REPLACEMENT OF BER ITEMS 2012 13 ie CRANES AT PXE CHANDIPUR UNDER GE I RnD CHANDIPUR

Amount

Dismantling of existing EOT cranes 5 Ton capacity at MT section and equipent wing (bldg No 584) at PXE chandipur and dispositd to MES store yard complete all as specified and directed.

CRANE : Supply, installation, testing and commissioning of electrically operated, overhead travelling (EOT) cranes of capacity 5 Ton, with a span 9.15m, lifting/hook height 5.5m, bay length 49.3m, floor operated conforming to IS : 3177 (latest revision), suitable for operation on 415 Volts, 3 Phase, 4 wires, 50 HZ supply, double girder box type, on existing steel supporting structures, with Hoisting, Cross Travel (CT) , and Long Travel (LT) with micro drives through VVVF Drive, control panel, power and controlling cables, confirming to relevant ISs, controlled by pendent push button station and radio remote control switch of operation, with and including the followings: - Girder: (i) Girders fabricated using fresh tested steel plates to IS: 2062 Gr ‘A’ obtained directly from Main steel producers (like SAIL, RINL, TISCO, Jindal, Vizag steel), cut to size using the latest CNC profile cutting machines and welded using modern welding practices. All welds shall be subjected to radiography test to ensure defect free welds.

(vi) Hooks shall be shank type supported on anti friction thrust bearing and the sleeve pulleys shall be made out of malleable cast iron or fabricated, conforming to IS: 3815. (vii) Controls: The crane shall be controlled by pendant. The main electrical components shall be housed in sheet steel enclosures suitable for indoor application conveniently located for easy maintenance. Standard protection devices for overload protection and short circuit protection shall be provided. (viii) All other incidental, Civil, Electrical and Mechanical works. For the followings: (a) Five (05) tons capacity, Approximately 9150 mm span, Approximately 49300 mm longitudinal travel, Top of the crane as per existing, Approximately 5500 mm hook height to be installed in storage building of Wksp but excluding RCC bracket( All Dimension Shall be as per Existing structure and site requirement)

Notes for item no 2 above: 1. The various dimensions given above are approximate. The contractor is advised to verify the ground details as well as visit the site of work for accurate measurements of these dimensions. In any case before undertaking fabrication work the contractor must ascertain the final finished dimensions. 2. The subject crane is meant for the purpose of handling small to medium load of various components. 3. The crane will be put to use for 365 Days’ continuous duty with CT, LT and Hoist movements 4. The department shall be responsible for providing suitably rated electrical outlet in the Main Electrical Control Panel/Main Distribution Board of the buildings .5. All other works as required at site. The contractor shall certify that these are sufficient and meets the requirements of his design.

6. The shop floor environment will be dust prone, humid, Corrosive (Due to coastal area)Weather conditions are tropical. Crane shall be kept in the normal shop floor condition without any temperature controlled enclosure / shop. Max. temperature variation is 25 deg Celsius in 24 hours. Sound level should be minimum and the crane should have decent aesthetic look. Ambient Temperature: 4º C - 50º C & relative Humidity: 95%. 7. The crane is to designed by the contractor. Major Technical specifications of the crane are given below. These are to be complied with by the contractor/manufacturer. The parameters which are not specified are to be as per Contractors'/OEM's own design. The contractor shall submit following drawings, giving all design parameters and get the drawings approved from the Garrison Engineer. The drawings shall be complete in all respect.

(i) Duty Class: M5 for Indoor operations, (ii) Lifting Capacity: 5 Ton, (iii) Span: 9.15 Metre, (iv)Hook Height : 5.50 Meter , (v) LT Wheel Rail Track Size: R-52, (vi) Bay Length: 49.0 Meter, (vii) Clearance between Rail Top to Enclosure Roof: As per design approved. (viii) Hoist: Hoist should be as per IS: 3938 (latest version) of STAHL, DEMAG, INDEF make. Only Low Head Room Hoist shall be acceptable. (ix) Maximum Speed (Meter / Min.): (a) Hoisting: 3 (b) Cross Travel: 10 (c) Longitudinal Travel: 12. (x).STRUCTURAL FABRICATION (Constructional Details): (a) Bridge Girder: Shall be of Double Girder Box Type construction having Minimum vibrations. (b) End Carriage: Fabricated from rolled steel sections / plates as per IS:2062 (c) Raw Material: Only tested quality steel Fe 410 WB as per IS-2062, IS:1964 & IS:808 and certified for quality by reputed inspection authorities, shall be used. (d) Number of Joints allowed: Single Joint (e) Welding Electrodes for all Horizontal Welding: E 7018 Electrode only should be used. (f) Welded Joint Testing: All Butt Welded Joints (both compression/ tension and flanges / web joints)shall be subjected to 100% X-Ray Testing and X-Ray Films to be produced for evaluation and form part of the completion documentation). (g) Mechanical Joints: Fit Bolts (as per IS 3640 –1982) for all joints coming in main members. (h) Heat Treatment & NDT Examination: The Trolleys shall be stress relieved, if necessary, by thermal heat-treatment process after welding & NDT. All welding shall be tested by NDT means [MPI, LPI & RT] after stress relieving operation (Govt. approved Test House & certificate). Manufacturer to furnish the details of facilities for Heat Treatment furnace & NDT Lab at their works. All the welded joints should be NDT tested by Govt. approved Test House & certificate / X-Ray films to be submitted at time of inspection

(x) Wheels: Wheels shall be of forged and made of C55 Mn75 Carbon steel, Hardened to BHN 300-350 (a) Cross Travel (CT) - Contractor to submit the size and supply Contractor to submit (b).2 Long Travel (LT) - Mention the wheel diameter in drawings & Shall be matched with the above rails. Contractor to submit (xi) Gear & Gear Boxes Details: Gear Box should be of fabricated type duly stress relieved. Pinions made of En 24 and gears of En 18. Gears in all the Stages shall be helical in design and to be of machined, lapped and hardened Straight and helical spur gearing shall normally be used for all motions. Worm and bevel gears shall not be used. First and high speed reductions shall be through helical gears. All first reduction pinions and also the other pinions if feasible shall be integral with the shafts. All gears shall be of hardened and tempered alloy or carbon steel with machine cut teeth. Gear tooth shall be cut in metric module system. Surface hardening of teeth is not allowed. The Gears / pinions should be hardened to HRC 50-55 and ground. Please note that gears and pinions must have pressure angle of 20° only. (xii) Lubrication: Suitable lubrication system shall be provided for gear box, all rotating parts wherever applicable. Details of the same to be furnished. Please indicate the type of Lube. Oil & grease, quantity also. (xiii) Rope Drum: Shall be of fabricated type stress relieved or seamless pipe. The circumferential weld joints shall be tested by 100% X-Ray quality (Please mention the size). (xiv) Type of Coupling: Couplings should be flexible geared Barrel type. No pin / bush / rubber type coupling to be used (xv) Machining Operation: All mechanical mating surfaces and wheel seating areas are to be machined to the required finish and protected.

Hoist Wire Rope Details: Fibre core confirming to IS: 2266. Mention Wire rope dia, No. of fall & Construction. Minimum Factors of Safety & Tensile Strength (1960N/mm² for wire rope) as per ISO:4309:1990.(Contractor to Comply &submit details Lifting Hook: Drop Forged with latch, Plain ‘C’ type, Swivelling on Thrust Bearing, Duly tested as per IS: 15560 (latest version) (Contractor to Comply & submit details) Buffers (End Stoppers): Buffers of adequate size shall be provided. Contractor to provide Maintenance Platform: Maintenance / service platform of load carrying capacity approximate. 250 Kgs. of sufficient width shall be provided & fixed through bolted joints only. A hand railing sufficient height Contractor to provide and toe guard (Min 100mm) shall also be provided. Platform shall have anti-skid grating. Guards: All the moving parts should be duly covered with guards as per safety norm. Proper guard / cover / tray to prevent falling of bolts from coupling etc should also be provided, wherever required. (Contractor to provide details)

(xvi) Input Power Supply: Shall be 415 ± 10% Volts, 50 ± 3% Hz, 3 Phase, AC. (xvii) Control Voltage: Shall be 110V AC (xviii) Protection: All Panels, Limit-Switches and Motors shall have IP 54 protection. Motor Details: Squirrel Cage Induction Crane duty motors, Totally enclosed, fan cooled, Insulation Class-F & confirming to relevant latest IS:325, and IS-123, S4 duty, 150 starts per hour and 40% CDF. Contractor to provide other details like No. of motors, capacity of motor, Frame size, make, type and No. of poles etc. (xix) Type & details of Brakes for all motions: Conical rotor type or "Fail to safe" action type Electromagnetic shoe / disc brakes type to be provided to hold the mechanism in position instantaneously as soon as the power supply is 'OFF' either accidentally or intentionally for all motions. (xx) Electric Contactors: shall have SIEMENS / L&T / GE contactors suitable for Crane operations. Crane duty AC-4 ratings. (xxi) Contactors Rating: The rating of all Contactors shall be at least 50% higher than the respective electric motor full load current, at the specified duty cycle.

(xxix) Painting Instructions: (a) Surface Cleaning: Girder to be shot blasted or chemically treated for surface cleaning, after completion of all operations but prior to painting. Contractor to furnish the details of facilities for Shot Blasting M/c at their/OEM's works. (b) Painting: One coat of Red Oxide Primer with 25 micron DFT (Dry Film Thickness) and 48 hours of compulsory curing after painting (c) The crane should be thoroughly cleaned and final painting with two coats of Corrosion Resistant Enamel Paint (Colour –Golden Yellow) each with a DFT of 25 micron and intermittent curing of 16 hours. Final touching will be done after erection & commissioning at site if required.

All same as per item srl No 2.00 above but of capacity 5 ton with span 12.0m, hook height 5.50m, bay length of 25.0 m complete all as specified and directed

CRANEX LIMITED

M/s. Tojym Steel Products