DESIGN, FABRICATION, TESTING, SUPPLY AND … FABRICATION, TESTING, SUPPLY AND INTEGRATION OF SS...

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1 DESIGN, FABRICATION, TESTING, SUPPLY AND INTEGRATION OF SS TANKER IN FLATBED TRAILER Quantity Required: 1 HTPB tanker 1.0 Introduction: This tender is meant for realization of 18 m 3 capacity Stainless steel tank mounted on semi-trailer which can be hauled for transportation of chemicals between production plant and ISRO work centers (SDSC SHAR Sriharikota, ASL Tanuku) 2.0 Scope of work: Design, Supply of Materials, Fabrication, Inspection, testing and Supply & integration of mobile / road tank on flatbed-trailer. i) Design: Vendor shall design the tanks based on the capacity mentioned and also suitable to the required semi-trailer based on the capacity. The design including calculation and drawings shall be appraised by TPIA engaged by vendor. (DNV / Lloyds / BV) ii) Preparation of detail procedures for welding (WPS & PQR), Fabrication, NDT, Hydro & Pneumatic testing, integration with Road Tanker trailer etc., including QAP schedule & PERT charts. The above procedures shall be approved by TPIA & Purchaser. iii) Procurement & testing of raw materials including the listed flow components as per Annexure-III. iv) Fabrication, Heat treatment, testing & painting as per details given in the specification v) Supply of Suitable semi-trailer for mounting the tank as per Annexure-V. vii) Integration of the Road tanker on above semi-trailer and qualification of roadworthiness viii) Preparation & submission of final document: production master file, Radiography films, etc.,

Transcript of DESIGN, FABRICATION, TESTING, SUPPLY AND … FABRICATION, TESTING, SUPPLY AND INTEGRATION OF SS...

Page 1: DESIGN, FABRICATION, TESTING, SUPPLY AND … FABRICATION, TESTING, SUPPLY AND INTEGRATION OF SS TANKER IN FLATBED TRAILER Quantity Required: 1 HTPB tanker ... (WPS & PQR…

1

DESIGN, FABRICATION, TESTING, SUPPLY AND INTEGRATIO N OF SS TANKER IN FLATBED TRAILER

Quantity Required: 1 HTPB tanker 1.0 Introduction:

This tender is meant for realization of 18 m3 capacity Stainless steel tank mounted on

semi-trailer which can be hauled for transportation of chemicals between production plant

and ISRO work centers (SDSC SHAR Sriharikota, ASL Tanuku)

2.0 Scope of work:

• Design, Supply of Materials, Fabrication, Inspection, testing and Supply & integration

of mobile / road tank on flatbed-trailer.

i) Design:

Vendor shall design the tanks based on the capacity mentioned and also suitable

to the required semi-trailer based on the capacity. The design including calculation

and drawings shall be appraised by TPIA engaged by vendor. (DNV / Lloyds / BV)

ii) Preparation of detail procedures for welding (WPS & PQR), Fabrication, NDT,

Hydro & Pneumatic testing, integration with Road Tanker trailer etc., including

QAP schedule & PERT charts. The above procedures shall be approved by TPIA

& Purchaser.

iii) Procurement & testing of raw materials including the listed flow components as

per Annexure-III.

iv) Fabrication, Heat treatment, testing & painting as per details given in the

specification

v) Supply of Suitable semi-trailer for mounting the tank as per Annexure-V .

vii) Integration of the Road tanker on above semi-trailer and qualification of

roadworthiness

viii) Preparation & submission of final document: production master file, Radiography

films, etc.,

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3.0 Design parameters:

Sl No

Description Service Fluid

Water capacity

(Cu.M Nominal)

Design Pressure at top of the

Vessel (Kg/cm 2) g

Material of Construction

Design Temperature

(Deg.C) Corrosion Allowance

Minimum Thickness (inclusive of allowances) Quantity

(Nos.) Shell

Thickness End Dome Thickness

1 Road Tanker HTPB 17 2.0 SS 304L 70 3 mm 8 mm 10 mm 1 Design data:

• ASME Boiler and Pressure Vessel code, Sec. VIII Div .1, (Latest version)

• Saddle supports shall be designed as per IS 2825. The included angle of the saddle support shall be 1600 minimum.

• Allowable Stress: For the design of pressure parts of tank like shell, dished ends etc., lower allowable stress shall only be

considered.

• The tank shall be designed for mobility on road with shock, acceleration / deceleration value of minimum 3g.

• Shell and dish ends plates will have minimum weld joints and dish ends will not be fabricated in petals.

• The tank saddle supports & internal baffle plates considering the mobility on road.

• Type: Horizontal, Cylindrical with 2:1 ellipsoidal Dished ends.

• Each tank shall have 4 lifting lugs

Note: i) Width of SS plates shall be chosen to minimize No. of cirseam welds (more than or equal to 2 mtr) ii) Each end dome shall be made out of maximum number of two plates preferably. iii) If the design calls for lower thickness than minimum thickness specified above, the thickness specified above shall be

provided. During design, if higher thickness is required than the minimum thickness specified above, higher thickness shall be provided. The same shall be considered while bidding.

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4.0 Fabrication Details: 4.1 WELDING:

• 100% TIG welding, shall be carried out by Argon Arc process, right from root to final passes for all butt welds (Long seams, ‘C’ seams, nozzles, pipe to flange joints) and all internal and external welds including fillet welds.

• Welding consumables (filler wire) shall be used as per AWS classification or ER 308L

for SS welding • Dye penetrant test shall be carried out for root and final passes of all types of welds,

4.2 Radiography: 100% on butt-welded joints including nozzle pipe to WNRF flange joints.

All welds other than butt welds shall be DP tested. Radiography for all butt welds by X-ray machine with 2-2T sensitivity.

4.3 Heat treatment:

i) Solution annealing at around 1050 Deg. C for a soaking time of 45 minutes of the end domes shall be carried out to relieve stresses caused due to cold working as per code.

ii) The total fabricated tank has to be stress relieved at 420+ 10 Deg.C for a

soaking time of 2 hours with rate of heating and cooling at 75 to 100 Deg C per hour (to be carried out prior to Hydrostatic test).

iii) Solution annealing of Domes and stress relieving of total tank shall preferably

be carried out in an Electric furnace. If oil furnace is used, the fuel shall be of lower sulfur content oil like High speed Diesel

4.4 After hydrotest, the vessel has to be degreased, pickled and passivated and fitment

of all flow components and replacing of all gaskets and fasteners. 4.5 Total fabrication shall be carried out in the presence of TPIA (M/s DNV/ LLOYDS /

BV) engaged by vendor as per the scope given in QAP. 4.6 Testing: 4.6.1) Testing of materials:

i) Materials of construction shall be as given in part No. 4.9 Table: 1 all materials used shall be tested as per Code in the Reputed Govt. approved testing labs before fabrication. All the plates proposed to be used for fabrication of tank, shall be tested in presence of TPIA for mechanical, chemical and IGC tests as per A-262 Practice-E in addition to availability of Mill test certificates.

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ii) Plates used for the fabrication of the tank shall be procured with 100% ultrasonic

testing shall be carried out as per Practice ASTM A-435 duly witnessed by TPIA. iii) If the plates procured by the vendor were UT tested but the same was not

witnessed by TPIA at manufacturer site, 100% UT testing of plates need to be carried out at fabricators shop in presence of third party inspection agency prior to taking up the vessel fabrication.

iv) Test on ferrite number of weldments shall be carried out to ensure within 3% to

12%. Test certificates shall be furnished to purchaser for approval.

4.6.2) Pneumatic Gross Leak Test: T he tanks shall be tested at 3.0 bar (g) using dry Nitrogen gas for gross leaks prior to Hydro test.

4.6.3) Hydraulic Pressure Test : with DM water having fluoride content less than 25

PPM shall be carried out at 1.5 times the design pressure as per ASTM A 530.

Note: Before hydraulic test, the internal surfaces of the tanks shall be mechanically cleaned

4.6.4) Pneumatic Leak Test: After Hydro test of the tanks, the tanks shall be tested at 3.0 bar (g) using dry Nitrogen gas with dew point of minus 40 Deg. C or better and leak check with soap solution.

4.7) Painting: The tank and related attachment shall be painted with acrylic / aliphatic

/ polyurethane paints with suitable epoxy primer of 100 +/- 10 micron DFT followed by a finished coat of 40 +/-10 micron DFT so that total micron DFT of 140 +/- 10.

Preferable make of paints: Berger/Bombay paints/CDC/Good Las Nerolac 4.8) The vessel shall be dispatched after integrating with trailer at positive pressure of

0.5 bar filled with dry Nitrogen.

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4.9) Material of construction of tanks shall be st rictly as given below. Table-1

MATERIAL SPECIFICATION

Sl No Components

HTPB tank

1. Shell and Dished ends * A 240 GR 304 L 2. Nozzle pipes A 312 TP 304L ( Seam less)

3. Nozzle flanges A 182 F 304 L

4. Supports, Baffle plates & all

RF pads SA 240 GR 304 L

5. Bolts and nuts A 193 GrB8M/A 194 Gr8M

6. Gaskets SS 304 spiral wound Teflon with SS 304 inner and outer rings.

7. Blind flanges A 182 F 304

8. Man hole cover removal assembly/ Davit arm

SS 304 L

9. Name plate / bracket SS 304 L

10. Pad plate SA 240 GR 304 L 11. Lifting Lugs SA 240 GR 304 12. Manhole Flange & Cover

Flange ASTMA182FGr SS 304L

13. Manhole Cover and Handles

SA 240 Gr SS 304L

14. Ladder SS 304 15. Wherever not mentioned SS 304 L

* The shell of the tank shall be fabricated with 2 mtrs and above wide plates.

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5.0 GENERAL CONDITIONS :

1) Vendor shall submit the offer in two parts-techno commercial and price bid:

� After receipt of order

• Detailed QAP.

• Design calculations.

• Drawings and procedures for approval.

� Along with the offer:

• Filled in checklist as per Annexure-IV.

• Compliance for tender specifications including General conditions.

• Deviations if any with justifications.

� Along with supply:

• Production Master file (3 copies) consisting of Design calculations, as

built drawings, BOM, test reports, fabrication procedures, HT & SR

charts, TPIA certified documents, rub-off,

• All radiography films.

• Scanned digital images of vessels put in and after removal from

furnace.

• Soft copy of as-built drawings.

2) Third Party Inspection Agency charges shall be quoted separately and will paid at

actuals.

3) Supplier shall arrange temporary registration along with clearance from State

Transport Authority (STA) for overall dimensions and roadworthiness of the

supplied items.

4) Cost of trailer shall be quoted separately. Purchaser reserves right to delete the

trailer from the scope of vendor and provide the sa me as free issue material.

5) All the testing charges like UT of plates, IGC, mechanical & chemical testing, etc.,

shall be included in the offer.

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ANNEXURE-I SCOPE OF INSPECTION: AS PER QAP The vessel should be fabricated under the inspection of Third party/Purchaser representative as per QAP

QUALITY ASSURANCE PLAN (QAP)

Sl. No.

Characteristics / type of check Ref. Document

Method of check

Quantum of check

Manufacturer QC

Third party Purchaser

1.a Identification of material with Mill T/C & witness of Physical, IGC Test for plates.

As per PO Visual 100% H 100% R R

1.b Witness of Physical & IGC Test for pipes, fittings, gaskets, flow components etc.,

As per PO Visual 100% H 100%W R

1.c Ultrasonic Testing of Plates *(refer note in specifications) As per PO Visual 100%W 100%W W/R

2 Review of fabrication drawings and Design Calculation

As per PO/ drawing

Material as per design

100% H 100% R R

3 Review of welding procedure & Qualification AWS Review 100% H 100% R R

3.a Welder Qualification AWS Review 100% H R R

4 Checking of root run & final weld by dye Penetrant test (butt welds)

As per PO Visual 100% W 100% R R

4.1 Measuring of Ferrite Number in all weldments As per PO

Checking with

meter 100% W W R

5 * Marking of nozzle orientation As per

drawing Location of nozzle 100% W 100% W R/W

6 Dye Penetrant test on all fillet welds. As per PO Visual 100% W 100% R R

7 Visual & Dimensional inspection

As per approved drawing

Dimension 100% W 100% W R

8 Shell rolling, long seam & Cir. Seam fit up As per std Visual 100% W 100% W R

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9 Back gouging of long & cir seam welds.

As per std Visual 100% W 100% R R

10 Circularity of shells after rolling As per std Visual 100% W 100% W R

11 Forming of dished ends & solution annealing As per std Visual 100% W 100%

W/R R

12 Fit up of nozzles, saddles and supports and welding As per std Visual 100% W 100% W R

13 Evaluation of radiography films of all butt welds

As per PO Film evaluation

100% W 100% R R

14 * Stress relieving of total fabricated tank As per PO Graph 100% W 100% W R

15 Mechanical cleaning and buffing As per PO Visual 100% W 100% R W/R

16 * Hydraulic test for tanks as per design code

As per PO Pressure

hold method

100% W H/ W W

17 * Pneumatic leak test for tanks As per PO Pressure

hold method

100% W H/ W W

18 Picking, passivation and painting As per PO Visual 100% W R R

19 Integration of Tank with trailer As per P.O Visual 100% W H H

20 Filling with dry nitrogen at 0.5 bar (g)

As per PO Gauge reading

100% W R R

21 Stamping of the vessel and issue of certificates As per PO Visual 100% R 100% W ---

22 Production Master File As per PO Document 100% R R R

23 Dispatch clearance As per PO Document - - H Legend : R – Review, W – Witness, H – Hold.

Note:The purchaser reserve right to participate in the Inspection at any stage of fabrication & the bidder shall intimate the work pr ogress periodically. However, purchaser will witness the activities marked as *

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ANNEXURE-II

PROCEDURE FOR PICKLING, PASSIVATION

i) Mechanical Cleaning:

All metallic surfaces inside and outside having scales and foreign materials and all welded

surfaces have to be cleaned. This can be done by scrubbing with metallic brush

(Stainless Steel). The loose scales and powders obtained from the above process can

be cleaned by blowing, sucking or washing with water. Mechanical cleaning shall be

carried out before stress relieving.

ii) Degreasing, pickling and passivation:

Degreasing, pickling and passivation shall be carried out as per the following method for

the tank after hydro testing.

Swabbing method using Barium Sulphate as an acid carrier for both inner and outer

surfaces of the tanks.

Degreasing has to be done by soaking with hot detergent solution of Lissapol at 60 Deg.

to 70 Deg. C for at least 2 hours till satisfaction.

Pickling and Passivation (Swabbing Method)

The pickling and passivation is done with barium Sulphate as carrier (chloride levels 25

PPM) in the form of paste. For each of pickling and passivation operations, the paste has

to be applied on the surface and has to be kept for at least two hours. Paste has to be

removed with waste cotton in each operation and finally the surface has to be rinsed with

DM water.

Note: If suppliers desires to adopt filling method for pickling & passivation of inner surface

of the tank the same may be adopted with the approval from the purchaser.

iii) Checking

All the relevant tests shall be carried out to ensure proper pickling and passivation as per

ASTM A 380.

iv) Drying

The drying is done to remove water and this is done as given below:

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Passing dry Nitrogen /Air having dew point less than –40 Deg. C and free from oil and

grease (less than 10 PPM) at 60 Deg. C till the moisture level at the exit comes to the

inlet concentration value.

ANNEXURE –III SPECIFICATION OF FLOW COMPONENTS TO BE MOUNTED ON T HE TANK 1) Ball valves: Type : Two-way Construction : Two piece Bore : Full Bore Design Code : BS 5351 / API 6D Testing Code : BS 6755 Part-I / API 598 Fire Safe Deign : BS 6755 Part-II / API 607 Face to Face dimension : ANSI B 16.10 Operations : Lever operated End Connection & Class rating

: Flanged as per ANSI B 16.5, 150 #, Raised face

Material : Body & Ball – CF8M / SS 316 or CF8 / SS 304 Stem – SS 316 Seats / seals – Grafoil /PTFE/ GFT

Make : L & T / VIRGO Quantity : 1) 15 NB – 4 Nos.

2) 25 NB – 20 Nos. 3) 50 NB – 8 Nos.

or to be mentioned by the supplier based on the design

2) Magnetic Level Indicator: Level range : 0-1300 mm Type : Bullet Type magnetic level indicator suitable to 50

NB, 150# Flange nozzle Guide Pipe : SS 304 L Schedule: 10S, 25 NB size Float : SS 304 L Working Pressure : 3 kg/cm2 Design Pressure : 5 kg/cm2 Make : R.K. Dutt Concerns, Thane. / Pune techtrol /

Magnetrol India Quantity : 4 Nos. (2 Nos. for HTPB & 2 Nos. for DOA)

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ANNEXURE-IV

CHECKLIST TO BE FILLED BY THE BIDDER

Sl. No Description Road Tankers

HTPB

1 Design code followed

2 Design pressure considered

3 Stress value considered at Design temperature for design of tanks

3.1 100% UT of plates as per ASTM A435 (If done at plate mfg. Plant, with TPIA witness)

4 Allowance considered: i) Corrosion allowance

5 Thickness selected a) shell (including CA) b) dish

6 Material of Construction as per Table-I

7 Welding 100% by GTAW process

8. Width of storage tank plates 2 mtrs (Minimum)

9 Radiography: (100%) X-ray machine with sensitivity of 2-2T

10.1 Solution annealing of dished ends

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10.2 Stress relieving of total tank before Hydro test at 420+10 deg.C

10.3

Details of Furnace like type, clear Dimensions, Type of Fuel, No. of Nozzles, Location & No. of Thermo (min. 6Nos) Couples and recorders proposed (min. 2Nos).

11 Mechanical cleaning

11.1 Degreasing, Pickling & passivation

11.2

Surface preparation & painting of epoxy primer and final coat Preferable make: Berger/Bombay paints/CDC/GP/ Good las Nerolac

12.1 Hydro testing of the tanks

12.2

Pneumatic testing of the total vessel

13.1 Third party Inspection agency Lloyds or DNV or BV

13.2 Third party inspection charges quoted separately

14 Acceptance of QAP

15 Accepting part order

16 Confirm Flow components also included in the offer

17. Confirm Trailer prices quoted Separately in the offer 18. Compliance to Annexure VI, VII & VIII

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Annexure V

DESIGN, FABRICATION, SUPPLY, TESTING AND COMMISIONING OF 20, 000 KG PAY LOAD CAPACITY FULLFLAT BED SEMI-TRAILER FOR MOUNTING THE ROAD TANKER.

SCOPE

A) The Scope of supply shall include design, raw materials procurement, manufacture, inspection, testing and supply of 20 T Capacity full flatbed semi-trailer for mounting the road tanker as per the technical specifications, terms & conditions given in Annexure-V , Quantity – 1 No.

SL. No.

ITEM DESCRIPTION Bidder’s acceptance

1 CAPACITY 1.1 Payload carrying

capacity and type 20, 000 Kg uniformly distributed load throughout the loading length of the trailer.

1.2 Prime mover to be used

Ashok Leyend UM 3518 TT hauler: 1/13 of wheel base 3300mm, king pin off set – 600 mm and height around 1310 mm.

Volvo make FM 400 heavy duty hauler of wheel base 3885mm, king pin off set 385mm

Volvo make FM 520 model heavy duty hauler of wheel base 3885mm, king pin of set 385mm

AMW make 4923-3850wb 6 x4 tractor of 375mm king pin off set.

1.3 Loading scheme The loading scheme on the trailer is explained in the Fig: 1.

1.4 Operating Speed 50 km -Under No load 30 km - With rated load.

1.5 Operating Environment

Operating temperature 10 deg C to 50 deg C. Relative humidity - 95%

1.6 Allowable g level Maximum 0.5g 1.7 Natural frequency Less than 5Hz

(Induced frequency on the top of the trailer platform.)

Requirement: Actual dimensions shall be worked out by the supplier and GA drawing of trailer (to scale) shall be submitted along with quotation. Dimensions like Turn circle radii, angle of approach, angle of descent and maximum ramp that can be negotiable (by trailer) shall be given by the supplier, as per relevant Indian standards.

2 WEIGHT & DIMENSIONS OF THE TRAILER

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SL. No.

ITEM DESCRIPTION Bidder’s acceptance

2.1 Length of the trailer 9000 mm 2.2 Overall width of the

platform 2500 mm (maximum)

2.3 Unladen height 1500 mm (maximum) 2.4 Minimum ground

clearance 350 mm ( maximum)

2.5 Acceleration/ Deceleration

Force due to Acceleration / Deceleration or vertical load (including self-weight) of 3.0 g shall be taken into consideration for design calculations.

2.6 Type of the trailer Flatbed type semi-trailer with tank saddle mounting provision on the chassis (Without Chequered plate on the platform and with suitable no. of axles.

3 CHASSIS FRAME 3.1 Trailer Structure The trailer frame shall be of all Electrically welded

and robust in construction.

Main longitudinal members- 2 Nos. of fabricated I-Sections of material ST52 running full length of the trailer.

Cross member made from preferably with rolled section shall be provided at close intervals with ST 52 and equivalent to latest edition of IS 2062 materials.

The trailer platform shall be fully covered with Structural steel plate of 12mm thickness meeting to latest edition of IS 2062 material and shall be welded to trailer longitudinal and cross members.

Structural welding shall be done as per AWS D1.1 code. Welding design Calculations shall be submitted. Welder qualifications shall be submitted along with this offer .

Footsteps along with handrail shall be provided at the rear side and side of the platform at two locations.

3.2 Factor of safety In design of trailer structures impact factor of 1.5

shall be considered only in the horizontal direction.

The factor of safety shall not be less than 2.5 times on yield stress and maximum working stress shall be yield stress/2.5

3.3 Deflection Deflection of the trailer platform shall be zero in

the no load condition of the trailer . The deflection

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SL. No.

ITEM DESCRIPTION Bidder’s acceptance

measured at the middle of trailer shall not be more than L/500 under maximum rated load where L is the wheel base.

Bidder shall mention explicitly the fabrication techniques/methods carried out by them to maintain Zero deflection in the No-load condition of the trailer.

4 Rubbing Plate The trailer Rubbing plate shall be so constructed

that the area shall be capable to take the reaction load imposing on the King Pin.

Minimum area of the rubbing plate shall be of 1200 mm x 1200mm.

Rubbing plate height from the ground shall be 1400 mm = 25mm & - 0 mm. shall be maintained

The clear space between the prime mover cabin rears to the front edge of the trailer platform shall be a minimum of 1450mm. Such that 90 deg turn can be taken up by the prime mover without trailer obstruction.

Trailer platform front edge projection from Kingpin center line shall be in between 750 mm & 900 mm

5. KING PIN DETAILS 5.1 Size of the King Pin

& make SAE 3.5 inch King Pin of reputed make preferably JOST, GF, SAF. HOLLAND and BPW.

5.2 Indian Standard Conforming to IS 6763 part 2 5.3 D - Value of 5th

wheel coupler King Pin D - Value shall be maintained

5.4 Testing Manufacture's test certificate shall be provided along with the supply as per standards.

6 Axles

Standard axle of adequate capacity shall be provided.

Standard axle assembly including hubs, brakes and suspension shall be of reputed make from M/s TATA/ Ashok Leyland/ Automotive Axles/YORK/ Holland/ADR/ BPW/Hendrickson.

Number of axles, axle spacing and axle loading shall be conforming to Central Motor Vehicle Rules (CMVR) - 1989.

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SL. No.

ITEM DESCRIPTION Bidder’s acceptance

The hubs and brakes drum shall be separate for attending to brake repairs easily without removal of hub.

Axle bearing used shall be of following reputed makes of like - SKF, FAG, TIMKEN, NBC only.

Inner wheels shall be accessible easily for attending to maintenance, tyre changing works and easy air filling.

Suitable provision shall be given in the hub for removal and replacing of bearing cones easily from the hub.

Necessary test certificates for axle assemblies shall be submitted during stage inspection of trailer.

7

SUSPENSION

The type of suspension shall be of leaf spring mechanical type. Preferably, standard make mechanical (along with shock absorbers, mounting brackets & shackles) which are used in heavy commercial vehicles of M/s TATA, M/s Ashok Leyland / YORK/ Hendrickson shall be used.

The suspensions shall be designed to offer a smooth ride under no load, part load and full load conditions.

Make of suspensions: M/s TATA/ Ashok Leyland/ Automotive, Axles/ YORK/ Holland/ADR/ BPW/Hendrickson.

Make of Shock absorbers : M/s Gabriel / Armstrong

8 BRAKE SYSTEM WITH FAIL-SAFE BRAKE

The trailer shall be provided with twin line (service and emergency line) air brake system coupled to hauler brake through palm coupling and actuated from hauler (preferably of M/s TVS / WABCO make)

All axles shall be fitted with service brakes and fail safe brake systems.

ISO palm coupling shall be provided at the coil type hose of suitable length at the front of the trailer.

Pneumatically operated parking brake at rear wheels with control mechanism underneath the trailer platform.

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SL. No.

ITEM DESCRIPTION Bidder’s acceptance

All brake actuation system shall be provided with adjuster for adjusting brake shoes.

The trailer shall be fitted with an air reservoir having capacity to give a minimum of four full brake application with pressure drops from cut-out to 0.7 times the cut – in pressure.

Brakes on each axle shall be capable of producing peak retarding force equal to 0.45 times the rated load on the axle.

The trailer air reservoirs shall be provided with auto drain valve.

All brake parts, air regulator, valves shall be TVS sundram clayton / WABCO make.

Trailer shall be fitted with emergency brake relay valve which automatically applies trailer brakes in case accidental de-coupling of the Fifth Wheel Coupler.

Brake system pneumatic hoses shall be routed properly without handling freely.

Air tubes shall be painted to SAE/ISO color code i.e., yellow for emergency line and red for service line. Similarly flexible hoses shall be also of same color.

9. WHEELS & TYRES

Standard Ring type wheel drums of wheels India or reputed make shall be used.

Heavy – duty pneumatic tyres of suitable size and ply rating to withstand high operation shall be provided.

Axle shall be provided with dual tyres on each side. The tyres shall be of indigenous make and size

available freely in the market.

Long inflation necks or adapter shall be provided for inflation of inner wheels and for checking tyre inflation pressure.

10. Landing legs 2 Speed worm gear type.

The trailer shall be provided with two sets of suitable capacity 2 speed landing gears, one at front and the other at rear, preferably of JOST / YORK / FUMA / SAF HOLLAND make.

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SL. No.

ITEM DESCRIPTION Bidder’s acceptance

The landing gears shall take minimum 1.25 times the static load of the rated payload and self-weight of the trailer.

Lifting Capacity : minimum 20t (20000 kg) Static capacity : Minimum 40t (40000kg) 11. Electrical System

All accessories shall function on 24 Volt DC supply

from prime mover batteries.

Shall be provided with SAE J 560, 7 pin connector with 7 core cable going all the way from trailer front to rear.

Wiring shall be covered in a safety conduit and property terminated so that no exposed loose wire are visible.

The trailer shall be provided with combination type tail lamp fittings consisting of parking lamps, brake lamps, side indicators and number board lights.

Trailer sides shall be provided with Red light fittings with separate switch control.

All electrical wiring materials shall be of fenolex make and routed through GI heavy duty piping with double pole wiring. All electrical wiring shall be underneath the chassis with minimum bends and with No JOINTS.

All light fitting shall be of LUCAS TVS, LUMAX or LUMAN make and weather proof construction.

Male and Female sockets shall be provided with sufficient length of cables to connected with the hauler supply point.

Electrical cable termination points shall be with as tight protection.

12. Other fittings 1. Steel Sturdy mudguard and metal mudguard

flaps for wheels

2. Side under run Protection Device (SUPD) shall be provided as per IS 14812

3. Rear under run protection Device (RUPD) shall be provided as per IS 14682.

4. Shall be provided with SAE J 560, 7 pin connector with 7 core cable from trailer to prime mover.

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SL. No.

ITEM DESCRIPTION Bidder’s acceptance

5. Reflex reflector of sufficient numbers on the rear and on the sides.

6. Shall be provided with reflectors, indicator and tail lights.

7. One no. of Tools box of size 1000 mm 9length) x 750 mm (width) x 750 mm (depth), with hinged lid and locking facility, to be provided under chassis. Lock (Godrej Navatal 7 Levers with three keys shall be provided.

8. 2000 kg tie down capacity lashing hooks on all four sides (Including trailer front side) of the trailer platform at a span of every 500 mm.

9. Number board, Name Plate and stop board at rear.

10. SWL of the trailer shall be legibly painted at the side.

11. Spare wheel mounting (1 No.) preferably below the trailer platform.

12. Greasing points for the trailer wherever required.

13. Red color reflex reflector should be provided on the rear end of the trailer – 4 nos (min). Reflecting surface dia 75 mm. Also on the side, 5 Nos. each(min)

14. Red flag holder – 2Nos at the rear side of the trailer platform shall be provide.

15. Lifting type of bras earth chains with 4 rows shall be provided at rear of the trailer at both corners such that the brass chain should touch the ground.

16. All fasteners shall be of electro galvanized / yellow passivated coating and of make UNBRAKO, TVS only shall be used (IS 1367)

13. PAINTING The trailer shall be surface prepared and painted as

per the following specifications:

1. Sand/Grit/Abrasive blasting: The entire surface of fabricated materials/ frames of trailer are to be sand/grit/abrasive blasted to near white metal quality of SA 2½ of Steel Structures Painting Council (SSPC)

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SL. No.

ITEM DESCRIPTION Bidder’s acceptance

standard. The surface shall be completely free from rust, oil, grease, dirt or other matter. Surface should be thoroughly from grit/sand dust before application of primer paint coat.

2. Painting: (Spray Painting only shall be

applied) Immediately after sand/abrasive blasting, one coat of epoxy primer shall be applied to a Dry Film Thickness (DFT) of 80 microns. Intermediate coating with epoxy paint shall be applied to a Dry Film Thickness (DFT) of 80 micron. A final coat with polyurethane finish paint shall be applied to a Dry Film Thickness (DFT) of 40 microns.

3. Any intermediate cleaning & drying time required between successive coats of paint is to be carried out as per the recommendation of paint manufacturers. All paints and primers shall be of standard quality and procured from any one of the standard manufacturer like M/s ASIAN PAINTS, M/s BERGER, M/s NEROLAC, M/s JENSON & NICHOLSON, M/s DULAX (ICI)

4. The supplier shall provide measuring instrument to the representative of the purchaser for measurements of thickness of paint at random locations selected by him to confirm the required minimum DFT.

14. Tentative Painting scheme shall be as follows:

1. Under chassis &Springs : Black

2. Axles, brake drum, hubs : Brown 3. Wheels : Golden Yellow 4. Sides and rear: Golden Yellow with black

stripes.

5. Top platform : Orange Painting colour scheme will be finalized during

detail engineering phase

SWL, stop, number/Nameplate, Solid Propellant Plant, SATISH DHAWAN SPACE CENTRE-SHAR,

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SL. No.

ITEM DESCRIPTION Bidder’s acceptance

L (long trailer) board etc., shall be painted at suitable location on the trailer

Letter writing shall be done as per purchaser requirement.

15. Item to be supplied along with the trailer 1. Self-closing Palm coupling – 2 sets for trailer

(one set consist of service line palm coupling-1 No & emergency line palm coupling – 1 No.)

2. Coil type pneumatic hose- 2 sets (1 set 2 Nos.)

3. Air Springs – 2 Nos. 4. Height control valve – 2Nos. 5. Auto drain Valve – 1 No. 6. Pressure regulator with pressure gauges – 2

Nos.

7. Wheel Nut spanner and long lever – I set. 8. Wheel Hub Nut Spanner with lever – 1 Set. 9. Hydraulic Hub Puller with Inner bearing

adapter -1set

10. Wheel bearings set ( one set consist of inner and outer bearing put together) – 4 sets.

11. Wheel Hub oil seal st (one set consist of inner and outer seal of all axles put together) – 6 sets

12. Spare wheel mounted with tyre and tube -1No.

13. Tyre inflation extension- 4 Nos. 14. Brake hoses set (10 mt length) – 02 sets. 15. 20t (20, 000 kg) capacity hydraulic jack with

jack rod – 1 set.

16. 6t (6, 000 kg ) capacity axle stands (operating minimum and maximum height suitable for axle maintenance) – 4 Nos.

17. Separate rate (cost per quantity) shall be provided in the quotation. The above spare parts shall be supplied along with trailer.

16. List of Maintenance tools.

Maintenance tools consisting of, but not limited to, wheel spanner, axle nut spanner, screw drivers, pliers, grease gun. Tool box of suitable size, with hinged lid and locking facility, to be provided below the trailer platform (at rear). Lock (Godrej Navtal 6 levers) with three keys shall be provided. List of

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SL. No.

ITEM DESCRIPTION Bidder’s acceptance

maintenance tools shall be provided along with quotation.

17. Quality Assurance & Inspection

17.1 QA Plan And other documents to be provided along with the tender

The tender should submit a quality assurance plan to ensure quality of raw material, bought out item and fabrication confirming to the specifications.

1. General assembly drawing with sectional views of structure ( with a soft copy of Auto CAD 2004 version )

2. Basic design details of the trailer including load reaction calculation for review and approval.

3. Welding design calculation shall be submitted.

4. Bill of materials 5. Brake system layout containing TVS

Sundaram Clayton pat numbers for each item, brake lining size and brake chamber sizes etc.,

6. Details of bought out items, technical literature of components, product catalogues, test certificates etc.,

7. Test corticated issued by the manufacture for the components such as 31/2” King Pin and other bought –out items shall be furnished at the time of stage Inspection.

8. Turning circle radius diagram with inner and outer turning circle radius with the combination of prime mover mentioned in the Para 1.

9. Technical specification / technical leaflets of the components and other Sub-assemblies.

10. Address of the organization for which the tender has supplied similar trailers.

The trailer Design shall be approved / cleared by the purchaser before taking up fabrication by the bidder.

17.2 Stage Inspection

The trailer will be inspected at various stages during fabrication stage.

1. Raw material Inspection.

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SL. No.

ITEM DESCRIPTION Bidder’s acceptance

2. In- process inspection. 3. Final inspection For stage and final inspection, the supplier should

extend all assistance to the representative of the purchaser. The supplier should correct any modification or corrections brought to the notice of the supplier at the time of Inspection, by the representative of purchaser.

The trailer and other accessories will be inspected by the representative of the Purchaser at the works of the supplier during the course of fabrication and testing, to ensure that the trailer is fabricated as per technical specifications.

17.3 Final Inspection

Pre delivery Inspection will be done at supplier’s works site after completion of all works before painting. After this inspection, the trailer will be cleared for dispatching to SDSC-SHAR, sriharikota.

Final inspection as per the purchase order specification after completion of all works.

17.4 Load testing at Supplier’s works Site

The trailer shall be load tested for rated capacity and overload tested for 125% of rated capacity at supplier’s works site. Necessary prime mover, dead weights and inspection equipment and procedure for load testing / overload testing shall be provided by the Supplier on free of cost or included of offer cost.

18.5 Commissioning and load testing at Purchaser’s works site Commissioning and final load testing shall be

carried out for trailer for smooth operation at Purchaser’s site i.e., SDSC-SHAR, sriharikota.

Necessary prime mover, dead weight and procedure for load testing will be provided by the purchaser.

The load testing will be carried out in presence of representative of the supplier. After load testing, minor modifications if any, shall be attended by the supplier with no extra cost.

19. Documents required for Registration The trailer will be used for transportation of the

specimens on public roads in between states and union territories.

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SL. No.

ITEM DESCRIPTION Bidder’s acceptance

MORT & H approval will be obtained by the purchaser as Overall width of the trailer if exceeds (> 2600mm) the permissible limit of Central Motor Vehicle Rules (CMVR). Required documentation for registering the trailer in Andhra Pradesh state, shall be furnished / supplied by the Supplier.

20. Documents to be Supplied along with the trailer

Two sets of MASTER DOCUMENT containing design details, stage Inspection reports, technical literature, product catalogue, test certificates of bought out components and assemblies, pneumatic system schematic diagram, spare parts details etc., in hard bound book form.

II. TERMS AND CONDITIONS OF SUPPLY:

Sl. No.

Item Description Bidder’s Acceptance

1. Submission of Quotation Supplier shall submit the following details of trailer along with quotation: 1. Technical specifications of trailer with

major component description. 2. General arrangement drawing with all

dimensions of trailer.

3. Weight of trailer.

4. Axles capacity.

5. Angle of approach, Angle of departure

and max. Ramp climbable by trailer

(without touching ground).

6. Turn circle radii.

7. Make of Materials & bought-out items

(Raw material plates/Sheets, Axles,

King Pin, pneumatic suspension, steel

plates, tyres, shock absorbers etc.,).

8. Delivery period.

9. Payment conditions.

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Sl. No.

Item Description Bidder’s Acceptance

10. Supplier shall declare that he will

fulfill all the conditions and technical

specifications of trailer for supply.

Any Deviation (technical) shall be

brought out by Supplier clearly.

11. Earlier references like purchase

order copy/details and capacity of

trailer of trailers supply to reputed &

prestigious organizations.

12. Validity of Offer

(Minimum 4 months)

Note: Tender shall be accompanied with all above mentioned details. The General Arrangement drawing of trailer shall be drawn to scale with the elevation and plan of the TRAILER and along with specimen & Saddles structure with its mountings. Tenders will be rejected, if compliance with this clause is not ensured. The tenderer shall also clearly specify any request for deviation from technical specifications on particular items by mentioning sl.no. of specifications. Generalized statements like trailer will be manufactured as per your specifications or as per IS standards etc. are not adequate. Otherwise, it may result in rejection of the tender. The purchaser team shall visit the supplier site at the tender enquiry stage for supplier validation against the supply of trailer and only

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Sl. No.

Item Description Bidder’s Acceptance

shortlisted party/ supplier shall be eligible for participating in the tender.

2. After placement of Purchase Order, Supplier shall submit/ provide the listed information, design details, calculations and drawings (in three copies each) to the purchaser for approval. Design & Detail Engineering

After Placement of Purchase Order ( Design & Detail Engineering):

1. Quality Assurance Plan to be followed in the fabrication, assembly and supply of trailer including load testing plan, with stages of inspection. This shall be supplied for our Approval.

2. The General Arrangement drawing of trailer to the SCALE clearly showing dimensions, air connections, Wheels, Turn circle radii , weight break up, etc.,

3. Structural calculations : General layout drawing of trailer frame to SCALE with design calculations (bending moment, deflection, maximum stresses, permissible stresses etc.,). Impact factor shall be considered in trailer calculations. All the drawings shall show the bill of quantities and material specifications.

4. Design calculations for weld joints

showing loads & stresses

5. Design calculation for King Pin & Rubbing Plate arrangement structure, with drawings & Bill of materials.

6. Calculations for turn circle radii

and max road width required at turnings.

7. Calculations for axle load and tyre

loading with selection criteria of axles, King Pin & rubbing plate

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Sl. No.

Item Description Bidder’s Acceptance

arrangement, Pneumatic suspension, wheels, tyres and bearings etc.

8. Braking calculations for trailer and

stopping distance. 9. Assembly drawings of Axles, wheel

assemblies, King Pin & Rubbing plate arrangements.

10. Circuit diagram for twin pipeline air

brake system containing details of components such as make, type, rating etc., with a technical description meeting the requirement mentioned in this technical specifications.

All the above drawings and calculations shall be submitted within 4 weeks after placement of order to the purchaser for approval. After approval only supplier shall starts the fabrication of trailer. If the drawings and other particulars are not accepted by the purchaser, because they are incomplete or faulty, the supplier shall make the necessary correction / modifications and resubmit the drawings and calculations within a reasonable time.

3. The following documents and manuals shall be supplied along with trailers (prior to commissioning of trailers at our site)

DOCUMETNS ALONG WITH SUPPLY:

1. Three copies of final drawings and data of trailer, which have been approved by the purchaser.

2. Three copies of Operation,

Maintenance manuals with lubrication charts, twin pipe line braking system.

3. Three copies of Spare parts manual.

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Sl. No.

Item Description Bidder’s Acceptance

ALL THE DOCUMENTS SHALL BE SUPPLIED IN THE FORM OF HARD BOUND BOOKS.

4. Apart from hardcopy, all final

drawings of trailer, major components assembly drawings of major components and circuit diagram shall be submitted in soft copy in ‘CD’ in AUTOCAD format.

4.

Warranty

12 calendar months from the date of supply against faulty design, faulty fabrication, faulty workmanship and defective materials. Any part or components found defective during warranty period shall be replaced with new one.

5. Performance Bank Guarantee

The party has to give a performance bank guarantee for a value of 10% of the order value, valid for the warranty period of 12 months from the date of commissioning and acceptance of trailer at SHAR centre.

6. SUBMISSION OF BIDS TWO PART BID

Supplier shall submit their offer in two parts. Part 1: Technical and commercial

Bid (with unpriced price bid format)

(Bidders QUESTIONNAIRE, BID QUALIFICATION CRITERIA, 20t trailer Technical specifications and etc.)

Part 2: Price bid comprising the prices

in Rupees for

1. Basic supply value of trailer

2. Transportation cost

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Sl. No.

Item Description Bidder’s Acceptance

3. Cost of stephney wheel,

4. Price for recommended spare parts

listed in specifications (Clause No. 14)

with breakup cost.

5. Applicable taxes and duties.

Signature of competent person

Name: Designation:

Date : Company seal :

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Annexure - VI VENDOR EVALUATYION CRITERIA

The pre-Qualification criteria shall be filled by supplier, duly signed and submitted along with technical bid for review by purchaser.

Sl. No

CRITERIA Vendor Compliance (YES*/NO)

1 Tenderer shall have at least 10 years of experience in the field of Design, Supply of Materials, Fabrication, Inspection, testing and Supply & integration mobile / road tanker system with semi-trailer (semi-trailer alone may be brought out from reputed suppliers). Tenderer shall submit the documentary proof of previous order along with quotations

2 Should have Configured, Designed, Manufactured and Erected & Commissioned mobile / road tanker. Integration of mobile. / road tanker with semi-trailer (own design / brought out item) and qualified during last 10 years. Proof to be enclosed.

3 Copies of the completion certificate/performance certificate and contact details from your client organization to whom similar size or higher size mobile tanker with semi-trailer. Performance demonstration of similar kind of machine supplied by tenderer at client site shall be arranged. Department reserve right to evaluate vendor & its sub-contractor capability to supply indented mobile / road tanker with semi-trailer to this tender specification and reject, if not capable

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Annexure – VII

Schedule of Prices

S. No Description Unit

Cost (in Rs/foreign currency as applicable.)

1

Design, Supply of Materials, Fabrication, Inspection, testing and Supply & integration road tank on semi-trailer (Without Spares and AMC).

Lump sum

1.1 GST on items in S.No.1 %

2 Packing forwarding and Transportation charges for total system

Lump sum

2.1 GST Item in S. no.2 %

3 Third party charges Lump sum

3.1 GST on Item in S.No.3 %

Total Cost (Sum of S.No. 1+1.1+2+2.1 + 3+3.1)

4. Cost of Spares (To be furnished by the supplier)

Lump

sum

4.1. GST on items in S.No.4 %

Total Cost (sum of S.No 4 +4.1) of system

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Annexure –VIII

EXCEPTIONS AND DEVIATIONS In line with Proposal Document, Bidder may stipulate Exceptions and deviations to the Proposal conditions if considered unavoidable. SL.NO

Reference in Specification

Dept. Spécification

Offered Spécification DEVIATION

PAGE NO

CLAUSE NO

NOTE : Only deviations are to be written in this Annexure – VIII. Any deviations taken by the Bidder to the stipulations of the Proposal document shall be brought out strictly as per this format and enclosed along with the bid. Any deviations not brought out as per this Proforma (Annexure – VIII) and written elsewhere in the Proposal document shall not be recognized and the same is treated as null and void. Any willful attempt by the Tenderer to camouflage the deviations by giving them in the covering letter or in any other documents that are enclosed may render the Bid itself non-responsive.

(SIGNATURE OF BIDDER)