NO delayed safety outputs (output delay adjustable 0.1 to 30 seconds), with NC signal output, suitable for 24V DC control voltage, for monitoring signals from safety devices and ensuring quick switch-off in emergency, having safety ratings conforming to EN 954-1, EN ISO 13849-1 up to PL e, and IEC 62061 up to SIL CL, complete all as specified and as directed

Supply & Fixing in repairs heavy duty fuse suitable for electrically operated door panel complete all as specified and as directed

Supply & Fix in repairs pendant cable trolley complete all as specified and as directed.

Supply & Fix in repairs pendant cable trolley 'C' rail complete all as specified and as directed.

Supply and fix in repair brake drum of 100mm to 600mm as per existing type suitable for EOT crane capacity of 5/6/10 ton complete all as specified and directed.

Supply and fix in repair brake liner shoe with lining including hinger pin and brake shoe backstep as per existing type and make suitable for thruster brake of 3 to 10 ton EOT crane complete all as specified and directed.

Supply and fix in repair mild steel hot rolled EOT crane rope guide set (05 nos each set) surrounded of the rope drum suitable upto 5 ton capacity crane including all connected accessories complete all as specified and directed.

Supply and fix in repair mild steel hot rolled EOT crane rope guide set (05 nos each set) surrounded of the rope drum suitable for 6 to 10 ton capacity crane including all connected accessories complete all as specified and directed.

Supply and fix in repair Motor for thrust brake of EOT crane all as specified and directed.

Supply and fix in repair 1.5 Sqmm, 4 core round copper cable for EOT crane all as specified and directed.

Supply and fix in repair 1.0 Sqmm, 8 core round copper cable for EOT crane all as specified and directed.

Supply & Fixing in repairs door magnetic detection sensors for feedback of blast doors functions internal reed switch in conjunction with a magnet complete all as specified and as directed

Supply and fixing in repairs Variable Frequency Drive (VFD) suitable for 1.1 kW motor, having input rating AC single phase, 200–240 V, 50/60 Hz, with current rating 13.8 A / 4.0 A, and output rating AC three phase, 0–440 V, frequency 0–400 Hz, with current rating 6.0 A / 5.0 A, complete all as specified and as directed

Supply & Fixing in repairs key pad with electronic lock PCB plate complete all as specified and as directed.

Supply & Fix in repairs contactor 3 pole, 15 amps miniature contactor with 1 normally closed base contact and a 24 volt DC rated coil , for 3/5 Hp @ 230/460 volts 3 phase complete all as specified and as directed.

Supply & Fix in repairs Gear Box of make Motrvento 6473/37-026L.7, with hydraulic oil of grade 52 complete with all accessories all as specified and as directed.

Supply & fix in repairs gear box supporting plate complete all as specified and as directed.

Supply & fix in repairs lock drum type cylinder lock with euro profile and alteration complete all as specified and as directed.

Supply & fix in repairs motor of capacity 0.75/0.90 KW, amps rating - 3.04, voltage 240-280/ 420 volts complete all as specified and as directed.

Supply & Fixing in repairs programmable logical control expansion module unit (expansion module) of Make - Eaton or equivalent complete all as specified and as directed.

Supply & Fix in repairs programmable logical control unit (PLC module) of Make- Eaton or equivalent complete all as specified and as directed.

Supply & fix in repairs thrust bearing 81112T2 NTN complete all as specified and as directed.

Supply and fix in repair bearing for motor upto 10 HP capacity complete all as specified and as directed.

Supply and fix in repair Mild steel gear shaft below 5 Ton capacity EOT crane as per existing complete all as specified and as directed.

Supply and fix in repair Mild steel gear shaft for 5 to 10 Ton capacity EOT crane as per existing complete all as specified and as directed.

Supply and fix in repair Main hoist driven pinion for 2 ton to 5 ton crane as per existing type and make complete all as specified and as directed.

Supply and fix in repair Hoist gear pinion as per existing type and make complete all as specified and as directed.

Supply and fix in repair Gear coupling for LT as per existing type and make suitable for below 6 ton EOT crane complete all as specified and as directed.

Supply and fix in repair Gear coupling for LT as per existing type and make suitable for 6 to 10 ton EOT crane complete all as specified and as directed.

M&L for servicing, repairs and maintenance of electrically operated doors of hangars / magazine buildings / workshop hangars at NAD, Vajrakosh and NARY, comprising electric motor, electrical control panel, MCCBs/main switch(es), step-down transformer, contactors, HRC fuses, mechanical wire rope with drum, brake unit, gear box(es), checking/maintaining oil level, attending motor bed/end carriage and allied mechanical works, electrical control cables etc., including complete overhauling, greasing and oiling for smooth operation, by skilled service engineer/mechanic, complete all as specified and as directed

Labour for attending emergency breakdown (during periods other than routine fortnightly/monthly/quarterly servicing/repair/maintenance, as applicable) by skilled service engineer/technician, and making the EOT/HOT crane functional within 03 (three) days of reporting of defect by the Engineer-in-Charge, including replacement/rectification of defective parts (as directed) for EOT/HOT cranes installed at Vajrakosh, NAD Complex (Site ‘E’), NSRY area and MO Complex (Site ‘A’), complete all as specified and as directed. Notes/Conditions: (i) M&L for periodical maintenance such as oiling/greasing etc. shall be carried out as per manufacturer’s recommendations and as directed. (ii) All spares to be replaced by the contractor shall be of specified make or as recommended by the manufacturer. (iii) All spares supplied/replaced shall be measured and paid separately under relevant items of this Schedule. (iv) Technician/Mechanic shall possess requisite qualification with minimum 02 years’ experience from recognised ITI/NCVT (or equivalent) in Electrical/Mechanical trade. (v) Servicing/repair of cranes shall be carried out by qualified tradesmen/technicians having minimum 05 years’ experience in repair/servicing of cranes. (vi) Contractor shall furnish service report on satisfactory completion of service/maintenance of all cranes, duly signed by respective unit in-charge after every visit, and submit the same to the Engineer-in-Charge for verification.

Supply and fix in repairs main hoist panel box as per existing, including phase preventer, contactor(s), indicating lamps, internal wiring/termination with copper cable connections and all connected accessories, suitable for EOT crane up to 10 ton capacity, complete all as specified and as directed

Material and labour for dismantling and taking down old defective hook and supply and fix in repairs high tensile mild steel lifting hoist hook complete with safety latch/lock pin, paint coated finish, proof load 1.25 times the safe working load (SWL)/maximum load, conforming to relevant IS, suitable for single/double girder EOT crane of capacity up to 10 ton, complete all as specified and as directed

Supply and fix in repairs thermal overload relay suitable for motors of capacity 3.0 kW to 10.0 kW, with AC coil/control voltage 110 volts, complete all as specified and as directed

Supply only gear oil of Grade 140 for topping up all as specified and as directed.

Supply only gear oil of Grade 68 for topping up all as specified and as directed.

Supply and fix ball bearing for gear box complete all as specified and directed.

Supply only low viscosity transformer oil for making up/topping up oil deficiency in transformer, complete all as specified and as directed

Note for Item No's. 03 to 90 :- The make of spare parts/accessories to be provided under these items shall be the same as the existing make, wherever available. In case the existing make is discontinued, not manufactured, or not readily available due to small quantity/availability constraints, spare parts/accessories of other approved standard makes, compatible with the existing system and ensuring proper fit, function and performance, shall be provided as approved by the Garrison Engineer

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