CERTAIN REPAIRS AND MAINTENANCE OF VARIOUS EOT CRANES INSTALLED AT EME WORKSHOP AND MH KHADKI UNDER GE MH AND RH KHADKI

Amount

Part-I Comprehensive manitainence and repairs to Cranes. Material and labour for servicing of over head traveling crane complete including checking / tighting of all nut , bolt & breaks complete system, adjusting etc of all breakes motions and VFD adjustment setting as per load testing run of flame proof / non flame proof/ normal type EOT cranes with having single or double girder type and providing greasing & oiling of travening / moving parts of crane with connecting motor girder parts for movment of crane hoist / long / cross traveling and including maintaining the controlling of speed / creeping micro speed of motors with checking / Adjusting / minor maint / repair to the electrically operated main control panel wire with connecting control wiring system consisting of main switch, step down transformer, contactor, HRC fuse, VFD, PLR, control pendent, wire rope with break drum unit, gear box unit , oil levels, motor bed / foot , electrical control cable, motor terminal, end cable carriage trolly,motor shaft, bush flange bearing with lathe work, chain pully block, rachet cluch, gear block, chain wheel, chain etc and including locating the defect/fault and rectification of the fault and rectification of oil leakage etc and replacement of defective nut, bolt & washer and making it sound proof and after trails testing run of crane for smooth functioning / operation for the following mentioned capacity cranes complete all as specified and directed.

EOT crane of capacity 02 Ton at Station workshop EME Aundh Camp / MH Khakdi

EOT crane of capacity 05 Ton at Station / Static workshop EME Khadki

EOT crane of capacity 10 Ton at Station / Static workshop EME Khadki

Note : Periodic inspection/servicing, to be carried out in every three months and making/keeping the cranes serviceable, for EOT cranes of rating load 1 Ton to 10 Ton capacity installed in various locations, including the properly checks as mentioned below:- (i) LONG TRAVEL MOTION AND CROSS TRAVEL MOTION (a) Checking Gear box oil level and filling with required oil and rectification of leakages if any. (b) Brake adjustment (c) Checking of long travel & cross travel wheel for any noise / mal functioning. (d) Checking grease of geared couplings, complete nut, bolt work for tightening and replacement of grease nipple. (e) Checking of oil in Hydraulic thruster brake, rectification of leakages if any and filling with required quantity of oil. (f) Checking of electric motor connections, insulation resistance value etc (g) Checking the cut-off at extreme ends with the limit switch. (j) Checking and greasing of shaft pedestal.

(ii) HOIST MOTION (a) Checking gear box oil level and filling with required oil and rectification of leakages if any.(Note: Gear Oil shall be measured and paid separately as supply only) (b) Brake adjustment (c) Checking of main bearings of the rope drum including greasing the same (d) Checking grease of geared couplings and nut tightening. (e) Checking of oil in hydraulic thruster brake, rectification of leakages if any and filling with required quantity of oil.

(f) Checking of electric motor connections, insulation resistance value. (g) Checking wire rope for any damage & greasing the rope. (h) Adjustment of the rotary limit switch. (j) Checking of bearing of the hook and greasing the same. (iii) ELECTRICAL PANEL (a) Checking the contactors for overheating or flashing. (b) General checking of contacts and connections. (c) Cleaning of control panels and checking of connections. (d) Checking of connections of VVVF drives/other drive, calibrating VVVF drive and PLC to get smooth movement & maximum efficiency / other drives for smooth functioning of the same. (e) checking the serviceability of cable including power/control cable, checking the serviceability of cable carrier/cable trolleys ,adjusting as possible to get maximum free for movement of moving part/ Aprons of EOT cranes (iv) DOWN SHOP LEAD (a) Checking the alignment and rectification. (b) Cleaning of the moving/sliding objects.

(v) GROUND MOTION CONTROL PANEL (a) Checking function ability of motion push buttons, function lock key operated switch, "ON &OFF", lamps. Note: 1.Periodic inspection/servicing shall be carried out by authorized service engineers/ agencies, without any disturbance of movement/ operation schedule of bldgs as approved by Accepting officer. 2.All expenditure for minor material & labour, T&P shall deemed to be included in quoted amount. 3. Major materials shall be measured and paid separately under relevant items of schedule 'A'.

Note :- (i) Servicing, adjusting etc of brakes motions and testing run work will be carried out by well qualified techanician having good experience in repairing field Of EOT cranes or as approved by GE or Engineer-in-Charge. (ii) It is personal resposibily / liabality of contractor for smooth function of crane for 6 month after the handing / taking over the all site with out any extra cost to department. (iii) Contractor shall immediately depute suitable nos of trade mans to attend the complaints on required basis for finding unserviceable cranes with in the effected time after lauching of complain all as specified and directed by Engineer-in-Charge. (iv) Major repair / replacement of items will be paid separately

Providing material and labour for load testing of over head traviling crane of following capacity EOT crane as per manufacture norm for safe working rating load including arrangment of dead load measurement unit with link steel wire rope and requred suitable load for testing with duly varying the load upto 110% of the rated capacity load test certificate in triplicate set from authorised crane inspector duly signed by inspector authority of crane complete all as specified and directed Note : Recovery of Rs 10,000/- per crane will be effected for non compliance of the job during the contract period.

EOT crane of capacity upto 05 Ton at Station workshop EME Khadki and Aundh Camp

EOT crane of capacity 10 Ton at Station workshop EME Khadki

Dismantling and removing of old Mild Steel 3 phase bus bars of any size/type including brackets, insulators etc from the height of 25 fts by gas cutting and taking it down carefully with the help of chain pulley block etc complete all as directed. Note :- Necessary safty measures for labours and tools/plant to be taken by the contractor while dismantling and refixing of busbar from the height specified.

Supply and fix in repair shrouded conductors with PVC sleaves RYBG, spices covers, hanger clamps, anchor clamps, power feed kit and caps, joining tool complete for 100 Amps GI conductor system busbar, including MS fabricated support for mounting of conductors made out of mild steel angle ( Fe-410-W,grade E-250,quality-B) of size 40X40X5 mm and 450 mm long including two coats of synthetic enamel paint over a coat of red oxide primer and to be provided at every one metre distance complete all as specified and directed

Supply & fix in repair current collectors, 100 Amps suitable for busbar specified herein befour including fabrication work complete all as directed by Engineer in charge.

Dismantling of crane track by gas cutting the pressure plates/rusted nuts & bolts /side supports and Grinding / sanding of gas cutted surface including making the surface smooth surface for shifting the track with proper alingment and cleaning the entire track with the help of air wash complete all as specified and directed.

Shifting the track at required position and aligning the joints in proper positions and providing pressure plates with nut bolts , side support plates at required distance complete all as directed. Note :- (i) Testing of track is to be done for 2 days by giving full load on the crane in front of Engineer in charge. (ii) Necessary saftey measures to be taken by the contractor while dismantling and fixing/shifting the tracks . (iii) Any damage/loss to the govt property while dismantling/shifting/fixing will be beared by the contractor. (iv) The cost of T&P such as Jacks, Chain pulley, ropes, ladders etc and welding work involved for the job is included in the quoted rates. (v) The work is to be carried out at the height of above 25 feets.

Matrerial and labour for taking down of unserviceable motor from OHT crane and including transporting and re-winding of electric motor of follwoing capacity with supper enameled copper conductor wire as per existing size/gauge including making varnishing drying and connecting fixing accessories etc including refixing on same position and testing on load complete all as specified and directed

0.5 to 2 HP, 3 phase 415 volts,

3 to 5 HP, 3 phase 415 volts,

7.5 HP to 10 HP, 3 phase 415 volts,

Matrerial and labour for taking down of unserviceable motor from OHT crane and including transporting and changing of bearing of electric motor of follwoing capacity with new bearing as per existing size including refixing on same position and testing on load complete all as specified and directed

0.5 to 2 HP, 3 phase 415 volts,

3 to 5 HP, 3 phase 415 volts,

7.5 HP to 10 HP, 3 phase 415 volts,

Supply, fixing, adjustment in repair AC Drive / verable frequency drive (VFD)/ frequency convertor device system for suitable capacity of 4.0 KW three phase supply system with required input 3 x AC 380 to 480 Volt, 50 HZ / 60 HZ and out put 3 x AC 0 to 480 Volt, frequency 0 to 400 HZ with having setting controling devices system and or all as per existing sample/ rating/ model for operating /controlling of slow / high speed for all motion and other controlling system etc for smooth functioning of over head electric traviling crane of capacity 5 Ton and including making controling cable connection of system and testing on load complete all as specified and directed.

Supply and fixing in repair MCB TP 10 Amps to 63 Amps 3 phase of any size or series type or as per existing sample / model of complete all as specified and directed.

Supply and fixing in repair power contactor 3 phase MNX series /Freedom Series type or as per existing sample / model of rated of following capacity along with suitable rating of coil voltage and NC/NO type Auxilary contactor block complete all as specified and directed.

16 Amp to 32 Amp

12 Amp to 15 Amp

06 Amp to 10 Amp

Supply and fixing in repair copper flexible cable of following size and core as per existing sample / model complete all as specified and directed.

2.5 Sq mm X 4 Core

4 Sq mm X 4 Core

Supply & fix in repair Cable Carrier as per existing sample / model complete complete all as specified and directed:-

Supply only R Y B indicator of any size or Series type complete all as specified and directed

Supply only Single phase preventor having system AC supply 415 volt 50 HZ complete all as specified and directed

Supply only Dynamic breaking resistance (DBR) device for over head traviling for 5 Ton / 10Ton EOT crane complete all as specified and directed

Supply only Step down transformer with having rating 440 volt to 110 Volt A.C upto 30 VA capacity complete all as specified and directed

Supply only Gear box oil SAF-90 grade type suitable for OHT crane LT, CT, Hoist complete all as specified and directed

Supply only Transformer oil suitable for OHT crane thruster brake assembly system complete all as specified and directed

Supply only Metal body flame proof weather proof rotary gear type limit switch assembly with having IP 65 protection for 5 Ton to 10 Ton complete all as specified and directed

Matrerial and labour for Painting of EOT / Double girder traveling over head travaling EOT/ cranes system along with trolly, foot parth , railing system and including both sides girder and its connected item fixing accessories / equpts complete for crane system by appplying two coats of flame proof paint of colour golden yellow /Tractor orange/ gray colour or existing sample of painting as per existing type colour code with providing painting of synthetic enamel Ist quality paint after scrapping of old rusted surface and cleaning of oil and grease, soil dust partical material by manually with sand paper suitable for capacity of 5 Ton to 10 ton crane (Span not more than 20 mtrs & girder length not more than 25 mtr long) complete all as specified and directed

Supplying and fixing in repair flexible type steel wire suspension rope heavy duty of size 16 mm dia suitable for lifting/ carring of load suitable for 10 Ton EOT Crane and including testing on load complete all as specified and directed.

Supplying and fixing in repair flexible type steel wire suspention rope heavy duty of size 12 mm dia suitable for lifting/ carring of load suitable for 5 Ton EOT Crane and including testing on load complete all as specified and directed.

Supplying and fixing in repair flexible type steel wire suspention rope heavy duty of size 06 mm dia suitable for cable carrier / crane pendent of load suitable for 5 to 10 Ton EOT Crane and including end clamps complete all as specified and directed.

Dismantling of existing reduction gear box with device for hoist/CT/LT motion traverse for EOT cranes of load 5 Ton to 10 Ton capacity and carrying out replacement of following unserviceable parts / Carrying out misc repair and refixing the gear box after checking alignment of brake drum & motor and motor & gearbox, in existing position, complete all as specified and directed:- (a) Replacing the worn out shaft seals & bearing deemded to be included in quoted rate (b) Replacement of internal cover gasket deemded to be included in quoted rate (c) Replecment of Gear coupling with nuts & bolts complete deemded to be included in quoted rate

Supply and fixing of electro hydraulic thruster mounting assembly Complete suitable for mounting of 18 Kgs/34 Kgs size/ capacity Hydraulic thruster all as existing type with nut, bolts etc including dismantling and removing old unserviceable thruster assembly for 5 to 10 Ton EOT Crane complete all as specified and directed.

Dismantling and Taking down hook/hoist assembly of Crane of capacity upto 10 Ton & transporting it to workshop for servicing and repair.by dismantling the complete assembly under hydraulic press and removing the body cover and taking out old wire rope pullies, unserviceable bearings and hook also removing the old locking bolts side covers of the hook with the help of necessary welding work and cleaning the slots of pullies , side cover, Hook, shafts with kerosene and reassembling the hook complete with new double roller bearing of make SKF/NBC of existing size &numbers and applying A grade grease to the moving parts of the hook assembly and making arrangement for new locking plate and painting the hook assembly with two coats of Red colour and shifting the hook assembly to the location and fitting it with wire rope at the same position complete and testing to be done to the satisfaction of Engineer in charge. Note :- (i) Necesssary safty measures to be taken while dismantling and Fixing the Hook. (ii) Testing of cranes is to be done on full load for 2 hrs in presence of Engineer in charge.

Attending breakdown / fault of crane with in one hour from call round o'clock as and when required upto the comfortable working of crane as the work shop activity held up and up to the entire satisfaction of user complete all as specified and directed. Note:- (i) incase failure of attending major breakdown / fault within 01 Hour from intimation will be charged 1000/- panelty per hour to the contractor on account of delayed attending the fault. (ii) Each crane fault will be count as a seperate Job (iii) Quotated rate shall be deemed inclusive of special tools required to attend the breakdown / fault (iv) Major Spares used in breakdwon will be measured and paid seperately as supply only in relavant item of schedule (v) Normal item like grease, oil, cotton west, nominal nut bolt used in breakdown / fault is inclusive in quotated rate

Disconnecting the unserviceable earthing and M & L for earthing for Lifts complete with copper earth plate electrode 60cm x 60cm x 3.15mm thick, buried directly in ground (earth pit not less than 2.25 mtrs deep below ground level) with top edge of the plate not less than 1.5 mtrs below normal ground level, connected to copper strip 20 x 3 mm as earthing lead by means of bolts, nuts, check nuts and washers of galvanised iron or steel all as shown in electrical plate No 3 in SSR Part -I 2009 connected to earthing test point all as specified complete with excavation & earth work in any type of soil, PCC pit in PCC 1:2:4 type B1 (20mm graded stone aggregate) with 50mm thick RCC cover (grade M-15) RCC 1:2:4 type B1 (20 mm graded stone aggregate) having suitable handle (10mm MS Rod) 20mm dia GI pipe medium grade ISI marked watering pipe with GI funned with wire mesh 40mm bore GI pipe medium grade ISI marked for protection of earth lead conductor and charcoal & salt complete all as specified and as directed and testing on completion.

Supply and replace copper strip of size 20 x 3 mm for extenstion of earthing complete all as specified and as directed.

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