Functional Specification for Deck Crane

SPEC No. 5301F

Rev. No. 2

Discipline Mechanical

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FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE: ODS/SOF/004A ODS/SOP/008 TO 015 01 01 15/10/2003

1

FUNCTIONAL SPECIFICATION

FOR

DECK CRANE

PREPARED BY

REVIEWED BY

APPROVED BY

TOTAL No. OF PAGES DATE REV. No.

AKM SKG JSS 31 17/6/2005 2

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FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE: ODS/SOF/004B ODS/SOP/008 TO 015 01 01 15/10/2003

CONTENTS 1. INTRODUCTION

1.1 Scope/ General

2. CODES AND STANDARDS

2.1 Codes , standards and regulations

2.2 Projects Specifications

3. SCOPE OF SUPPLY

4. ENVIRONMENTAL DESIGN CRITERIA

4.1 Climatic conditions

4.2 Area classification

5. DESIGN REQUIREMENTS

5.1 General

5.2 Operating Conditions

5.3 Package Limits

5.4 Hydraulic Systems

5.5 Hoist & Winches

5.6 Boom

5.7 Swing

5.8 Mounting

5.9 Controls

5.10 Electrical

5.11 Data Sheets

5.12 Acceptance Criteria

6. SPARES PARTS AND TOOLS

6.1 Spare Parts

6.2 Special Tools

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7. INSPECTION , TESTING AND CERTIFICATION

8. PREPARATION FOR SHIPMENT

9. DOCUMENTATION

10. WARRANTY

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1.0 SCOPE This specification covers the minimum requirements for the design, manufacture, testing, and supply of diesel engine driven pedestal mounted deck crane for new platform

The deck crane shall be used for handling of equipment, materials, drums and personnel baskets from barges and supply vessels etc. and for loading and unloading of materials between boat landing area and the main deck, cellar deck, helideck of the platform.

The Supplier should draw upon his existing, pre-engineered or standard design to satisfy the functional requirements described below and in the attached datasheets. The supplier shall submit full technical details of his standard equipment that meets the requirement detailed herein. . Vendor shall have final and total responsibility for design and performance of the equipment supplied in accordance with this specification, codes/standards and attached Functional Specification.

2.0 CODES AND STANDARDS

2.1 Codes, Standards and Regulations

As a minimum, all equipment supplied as part of this package shall be designed, manufactured and delivered in accordance with the following codes & standards. The latest editions, as of the Enquiry date, of the following Codes, Standards and Regulations are generally applicable and are to be used by Suppliers in their Package Designs. Where “in-house” Standards have either been developed or are based on recognized National/ International or industry standards may be offered as an alternative, provided adequate detail is contained within the Technical specification referred to in Functional Specification.

Diesel Engine : BS 5514, ISO 3046

Electrical Cables : IEC 331 and 332 part 3 for flame re-trading properties and fire survival.

Piping Systems : ANSI B31.3, BS 10, API 5L, BS 1387, ISO 65

Performance : Vendors standard

Welding

: Recognized National or industry standard BS /EN 288

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Fire & Gas System : NFPA 12 and BS 5306 part 4, 1979 for CO2 systems

Safety : IS 289, 1974, The Offshore Installation (Construction and Survey) regulations, HSE, OSHA and other mandatory regulations applicable to destination territory shall also be satisfied.

Pressure Vessels : BS5500 or ASME VIII Div. I

Certification : BS/EN 10204, Metallic Products – Type of Inspection Documents

Hazardous Areas : As defined in Data sheet

Painting System : Vendor’s Standard( suitable for marine environment) – For equipment Spec 2005 – For structure and vessels.

Noise : As defined in data sheets and company’s standard. In the absence of any specific requirements then the vendors shall generally satisfy and/or exceed the HSE minimum requirements, (following EEMUA 140 guidelines)

Vertical Tanks : BS 2654

The following codes and standards (latest edition) are referenced to and made a part of this specifications. API Spec 2C Specification for Offshore Cranes.

API-RP-9E Recommended Practice on Application, care and use of Wire Rope

for Oil Field Service.

API-RP-2D Recommended practice for Maintenance and Operation of Offshore Cranes.

API-SPEC-7B-11C Specification for internal combustion Reciprocating engines for Oil Field Service.

AGMA American Gear Manufacturer’s Association

NEMA National Electrical Manufacturer’s Association.

OSHA Occupational Safety and Health Act.

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EEMUA Engineering, Equipment and Material Users’ Association (Publication No. 107) Recommendation for the Protection of Diesel engine operating in hazardous area.

ISO 3046/BS-5514 Reciprocating I.C. Engines. Part-I through VI.

API-RP-2L Heliports for fixed offshore Platforms.

BS-668 British Standard Specification for flame proof equipment for diesel

engines for use in coalmines and other mines susceptible to firedamp.

2.2 Project Specifications : The following specifications shall also be referred while

designing this package 1. 1050 ; Definition 2, 2005 : Protective Coating 3. 2009 F : Welding and NDT

4. 4017 : Functional specification of electrical equipment of packaged plant.

3.0 SCOPE OF SUPPLY :

The vendor shall supply all necessary equipment to make a complete and operable unit as per codes/standards and specification. This shall include but not be limited to the following. i. Boom and rotating superstructure including mainframe, gantry, cab with

controls, platform walkway with railing and approach ladders. ii. Hydraulic powered winches with wire ropes for main hoist, auxiliary hoist and

boom hoist system. iii. Diesel engine drive with engine starting system Diesel engine drive with

engine starting system. iv. Engine driven on board generator for power supply to the crane cab

accessories. v. Adequate working platform for maintenance of the crane engine, hydraulic

system, winches, crane boom and other accessories. vi. Mating flange and mounting hardware for locating the crane on a steel

pedestal. vii. Necessary multipurpose swivel. (Pl. refer data sheet). viii. Priming system for diesel fuel (in case of bottom fuel tank) shall be mounted,

consisting of a hand priming pump, fuel transfer pump, valves, piping etc). ix. Protective coating shall be done as per Vendor’s Standard suitable for marine

environment. x. Commissioning spares parts and consumables for start-up.

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xi. A list of spare parts for one year normal operation. 4.0 ENVIRONMENTAL DESIGN CRITERIA:

4.1 Climatic Conditions :

The basis under which the Equipment will operate are detailed in Design criteria -general (section 3.1 Vol II of bid document). The equipment will be operated on an offshore platform. The contractor is responsible for ensuring that all equipment and components provided are suitable for the utility and environmental conditions as specified during the entire design life.

4.2 Area Classification Refer Electrical Design criteria attached in the bid document.

5.0 DESIGN REQUIREMENTS : 5.1 General :

The deck crane shall meet API Spec. 2C requirement unless otherwise specified in the bid document.

5.2 Operating Conditions:

The deck crane shall operate on No. 2 Diesel Fuel and utilities as indicated in the data sheet. Where the suppliers standard or preferred design option does not meet the operating conditions, the supplier shall give details of the technical changes and commercial impact of complying with the stated conditions for company’s review and acceptance.

The equipment shall be designed as per codes and standards and for outdoor location

on an offshore platform with site conditions as detailed in description of work of bid package.

The Crane shall be suitable for operation at rated load under the wind and ocean

conditions listed below :

Wind Speed (Km/hrs) : 49 Wave Height (m.) : 3.66 Offload Angle (in plane of jib) : 8° Side lead Angle (lateral to jib) : 4°

The dynamic co-efficient for design shall be arrived at from API Spec-2C based on condition listed above.

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Engine shall be sized for carrying out the 100% of main hoisting, 50% of luffing and

50% of slewing actions simultaneously at full load and rated maximum speeds. However crane engine shall not be sized less than 125% of the horse power of the largest hoist.

5.3 Packaged Limits :

The intended location of the Deck Crane on the layout drawings is to be developed by the successful contractor. The package shall be delivered in the minimum economic number of assemblies. Each assembly shall be complete tested and pre commissioned in accordance with the requirements in the enquiry document taking due account of preservation and transport requirement. The supplier shall indicate the package envelope and interface points in the bid documents, and no change shall be made unless by mutual agreement.

5.4 Hydraulic Systems :

Separate hydraulic pumps of modular construction shall preferably be provided for main and auxiliary hoists drives, boom hoist drives, and swing drive. Suitably sized hydraulic reservoir (so located to provide positive suction to hydraulic pump) filters, relief valves and air to oil finned tube heat exchanger shall be provided. Hydraulic system components and piping shall be located within a drip pan.

5.5 Hoist & Winches :

The crane shall have main hoist, auxiliary hoist and boom hoist winches, and fitted with automatic braking systems. A separate hydraulic motor shall be provided for the swing drive. No winch shall be mounted on the crane boom.

5.6 Boom :

The crane boom shall be latticed construction with suitable connected sections, and complete with cable guards, deflectors and shock absorbing boom stops. It shall also be fitted with a hydraulic boom stop valve to prevent over topping of the boom. Automatic high and low boom angle limit switches shall be provided along with audible and visual warning devices. An automatically engaged locking pawl shall also be provided for the boom hoist drum. Boom shall also meet the requirements of code.

A suitable boom rest (removable type) shall be supplied by Installation Contractor on

the platform deck. The boom rest shall be installed in such a way that the boom tip is easily accessible for the servicing of main and auxiliary hoist pulley. Suitable provision (cat ladder) shall be integrated in the construction of boom to enable reaching boom tip from boom base. Cat ladder shall be of suitable width for a normal man and hand rails shall be provided for ease of movement.

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5.7 Swing : Crane shall be capable of rotating 360 degrees with a swing speed of zero to 1.5 rpm.

Adjustable stop switches shall be provided to enable fixing of crane rotation limits at a future date. A lever operated swing brake shall be provided in the cabin.

The swing circle shall consist of a slewing ring bearing with integral swing gear, of

gear and pinion type and flange for mounting it on the adapter ring flange at the top of the pedestal. The swing drive shall be provided with mechanical positive lock arrangement, controllable by the operator.

5.8 Mounting :

Crane cabin should be approachable from deck / intermediate working platform at all angles of crane position and also provide the crane operator with full vision of boom and load tackle at all times. A circular platform with ladder approach shall be provided (by Contractor) all around the crane pedestal at height such that it is 5 ft. (1.5m) below the swing mechanism for ease of maintenance and approachability of crane from platform in any direction. A ventilation fan shall be provided in the operator’s cabin. The material of fan shall be suitable to marine environment.

Necessary access platform shall be provided for servicing of boom sheaves on top gantry and slew mechanism underneath..

5.9 Controls : The crane shall be fitted with a load-sensing device which shall automatically

and continuously weigh the load being carried to an accuracy of ± 5 percent and

register the weight as well as the radius on an indicator clearly visible to the

operator. The indicator shall be calibrated for the boom length mentioned in data

sheet and load ratings resulting from this specification. A boom angle indicator shall

also be provided.

An automatic safe load indicator shall be provided to give the crane operator a clear and continuous visual warning when the load being carried exceeds the safe working load of the crane at that radius. And also a high level alarm to persons on the platform in case the load reaches dangerous level.

Vendor shall ensure that all the controls and safety parameters including alarms shall

be factory set for crane operation at readings corresponding to dynamic load charts.

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However, it shall also be possible inside the cab to reset manually the controls and safety parameters, when the crane is required to be recommended under static conditions, in accordance with charts furnished by the vendor.

Visual lighted indications shall be provided inside crane cabin to indicate whether

the crane is being operated in the STATIC or DYNAMIC mode of operations. The method of manual resetting of the controls for static lifting shall be clearly described in the bid offer and the procedure be indicated in the cabin.

All limit switches described above shall be hydraulically operated. The audible and

visual warning devices shall be of flame proof construction. A hydraulic emergency stop, to stop all functions of crane instantaneously, without stopping the engine , shall be provided.

All the alarms and shutdown indications are to be placed inside the crane cabin. in the same panel located in front of operator

5.10 Electrical :

Adequate lighting having flood lighting, boom walkway lighting, cabin lighting,

cabin fan etc, capable of independent night operation of crane without any platform

lighting, shall be provided . One red aircraft warning blinker light on the tip of the

boom and another on the crane frame shall be provided.

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5.11 DATA SHEETS :

1.0

OPERATING CONDITIONS AND DATA :

1.1 Operating Data 1.1.1 Nos. of Cranes required : Refer Description of work in bid document

for detail. 1.1.2 Equipment tag Nos. :

i Net dynamic lifting capacity(INDICATIVE) radius with specified boom under Ocean wind conditions @ Clause 3.2.2

: Refer Description of work in bid document for detail.

ii Net static lift at radius(∆) : Refer Description of work in bid document for detail.

1.1.3

Note : The above weight capacity are exclusive of the weight of Hook, Block, Wire ropes etc.

1.1.4 Booms length : To be computed as per API RP-2C ** 1.1.5 Auxiliary Hoist capacity : 2000 Kgs.,(No auxiliary hoist for 5 MT or

les capacity crane). Capacity is indicative, to be finalized in detailed engineering.

Hook speeds − Main Hoist : 0-37 meter/min. for fast line

0-18 meter/min. at full load

1.1.6

− Auxiliary hoist : 0-76 meter/min. Pedestal Size − Outside diameter (mm) : − Thickness (mm) : (to be finalized based on cl. 1.4.8 of

specific requirement)

*1.1.7

− External load moments : See special requirement vide cl. 1.4.8 *1.1.8 Approximate elevation of top of

pedestal w.r.t. chart datum (mts.) : Refer Equipment Layout drawing.

*1.1.9 Elevation of deck level (top of grating to approach crane (mts.)

:

*1.1.10 Approximate hook travel for each line (mtrs)

:

Note: --- - Data marked (*) are tentative and to be firmed up by the contractor during detailed

engineering. - Data marked (**) Boom length and pedestal location shall be selected in such a way

that it is possible to handle loads/equipment at heli-deck level and farthest future clamp-on wells.

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- Data marked (∆) The static capacity shall be so selected to suit the work over operations with 1.25 inch Coil Tubing Unit (CTU).

− Contractor shall ensure to locate and elevate crane pedestal so as to provide a clear view

(from the cabin) of the items to be handled on platform as well as boat landing. − Material for pedestal shall be as per API SPEC. 2H GR 50 minimum. 1.2 Area Classification :- 1.2.1 Deck Crane on platform will be located within : Class-1 GR-D, Temperature class-T3,

Division-2, hazardous area classified as per APR-RP-500B 1.2.2

Utilities available from Platform − Utility Air for starting diesel

engine : Nil

− Water : Potable water − Diesel fuel ISI-1460-1974

The fuel shall be No. 2 diesel for

marine applications. However, for

platform facilities design purpose water

content shall be considered 1 % Vol.

Max.

1.3

− Electric power : Nil Supplier shall specify the utilities required along with their rate of consumption in his

bid. 1.4 Specific requirement 1.4.1 Chain drive shall not be acceptable for crane swing system. 1.4.2 Power required for lighting and electrical shall be generated from primary power

source of engine. 1.4.3 Vendor shall attain the maximum speed of hook at the first layer of the drum i.e. at the

minimum diameter of the drum. 1.4.4 Limit switches for all motions shall be provided to cause sufficient reduction of

velocity before physical activation of mechanical stopper so as not to impair the mechanical stopper device. All limit switches shall be in explosion proof construction.

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1.4.5 Hydraulic tank shall have the following features in addition to other standard requirements, a) Low oil level alarm b) Magnetic particle collector a) Anti frothing arrangement. b) 100-micron full flow filtration system with field replaceable element mounted

externally to the hydraulic oil tank on the suction of pump, with built-in indicator system.

c) 5 micron full flow filtration system with field replaceable element, with built-in indication system for the entire system.

1.4.6 Multi-swivel connection shall be provided by crane manufacture for following utilities i) Fuel

1.4.7 All controls, warning, other safety features and indicator shall be minimum as per the specification. All electrical fixtures shall be flame proof. All controls shall operate in a fail-safe mode.

1.4.8 In respect of pedestal deflection contractor shall establish compliance of API Spec. 2C after due co-ordination with the deck crane supplier.

1.4.9

Crane base operating control arrangement shall be four lever type as per API Spec 2C.

1.4.10

An air / hydraulic driven diesel transfer pump to transfer the diesel from diesel storage tank to diesel engine day tank, consisting of piping, NRV etc.

1.4.11 All the devices shall meet the requirements for the area classification in which they are installed.

1.4.12 All couplings, gears and exposed rotating parts shall be provided with non-sparking type guards. Drive belts, if used shall be anti-static type.

1.4.13 Oil heat exchanger sized with respect to maximum ambient temp. 1.4.14 Means shall be provided for manual and controlled lowering of loads in case of power

or control failure. 1.4.15 Suitable boom rests(Removable type) to be provided at convenient locations on deck. 1.4.16 Commissioning spares parts and consumables for start-up . Also list of spare parts for

one(1) year normal operational requirement. 1.4.17 Two sets of special tool with normal tool kit to be provided. 1.4.18 Length of wire rope shall be selected in such a manner that while boom is in highest

position hook shall be able to reach chart datum, while retaining two full wraps of rope on the rope drum.

1.4.19 Operability and load test of the crane shall be carried out at fabrication yard and offshore per specified load for which crane is designed, including overload test. Also vendors Engineers to be involved for Mechanical erection, Commissioning and Testing at yard and offshore

1.4.20 Access platforms shall be provided for servicing of hook sheaves (top), top of gantry, slew mechanism.

1.4.21 API Medallion to be placed on the crane as evidence of certificate for meeting API Specification

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1.4.22 The design of crane and platform pedestals shall ensure that external moment be limited to 460 ton-meters and axial load to 70 tones . In case the crane parameters do not match with this and are expected to exceed, then the contractor has to design for higher load data.

2.0 Construction Features: 2.1 Manufacturer

Model:

2.2 a) Capacity as per operating conditions (INDICATIVE)

b) Deviation, if any

: :

Refer Description of work of bid document Yes/No

2.3 Maximum Dynamic Vertical Load T : 2.4 Maximum Overturn moment dynamic T

Boom Construction 2.5 Type Material Walkway provided Walkway position relative to Boom

: : : :

Lattice Boom ASTM A36 or A 500 Gr. B Yes/No Left/Right

A Frame Construction, Type / Material :

2.6

Lifting Aids provided : Yes / No Base Frame Construction, Type / Material

2.7

Tail Radius Limit Driver’s Cab Position Related To Boom : Left / Right

2.8

Mounting Dimensions, MM (L x B x H) : Slew Ring Manufacturer Model No.

2.9

Material, Ring / Rollers Pedestal Adopter Diameter, Top / Bottom Material

2.10

Wall Thickness Prime Mover Type

2.11

Power

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Speed Manufacturer

Gear Box Gear Box Splitter Main Hoist Boom Hoist Slew Drive Type Make

2.12

Power

Hydraulic Pumps (Manufacturer to Substantiate with Hydraulic Schematic Block Diagram) Hydraulic Pumps Main Hoist Whip Hoist Boom Hoist Slew Drive Model Type Make Flow M3/Hr 000

2.13

Power/KW Speed, RPM

Hydraulic Motors

Main Hoist Whip Hoist Boom Hoist Slew Hoist Type Make Flow M3/Hr Pressure, Kg/Cm2

2.14

Power/Speed, KW/RPM

Hoist Hoists Main Hoist Boom Hoist Whip Hoist Drum Dia, mm Drum width between flanges, mm No. of Layers No. of Dead Turns Brake Type

2.15

Line Pull

Total Power Demand @ Maximum operating conditions Hydraulic : Open Loop / Close Loop

2.16

Gear Box Type 2.17 Sheaves

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Sheaves Main Hoist Boom Hoist Whip Hoist Diameter, mm

No. of falls

Wire Ropes – (suitable for saliferous atmosphere of a tropical offshore platform) Wire Ropes Main Hoist Boom Hoist Whip Hoist Wire Ropes Code Make Construction / Galvanized Dia, mm

Max. Operating Load, T Safe Working load, T

2.18

Min. Breaking load, T

Hooks with stop limit switches with warning lights and audible devices. Hooks Main Hoist Boom Hoist Whip Hoist Type / Standard

2.19

Safety Latch 2.20 Swing Brake Type : 2.21 Noise Level Within Machinery room : Within driver’s cab : External to crane : 3.0 Inspection and Testing Test as per Spec. : YES 4.0 Manufacturer’s Data

Technical data / literature for cranes and duly filled-in attached data sheets shall be submitted along with the bid.

Contractor shall provide sufficient details for evaluating the crane system during the bid offer.

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5.0 NOTES: 5.1 Flexible low pressure lines shall be wire spiral reinforced hose with a minimum

rated pressure shall be 1.5 times of maximum working pressure encountered. 5.2 The hydraulic lines shall be neatly laid-out, clamped, to avoid any whipping and

sharp bends and tagged as per good engineering practice. 5.3 Winches shall be designed for marine conditions and shall be of sealed type and

shall be installed in enclosed areas. 5.4 Bolting between base and pedestal shall be cadmium plated or equivalent with

corrosion resistant finish.

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DIESEL ENGINE FOR DECK CRANE 1.0 PURCHASE SPECIFICATION 1.1 PROJECT : New Platform PLATFORMS All JOB NO. 1.2 PLANT LOCATION : OFFSHORE REQUISITION NO. DATE 1.3 ITEM NO.: UNIT NO : 1.4 NO. REQD.: WORKING: ONE / Per Platform STANDBY : NIL SERVICE : DECK CRANE 2.0 OPERATING CONDITIONS 2.1 AMBIENT TEMP.0 C: AREA CLASSIFICATION: AS per Electrical Design Criteria

2.2 BAROMETRIC PRESSURE: ALTITUDE ABOVE M.S.L. M: As Per Equipment Layout 2.3 RELATIVE HUMIDITY: LOCATION: OUT DOOR 2.4 CODE/STD: ISO 3046/EEMUA NO. 107/BS-5514 3.0 UTILITIES 3.1 COOLING WATER TEMP.0C SUPPLY RETURN (MAX) 3.2 COOLING WATER PR. kg/cm2 g SUPPLY RETURN 3.3 COOLING WATER PROPERTIES: POTABLE WATER 3.4 TOTAL ALKALINITY CALCIUM HARDNESS 3.5 TOTAL HARDNESS CHLORIDES 3.6 CHLORIDE INJECTION LEVEL TOTAL DISSOLVED SOLIDS 3.7 SUSPENDED SOLIDS Ph VALUE 3.8 FUEL OIL NO.2 DIESEL 3.9 INSTRUMENT AIR Kg/cm2g DEW POINT 3.10 STARTUP UTILITY AIR: TO BE PROVIDED BY DIESEL ENGINE DRIVEN COMPRESSOR 3.11 VENDOR SHALL INDICATE THE ESTIMATED UTILITY CONSUMPTION FOR EACH UTILITY IN

HIS OFFER. 4.0 DRIVEN MACHINES 4.1 DRIVEN MACHINE: DECK CRANE HYDRAULIC PUMPS AND AUXILARIES STARTING TORQUE Kg-M 4.2 DUTY: INTERMITTENT GD2 VALUE Kg-M2 4.3 POWER REQUIRED AT SHAFT (NORMAL) KW * (MAX) KW* RPM 4.3 ROTATION OF MACHINE VIEWED FROM COUPLING END 4.4 METHOD OF DRIVE FLEXIBLE / RIGID COUPLING O V-BELT O GEAR DRIVE 4.5 DRIVE THROUGH POWER TAKE OFF CLUTCH 4.6 RECOMMENDED RATED POWER OF PRIME MOVER AT SITE

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* TO SUIT POWER REQUIREMENT FOR THE ENTIRE SPECTRUM OF DECK CRANE 5.0 MANUFACTURER’S SPECIFICATION

5.1 CONSTRUCTION AND PERFORMANCE FEATURES 5.2 MANUFACTURER ENGINE MODEL 5.3 CYLINDER ARRANGEMENT NO. OF CYLINDERS 5.4 BORE / STROKE COMPRESSION RATIO 5.5 SPEED RPM MEAN PISTON SPEED M/Sec. 5.6 CHARGING: NATURALLY ASPIRATED O MECH SUPERCHARGED O TURBO CHARGED O INTER COOLED 5.7 RATING: CONTINUOUS WITH 10% OVERLOAD PROVISION FOR 1 HR. 1N 12 HOURS 5.8 PERFORMANCE STANDARD: ISO 3046 /BS-5514 BMEP AT RATED LOAD Kg/cm2 5.9 TYPE OF COMBUSTION CHAMBER FIRING ORDER 5.10 ROTATION VIEWED FROM COUPLING END 5.11 ENGINE COOLING O AIR COOLED WATER COOLED 5.12 METHOD OF STARTING PNEUMATIC & HYDRAULIC O AUTOMATIC 5.13 METHOD OF STOPPING MANUAL O AUTOMATIC 5.14 TYPE OF COLD STARTING AID 5.15 RATED ENGINE POWER AT STANDARD OPERATING CONDITIONS KW ( WITH ENG. DRIVING ALL ANCILLIARIES, EXCLUDING RADIATOR FANS AND MOTOR

DRIVEN PUMPS 5.16 POWER REQUIRED FOR DRIVING RADIATOR FANS ………… MOTOR DRIVEN PUMPS……… 5.17 RATED ENGINE POWER AT SITE CONDITIONS (GUARANTTED, NO NEGATIVE TOLERANCE) KW 5.18 SPECIFIC FUEL CONSUMPTION (GUARANTEE) AT VENDOR’S WORKS

10% OVERLOAD FULL LOAD ¾ LOAD ½ LOAD ¼ LOAD 5.19 ENGINE GOVERNING SPEED RANGE RPM 5.20 GOVERNOR TYPE: MAKE: MODEL: 5.21 GOVERNOR CONTROL MECHANISM MANUAL / REMOTE 6.0 STARTING SYSTEM

6.1 O HAND STARTING WITH STARTING HANDLE. 6.2 MANUAL HYDRAULIC STARTING WITH AUTO CHARGING FACILITY, ENGINE DRIVEN HYDRAULIC PUMP WITH CHARGED ACCUMULATOR. 6.3 HYDRAULIC STARTER MAKE MODEL 6.4 COMPRESSED AIR STARTING WITH INTERCONNECTING PIPING, FITTING, VALVES, STRAINERS & LUBRICATOR., CRANE ACCESSORIES AND STARTERS 6.5 AIR COMPRESSOR DRIVE BY CRANE DIESEL ENGINE 6.6 COMPRESSOR TYPE CAPACITY PRESSURE KG/CM2G 6.7 DRIVER RATING KW RPM VOLTS 6.8 AIR RECEIVER WITH PR. GAUGE, RELIEF VALVE & MANUAL DRAIN VALVE 6.9 START STOP SWITCH FOR COMPRRESSOR MANUAL / AUTO 6.10 AIR RECEIVER CAPACITY (M3) DESIGN CODE –ASME - SEC VIII 6.11 AIR / GAS STARTER MAKE MODEL

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6.12 O BATTERY STARTING WITH CABLE LUGS 6.13 O BATTERY NO. MAKE RATING

NOTE: BOTH HYDRAULIC AND AIR STARTING SYSTEM SHALL BE SUPPLIED MOUNTED ON THE ENGINE WITH A PROVISION TO USE ANY ONE AT A TIME TO START THE ENGINE.

7.0 WATER COOLING SYSTEM 7.1 RADIATOR COOLING INCLUDING INTERCONNECTING PIPING AND FITTINGS, VALVES

ETC. 7.2 RADIATOR WITH TEMP. CONTROL VALVE O EXPANSION / MAKE UP WATER TANK 7.3 FAN DRIVEN BY ENGINE O DRIVER RATING KW / RPM 7.4 ENGINE DRIVEN WATER CIRCULATING PUMP WITH FULL BYPASS ARRANGEMENT 7.5 ENGINE WATER INLET / OUTLET TEMP. O C 7.6 O OPEN CIRCUIT COOLING WITH ENGINE DRIVEN WATER CIRCULTING PUMP 7.7 O CLOSED CIRCUIT COOLING INCLUDING 7.8 WATER PUMP DRIVEN BY ENGINE SHAFT DRIVER RATING KW RPM 7.9 O PRIMARY (SOFT) CIRCUIT PIPING WITH TEMP. CONTROL & MAKE UP TANK 7.10 O HEAT EXCHANGER: SKID MOUNTED 7.11 O SECONDARY (RAW WATER) CKT. PIPING WITH PR. REGULATING VALVE 7.12 O BY PASS VALVE FULL FLOW O CHECK VALVE O STRAINER 7.13 O HEAT EXCHANGER INLET / OUTLET TEMP. (PRIMARY CIRCUIT) O C 7.14 O WATER PRESSURE (SECONDARY CIRCUIT) Kg/cm2g 7.15 O HEAT EXCHANGER TESTING PRESSURE Kg/cm2g 7.16 Radiator fan shall be non-metallic 7.17 Radiator shall be constructed of material resistance to offshore marine environmental coated to resist corrosion.

8.0 FRAME LUBRICATING SYSTEM 8.1 O SPLASH LUBRICATION 8.2 FORCED FEED LUBRICATION INCLUDING OIL PUMP, PIPING & FITTINGS, VALVES 8.3 OIL COOLER TYPE : SHELL & TUBE 8.4 OIL FILTERS O SELF CLEANING DUPLEX WITH INDICATOR 8.5 LUBRICATION OIL PUMP DRIVEN BY ENGINE SHAFT 8.6 PRELUBRICATION O MANUAL O AUTO AT INTERVALS 8.7` LEVEL INDICATORS AT CRITICAL LOCATION (HOUR) 8.8 OIL COOLER TESTING PRESSURE Kg/cm2g OIL CONSUMPTION 8.9 OIL SUMP CAPACITY TYPE / GRADE OF LUB OIL 8.10 CRANKE CASE BREATHER

NOTE:- DUPLEX FILTERS SHALL BE PROVIDED IN SUCH A MANNER THAT CLEANING/REPLACEMENT AND MAINTENANCE OF FILTERS IS POSSIBLE WITHOUT INTERRUPTING THE OPERATION OF THE MACHINE

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FUEL SYSTEM 9.1 DIESEL TRANSFER SYSTEM FROM DIESEL STORAGE TANK TO ENGINE DAY TANK WITHPIPING AND AIR DRIVEN PUMP 9.2 FUEL LIFT PUMP ENGINE SHAFT DRIVEN 9.3 FUEL FILTERS DUPLEX WITH INDICATOR O PAPER CARTRIDGE 9.4 FUEL INJECTION PUMP MAKE MODEL 9.5 DAILY SERVICE FUEL TANK O ENGINE MOUNTED O WALL MOUNTED 9.6 O GROUND MOUNTED SKID MOUNTED 9.7 CAPACITY OF FUEL TANK: FOR 12 HOURS (FULL LOAD RUN) O FOR 24 HRS. (FULL

LOAD RUN) 9.8 O FUEL FLOAT TANK O GROUND MOUNTED WITH BASE PLATE O SKID

MOUNTED 9.9 O SEMI ROTARY FUEL TRANSFER PUMP 9.10 O MOTOR DRIVEN FUEL TRANSFER PUMP 9.11 FUEL PIPING & FITTINGS 9.12 DAILY TANK TO ENGINE TRANSFER PUMPS TO DAILY TANKS HAND-HOLE

FLOAT VALVE 9.13 OVER FLOW PIPES DIPPED IN TANK VENT PIPE WITH FLAME ARREST 9.14 ALL NECESSARY INTERCONNECTING PIPING, VALVES, SEALED LEVEL GAUGE. 9.15 STRAINER, DRAIN VALVE WITH FLANGED END ETC., ON THE FUEL TANK 9.16 DRIP PAN

NOTES: 1) FUEL SYSTEM SHALL BE SUCH THAT THERE SHOULD NOT BE ANY AIR LOCK OR AIR TRAP IN FUEL LINE. A MANUAL FUEL PRIMMING PUMP WITH ASSOCIATED PIPING. VALVES ETC. SHALL BE PROVIDED FOR FUEL PRIMING, IN INSTALLED CONDITION ON THE ENGINE.

2) DUPLEX FILTERS SHALL BE PROVIDED IN SUCH A MANNER THAT

CLEANING/REPLACEMENT AND MAINTENANCE OF FILTERS IS POSSIBLE WITHOUT INTERRUPTING THE OPERATION OF THE MACHINE

10.0 MATERIAL OF CONSTRUCTION 10.1 CHARGE AIR COOLER SHELL TUBES 10.2 WATER COOLER SHELL TUBES 10.3 AIR COOLER SHELL TUBES 10.4 AIR RECEIVER CYLINDER HEAD CYLINDER LINER 10.5 FUEL TANK CRANK SHAFT GUDGEON PIN 10.6 PISTON, PISTON RINGS CONNECTING ROD CONNECTING ROD BOLTS 10.7 MAIN BEARING VALVES CRANK CASE 11.0 TESTING & INSPECTION 11.1 O STAGE INSPECTION DURING MANUFACTURE 11.2 W FULL LOAD TEST AT VENDOR’S WORKS FOR 4 HOURS 11.3 W 10% OVERLOAD TEST FOR 1 HOUR VENDORS WORK’S 11.4 W FUEL CONSUMPTION GOVERNING TEST 115 W CONTROL PANEL FUNCTIONAL TEST INCLUDING ALARMS & SHUT-DOWN 11.6 O OTHER TESTS AS PER APPLICABLE CODES & STANDARDS

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11.7 O CHECKS FOR ENGINE SAFETY & SHUT DOWN DEVICES 11.8 O TYPE TEST CERTIFICATE AS PER EEMUA SHALL BE FURNISHED 11.9 O CHECKS FOR CRANE ENGINE DRIVEN COMPRESSOR 11.10 INSPECTION / TESTING BY COMPANY/ AUTHORISED REP. CERTIFYING AGENCY 11.11 TESTS MARKED WITH “W” SHALL BE WITNESSED BY INSPECTOR 12.0 INSTRUMENTS & CONTROLS 12.1 PRESSURE GAUGE – LUB OIL HEADER GB O PR. GAUGE-BOOST AIR PRESSURE 12.2 PRESSURE GAUGE – AIR RECEIVER PR. GAUGE – COOLING WATER - GB 12.3 FUEL LEVEL GAUGE – GB TACHO – HOUR – METER - GB 12.4 TEMP. INDICATOR – LUB OIL TEMP. INDICATOR COOLING WATER 1N GB 12.5 O TEMP. INDICATOR - CHARGE AIR COOLER TEMP. INDICATOR COOLING WATER OUT GB 12.6 HYDRAULIC PRESSURE GAUGE FOR EACH FUNCTION OF CRANE 12.7 LOW LUB OIL PRESSURE ALARM(A-V)GB 2ND STAGE SHUT DOWN WITH

ALRAM (A-V) 12.8 HIGH ENGINE WATER TEMP. ALARM (A-V) GB 2ND STAGE SHUTDOWN WITH

ALARM (A-V) 12.9 O LOW RECEIVER AIR PR. O ALRAM (A-V) 12.10 LOW FUEL OIL LEVEL ALARM (A-V) GB 12.11 LOW WATER LEVEL ALARM (A-V) GB 12.12 ENGINE OVERSPEED ALARM (V) GB SHUT DOWN BY FUEL & AIR SUPPLY CUTOFF 12.13 ENGINE FAILS TO START ALARM (V) GB 12.14 KEY SWITCH START AND PUSH-BUTTON STOP 12.15 O A – AUDIO, V-VISUAL 12.16 REVERSE RUNNING OF ENGINE SHALL NOT BE POSSIBLE. 12.17 ITEMS MARKED (GB) TO BE HOUSED IN GAUGE BOARD INSIDE OPERATOR’S CABIN 12.18 O ITEMS MARKED (LP) TO BE HOUSED IN LOCAL CONTROL PANEL (FREE STANDING TYPE) 12.19 ELECTRICAL SWITCHES FOR ALARM & SHUTDOWNS TO HAVE ENCLOSURE 12.20 TEMP. INDICATORS SHALL BE BIMETALLIC DIAL TYPE 12.21 ALL WIRING, PIPING BETWEEN ENGINE-GAUGE BOARD-CONTROL PANEL IN VENDOR’S SCOPE 12.22 PANEL SHALL BE INSIDE CRANE OPERATOR’S CABIN 13.0 SCOPE OF SUPPLY / WORK (EACH ENGINE) 13.1 DIESEL ENGINES SHALL BE HEAVY DUTY, PREFERABLY NATURALLY ASPIRATED

INDUSTRIAL TYPE (FROM REGULAR PRODUCTION MODEL), LUBRICATION SYSTEM, GOVERNING SYSTEM CHARGING SYSTEM, FUEL SYSTEM, COOLING SYSTEM & STARTING SYSTEM AS DEFINED ABOVE

13.2 SUCTION AIR FILTER WITH SUCTION PIPING DRY WITH DP O OIL BATH INDICATOR 13.3 FLYWHEEL, WITH BARRING DEVICE 13.4 GUARDS FOR MOVING PARTS – NON SPARKING TYPE 13.5 FLAME ARRESTOR IN ENGINE INTAKE SYSTEM 13.6 INLET & EXHAUST MANIFOLD – WATER COOLED

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13.7 EXHAUST SILENCER WITH EXPANSION BELLOWS – SPARK ARRESTING TYPE CERTIFIEDFOR HAZARDOUS AREA WITH RAIN HOOD

13.8 INSTRUMENTS & CONTROLS DEFINED ABOVE 13.9 O BATTERY CHARGING EQUIPMENT MOUNTED IN INCLUDING TRANSFORMER 13.1O O RECTIFIER DC AMMETER DC VOLTMETER CHARGE RATE SELECTOR SWITCH 13.11 O SET OF BATTERIES VOLTS RATING AMPS. WITH CABLES & LUGS 13.12 COUPLING FOR ENGINE TYPE-FLEXIBLE 13.13 COMMON SKID FOR ENGINE, HYDRAULIC SYSTEM 13.14 SPECIAL TOOLS FOR NORMAL MAINTENANCE OF ENGINE 13.15 O FOUNDATION BOLTS & ANCHOR BOLTS 13.16 TORSIONAL ANALYSIS REPORT ON ENGINE. CARRIED AS LAB TEST FOR SIMILAR

UNIT 13.17 LIST OF SPARES FOR ONE YEAR OPERATION 13.18 ANTI-VIBRATION MOUNTING 13.19 PROTECTIVE DEVICES AS PER EEUMA AS APPLICABLE FOR HAZARDOUS AREA IN

WHICH CRANE IS INSTALLED. 13.20 O TURBO CHARGING (IF REQUIRED) WATER COOLED 13.21 FLAME TRAP IN AIR INTAKE AND EXHAUST SYSTEM 13.22 O GAS COOLER IN EXHAUST SYSTEM 13.23 FLAME ARRESTER IN EXHAUST SYSTEM CERTIFIED FOR HAZARDOUS AREA. 13.24 GOVERNOR – VARIABLE SPEED WITH MAXIMUM FULL LOAD. 13.25 TWO SPARE SET OF FILTER ELEMENTS FOR ENGINE FUEL, LUBE OIL AND AIR

FILTER. 13.26 SUITABLE WEATHER PROTECTOR COVER 13.27 SPARE FOR STARTUP AND COMMISSIONING. 14.0 ERECTION & MAINTENANCE 14.1 NET WEIGHT OF ENGINE WITH MOUNTED ANCILLARIES 14.2 MAXIMUM WEIGHT TO BE HANDLED DURING ERECTION & MAINTENANCE 14.3 CHANGE OF LUBRICATING OIL AFTER HOURS 14.4 EXPECTED PERIOD OF RUNNING BETWEEN TOP OVERHAULS HOURS 14.5 EXPECTED PERIOD OF RUNNING BETWEEN MAIN OVERHAULS HOURS 15.0 PURCHASER’S NOTES 15.1 ALL ITEMS MARKED AS “X” SHALL BE IN VENDOR’S SCOPE OF SUPPLY /WORK 15.2 ANY ADDITIONAL INFORMATION NOT COVERED BY THESE DATASHEETS BUT

CONSIDERED NECESSARY BY THE BIDDER TO DESCRIBE THE SALIENT FEATURES OR TO CLARIFY SCOPE OF SUPPLY SHOULD BE BROUGHT ON SEPARATE SHEETS.

15.3 BIDDER SHALL RETURN THESE DATASHEETS DULY COMPLETED IN ALL RESPECT WITH PROPOSAL. 16.0 VENDOR DATA REQUIREMENT 16.1 FOLLOWING DATA / DRAWINGS SHALL BE FURNISHED IN SET OF 8 COPIES EACH :

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PRINTS WITH PRINTS AFTER QUOTE ORDER

16.2 TECHNICAL CATALOGUES WITH RATING CURVES 16.3 LINE SCHEMATICS FOR AIR STARTING / COOLING & FUEL OIL SYSTEM 16.4 RECOMMENDED LAYOUT FOR FUEL OIL SYSTEM & EXHAUST LINES 16.5 GEN. ARRANGEMENT DRAWING. ENGINE & AUXILLIARIES 16.6 FOUNDATION PLAN – ENGINE & AUXILLIARIES - 16.7 TORSIONAL ANALYSIS REPORT - 16.8 ASSEMBLY DRG. RADIATOR / AIR RECV. / WATER COOLER - 16.9 OPERATION & MAINTENANCE MANUAL - 16.10 SPARE PARTS CATALOGUE - VENDOR TO FILL THIS DATA SHEET AND SUBMIT WITH BID

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5.12 Acceptance Criteria

The equipment selection shall be in accordance with the applicable codes, standards and regulations together with additional requirements noted in the specification and in the data sheets.

As a minimum requirement, the offered equipment or the equipment of similar design manufactured by the same supplier:

- Shall have been type tested; and - Shall have been in continuous satisfactory service on offshore for a

minimum period of two (2) years. The final acceptance of the package shall be based upon the comprehensive tests, both functional and performance which shall include load and over load, of the equipment. The tests shall demonstrate the integrity of the crane systems.

6.0 SPARES PARTS AND TOOLS :

6.1 Spare Parts

The overall maintenance philosophy of platform is to keep the onboard maintenance as low as responsibly practical and minimize equipment sparing. Based on overall platform philosophy, it is essential to minimize the need of breakdown maintenance by using predictive condition monitoring techniques and carry out preventive routine maintenance. In view of above, the complete maintenance and spare parts requirements for the deck crane shall be furnished with the Tender. This shall include spares for start-up, commissioning and one year’s operations. The Contractor shall provide a recommended spare parts list to cover the commissioning and start-up for deck crane.. When preparing recommended spare parts lists, the Contractor shall follow the Equipment manufacturer’s recommendations. The Contractor shall note long lead items and available shelf replacement parts, All spare parts furnished by the Contractor shall be wrapped and packaged to preserve the parts as in original condition. The same parts shall be appropriately tagged using stainless steel tags and coded so that later identification as to their intended equipment usage will be facilitated. All items supplied shall be packaged separately and clearly marked as “Spare Parts” and

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shipped with the equipment in accordance with the instruction from the Company. Packing lists shall be furnished complete and in detail so that parts can be handled without uncrating, should this be required. Recommended spares should take into account related factors of equipment reliability, effect of equipment down-time upon production and safety, cost of parts and availability of equipment service facilities.

6.2 Special Tools

With its Tender, the Contractor shall provide a list of any special tools required for the erection and maintenance of the deck crane The Contractor shall furnish (2) sets of special tools. Prior to shipment each special tool shall be tagged with stainless steel tag detailing its description and where it is to be used.

7.0 INSPECTION , TESTING AND CERTIFICATION :

The vendor shall completely assemble the crane and accessories and shall test the crane to ensure proper operation of the equipment prior to shipment. Vendor shall carry out comprehensive tests as per data sheets, applicable codes/standards. All Test certificate shall be submitted for company’s approval.

Company/ its authorized representative or certifying agency shall have access to

inspect the equipment at any stage during manufacture. During inspection, material certificate and any other relevant information shall be furnished to facilitate verification of compliance with specification and quality assurance requirement. The company or its third party inspection agency shall have confidential access to design calculations and for any other relevant information as provided in the API-2C to verify the safety of equipment.

8.0 PREPARATION FOR SHIPMENT

Prior to shipment, all instrumentation and other equipment vulnerable to damage shall be disassembled and boxed separately for shipment. All items shall be adequately packed and protected against damage during shipment. Each crate, bag or packages shall be clearly identified with the purchase order number and identification symbol, and shall be securely fastened to the Package. All flanged openings shall be protected with steel plate covers attached by proper bolting and sealed with plastic compound.

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All electrical control enclosures shall be appropriately plugged at entries and loaded with silica gel bags. Screwed connections shall be protected with threaded forged steel plugs. Contractor shall state in the proposal his recommendations for long term storage (up to 12 months) for both indoor and open-air storage in a marine environment.

9.0 DOCUMENTATION

Data shall be submitted as per attached “Vendor Data Requirements”

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SPECIAL NOTES ON VENDOR DATA REQUIREMENT

FOR VENDOR TO COMPLY

1. Vendor to comply with the Documentation listed herein. Minimum (8)

eight sets of dossier shall be included for purchaser/consultants.

2. The Vendor shall be held accountable for furnishing all data/drawings in proper

form and quality in accordance with these requirements. The Vendor shall also

be accountable for the documentation required from his sub-vendor.

3. Each vendor data item requested above must be identified by the purchase order

number and equipment tag number location on the cover sheet or first page of

said item and in the case of engineering drawings, on each and every drawing.

4. Any additional data/drawings required as a result of issuing supplements to a

purchase order or during detailed engineering shall be furnished by Vendor and

handled in the same manner as the original order.

5. All drawings and literatures shall be in the English language and in the Metric

Measurement System.

6. The reproducible drawings, 279 mm x 432 mm (11” x 17”) size and full size are

to be of such quality that Clear Legible prints can be made with Osalid type

reproduction facilities.

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Vendor Data Requirements

With Proposal

After Order Placement

Sl. No.

Description For Company Evaluation

For Company Approval / Review

With Eqpt. Data Book

1 Technical Data of Crane X X - 2 Catalogues / Leaflets X - - 3 Load Capacity Chart X X X 4 Winch Performance Data X X - 5 Power Requirement Calculation X X - 6 Dynamic Coefficient Calculation X X - 7 Write up on operation, controls and

safety X - -

8 Comparative power ratings of Hoist System

- X X

9 Dimensional Outline Drawing of the Crane

X X X

10 Pedestal loads and moments X X X 11 Pedestal Mounting Details - X X 12 General Arrangement drawings of

the crane showing detailed arrangement of Transmission system and other components

X X X

13 Details of hydraulic pump / transmission system

X X X

14 Hydraulic system schematics with details and catalogue

X X X

15 Inside cab view X X - 16 Electrical Details / Swivel data

(single line diagram, schematic diagram and lighting arrangement).

X X X

17 d) Filled in data sheet for diesel engine

X X X

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X Means Data required in Eight copies * Means Requirement at Inspection Stage.

Sl. No. Description With Proposal

After Order Placement

For Company

Evaluation

For Company Approval / Review

With Eqpt. Data Book

18 Catalogue for diesel engine X - - 19 De-rating calculations / charts for

diesel engine X X -

20 Schematics of engine lubrication, cooling, starting, intake and exhaust systems

X X X

21 Utility requirements X X X 22 Material certificates, certificates of

bought-out components - * -

23 Inspection / Test Reports - * X 24 One year spare parts List X X X 25 List of special tools and tackles X - X 26 Operation and Maintenance Manual - - X 27 List of deviation from API Spec.

2C (latest edition) X - -

28 List of deviations from specifications

X - -

29 Reference list of previous Offshore installations

X - -

30 Spare parts catalogue - - X 31 Quality Plan X X - 32 Manufacturing and delivery

schedule X

32 Reliability and Availability data X

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10. Warranty :

Vendor shall have final and total responsibility for the design and performance of all equipment furnished by him. Vendor shall warrant that the equipment furnished by him and the performance of the said equipment is in accordance with this specification and general codes. Vendor shall warrant and guarantee that all the materials and equipments incorporated in the entire equipment under his Scope shall be new, and all work shall be of good quality.

Vendor shall also be responsible for all system and detailed designing, the aspects of which may not have been covered in this specification as regards the workmanship, performance etc., of the equipment supplied by him. Vendor shall, upon notice from Company, make good at his own expense all defects found during the warranty period expeditiously. Vendor shall, if required, supply the services of an experienced engineer to supervise the correction of any defects found during the warranty period.

Vendor shall also warrant and guarantee all work, materials and equipment

furnished by any Sub-Vendor and which is incorporated in the Package.

Functional Specification for Deck Crane

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