COMPREHENSIVE MAINTENANCE AND REPAIRS OF EOT CRANES OF VARIOUS CAPACITIES INSTALLED AT T-COMPLEX BLDG AT NPOL KOCHI

Amount

Comprehensive maintenance consisting of Repair, Maintenance and servicing including replacement of spares for electrically operated overhead travelling EOT cranes, single/double girded, gear type with electric motor for long travel, cross travel, hoisted creep, control panels, protective panels, gear box, gantry rail, main switches, resistance coil, wire ropes, rope drum, brake control, cable and switches, Servicing Break drum cleaning, all electrical connection checking & connecting. Lubricating of all moving parts, cleaning of DSL, proper alignment of cable trolley, festoon cable system etc. of the following capacity of crane in the T-Complex building of NPOL Kochi.

EOT crane of Capacity 01 Ton, Single Girder, 7.44Mtr Span Make:-TOJYAM Ltd - 01 No in T Complex mini Tank Building.

EOT crane of Capacity 05 Ton, Double Girder, 9.74m Span Make:-TOJYAM Ltd - 01 No in Encapsulation Room(Moulding Shop) , T Complex Building.

EOT crane of Capacity 10 Ton , Double Girder, 27.40Mtr Span Make:-TOJYAM Ltd - 01 No at Acoustic tank, T Complex Building.

Notes for Items No:1.00 to 1.07 :- a) The items also includes the cost of grease, oil for oiling the parts, oil seal any type, nutbolts &washers, soldering & welding works, cleaning of LT control panel board by hot blower including one coat of spray painting with synthetic enamelled paint of approved quality with and including E/M & MES Srl No. making neatly on each machine complete with connected accessories of existing colour of EOT Cranes & LT panel, The other major parts replaced shall be measured and paid separately. b) The contractor shall be maintain maintenance register of each crane as per the direction of the Engineer-in -Charge. (c) Check to make sure all bolts are tight and lockwashers are compressed, (d) If required touch up the crane with existing paint wherever necessary, (e) Check clevis pin, cotter pin, (cotter pin should be fully wrapped around clevis pin) and check clevis bolt and hard wares, (f) Check for cracks, puts, and / or grooves of wheels, If any of this conditions exist, wheels should be replaced, (g) Ensure correct position on bridge to match specified cantiliveres, (h) All safety features shall be check properly including checking of HRC fuses or MCBs or MCCBs, O/L Relays, single phase preventers, under voltage protection, main incommer circuit breaker/ contactors, Limit switches, brake, clutches & other switch gears & control equipments, (k) One experienced supervisor who is thoroughly conversant with crane operation shall be deputed while works on progress. (I) Tools for the repairs and safety of the mechanic/ engineer shall be at contractor’s risk. (m) The spare parts mentioned in srl no of the item shall be measured and paid separately under item no 9.01 to 9.04. Quoted rates aiso includes taking down of all items/parts mentioned in srl no 9.01-9.04.

Load testing of EOT Cranes of capacity 10 Ton installed at Main Acoustic tank of T complex by hiring load (RCC cubes ) 10 Ton capacity in 3 Stages (50% , 75 % and 100% ) including suitable transport, cranes and safety measures required for loading and unloading weight and submitting the test report in specific forms duly signed by testing authority all as specified and directed by Engineer-in-charge.

All as per item No 2 above but of Capacity 05 Ton , Make:-TOJYAM Ltd - 01 No installed at Encapsulation Room(Moulding Shop) , T Complex Building.

All as per item No 2.00 above but capacity of 01 Ton Single Girder of Span 7.44 Mtr in Mini Tank Building at T- Complex building.

Note for Item No 2 .00 to 4.00 :- The item includes inspection of the following sub systems and submitting report along with load test certificate duly load tested and signed by Govt authorised/approved Engineer. Any defects noticed by the Govt approved, authorised Engineer shall be rectified by the contractor and retest shall be carriied out at his own cost. (A) LT DRIVE SYSTEM :- (a) Inspection for wear and tear of gears, drive shaft coupling, plummer block and break lininer, greasing, oiling, etc.(b) Checking og Girders and Carriage, coupling bolt, foundation bolt of gear box and motor, (c) Checking of DSL System including carbon brushes, brush holder insulators and tightness of copper conductors, (d) Checking and serviceability of electric motors, power contactors, relays, limit switch, push buttons and electrical circuit cables and wiring. (B) CT DRIVE SYSTEM :- (a) Inspect wear and tear of gears, drive shaft, coupling plummer block and brake liner etc. (b) Checking of tightness of rail clamp bolts, alignment of rail joint, (c) inspection of cross travel conductor cable for motor, power conductors, relays, limit switch, push button etc. (C)HOIST :- (a) Inspect wear/ tear of wire rope, Hook block and break lines etc. and testing of rope, (b) Checking of electrical circuit limit switch and wiring (D) LOAD FOR LOAD TESTING :- (a) Contractor shall arrange necessary load as per the site requirement of the crane including shifting of load to the site by using crane, truck, labour, etc, (b) Contractor shall take care of the floor while shifting/ lifting the load and if any damage found at site shall be rectified with in 24 Hrs, (c) Load test shall not be more than 110% of the rated load. , (d) Contractor shall shift the load to inside the bulding for load testing of crane carefully by using crane/truck/fork lift/ labour without damage to the existing infrastructure, (e) Load testing shall be carry out as per ISO:4310 of 1981 and IS:14470 of 1997 with latest amendments on the IS . (E)TEST REPORT:- (a) On completion of the load test, a test report shall be prepared listing the conclusions and finding of the test for each crane, The report shall identify the crane tested, shall give the date and location of the tests, name of the Engineer tested, details of load, positions, configurations and findings if any in each case. (b) T&P for the load test and safety of the mechanic/ Engineer shall be at contractor's risk.

Supply & fixing in replacement of following spares/components of the unserviceable cranes as directed.

Cranes Capacity 1 TON :-

3 pole Contactor 10 Amps, 415v,

Over load relay

Brake Pads.

Gear box bearing

Brake lining

Limit switch for LT/CT

Crane Capacity 5 Ton

Limit switch for LT/CT

Brake lining 6mm

Brake Pad

Brake Coil for 100mm &150mm dia

Key Switch.

Gear Coupling for LT.

Gear Wheel.

Ball bearing for 5 T

Over load relay

Hoist gear pinion

Current collector for DSL

Moulded terminal block

Variable Frequency drive (VFD) For HoistMotor Make - Yaskara/Mistubishi

Variable Frequency drive (VFD) For LT/ CT Motor Make - Yaskara/Mistubishi

Crane Capacity 10 Ton

Hydraulic brake for LT/CT

Limit switch for LT/CT Make Speed-o- control or relevent make

Limit switch for Hoist Make Speed -O-Control or relevent make

Over Load Relay for CT/LT Make -Siemens/L&T

Over Load Relay for Hoist Make -Siemens/L&T

Control Transformer 440/24 Volts 200 VA

Brush holder assembly incl carbon brush

3 Pole Power contactor 32A

3 Pole Power contactor 25A

Magnetic coil 150mm

Bearing for Motor up to 10HP Make SKF/TATA

Brake Lining.8mm

Brake pad

Common Spares

Gear Oil C-320 Grade for LT/CT /Hist

Transformer oil for brake thruster

Wire rope guardian compound

Muti speed radio remote control

Control Push button for NO/NC

LT PVC insulated and PVC sheathed copper conductor cable 2.5 sqmm 10 core for pendent

LT PVC insulated and PVC sheathed copper conductor control cable 2.5 sqmm 4 core

Crane cable trolly

MCB TPN 415 V, 32 Amps , C curve. Make Indoasian/ LT/Havells

MCB TPN 415 V, 63 Amps , C curve. Make Indoasian/ LT/Havells

Note for item No 5.01 to 8.10 : (i) The spares/electrical items as listed above will be used whenever required only and it shall measured and paid separately under respective items. (ii) The rate is inclusive of all items as required at site except those items above and any major and overhauling works involved to keep the cranes operational round the clock including cleaning and greasing all moving parts on monthly basis complete all as specified and as directed by Engr-in-Charge. (iii) If spare parts of original make is not available in market necessary suitable spare equivalent to existing crane part as approved by Engr-in-charge shall be used in the work so that to run the crane with smooth functioning. (iv) The contractor should attend any complaint / breakdown immediately on call basis. (v) Contractor should submit the inspection / maintenance report of every visit in spite of no of visits during breakdown calls including mentioning the status of lift and spares any replaced. (vi) The old unserviceable spares replaced under comprehensive maintenance is the property of contractor.

Disconnecting gear box assembly and taking out gear wheel and replacement of other worn out parts, oil seal and gear oil after over hauling including lath work as required at site, re-assembly and re-fixing the same and testing complete for 5 Ton /10Ton capacity EOT cranes Note :- Gear oil and other major spares will be measured in relevant items

Disconnecting and taking out the defective electric motor from the cranes, transporting to workshop for replacement of burnt out winding with existing gauge super enameled copper wire including insulating paper and varnishing and re-fixing motors to crane after testing, upto 3 HP motor complete all as directed

M & L for Earthing complete with using galvanised steel earth plate 60 X 60 cm X 6 mm thick electrode , buried directly in ground (earth pit not less than 2.25 metres deep below ground level) with top edge of the plate not less than 1.5 metres below normal ground level, connected to 25 X 4 mm galvanised iron strip as earth lead by means bolts, nuts, check nuts and washers all as shown in electrical plate No.3 connected to earthing test point all as specified or indicated including testing on completion necessary complete all as specified and as directed.

Material & Labour for Earth continuity conductor fixed to wall on batten or recess or chases or buried in ground or drawn in conduit/pipe or fixed to poles or any other indicated situation for loop earthing etc. as required 32 x 6 mm dia galvanised iron strip

WELTRONENGINEERINGSERVICES (BID ID -3095495)