Tender Technical Specifications for 2 Te In-Cell Crane...

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GOVERNMENT OF INDIA

BHABHA ATOMIC RESEARCH CENTRE NUCLEAR RECYCLE BOARD

FAST REACTOR WASTE MANAGEMENT DIRECTORATE TROMBAY MUMBAI- 400085, INDIA

Tender Technical Specifications

for

2 Te In-Cell Crane – QTY: 10 Nos.

of

WMP (FRFCF), KALPAKKAM, Tamil Nadu

Tender Specification No.: FRFCF/43270/SP/1169

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INDEX

TITLE Page #

PART-1 SCOPE OF THE WORK 3

PART-II TECHNICAL SPECIFICATIONS:

1. INTRODUCTION 5

2. SPECIFICATION FOR IN- CELL CRANE 5

3. REFERENCE CODES AND STANDARDS 8

4. MATERIAL OF CONSTRUCTION 9

5. DESIGN REQUIREMENTS: MECHANICAL 10

6. DESIGN REQUIREMENTS: ELECTRICAL 14

7. ADDITIONAL DESIGN FEATURE REQUIREMENT 19

8. SPARES AND MAINTENANCE TOOLS 19

PART-III DESIGN, DRAWING AND INSTRUCTION MANUAL 21

PART-IV FABRICATION, INSPECTION AND TESTING 24

PART-V PACKING, TRANSPORTATION & PLACE OF DELIVERY 28

PART-VI INSTALLATION AND COMMISSIONING 29

PART- VII CONFIDENTIALITY CLAUSE 31

PART-VIII DELIVERY SCHEDULE, GUARANTEE, FACTORY REPORT, SUB CONTRACTS AND GENERAL INSTRUCTIONS / NOTES

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ANNEXURE–A: COST STRUCTURE PERFORMA 34

ANNEXURE–B. IN F O R MA T IO N R E GA R D IN G C ON ST R U C T ION OF T HE C R AN E , T O B E S UP P L IE D B Y T H E SU P P L I E R / B ID D E R

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INDEX : NOTES FOR THE BIDDER 45

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PART-I

SCOPE OF THE WORK

The scope of the work for supplier includes design, drawing, procurement of raw material, manufacture, factory testing, packing, forwarding, transportation and installation, testing & commissioning of crane at WMP, FRFCF, Kalpakkam, Tamil Nadu site of 2Te In- cell crane – Qty 10 Nos. as listed in Table- A and detailed below-

TABLE –A

Crane Identification Number

Installation Block location

Crane location With the block

Qty. Span (mm) (A)

Baylength (mm) (L)

Height of lift (mm) (E)

Cross travel approaches

Long travel approaches

C1

C2 L1 L2

C1, C3, C5 HL bay 1, 2 & 3 respectively

Melter cell 3Nos. 8300 10000 14000 800 700 900 1100

C2 HL bay 1 W & DC cell 1No. 6500 13600 7500 750 650 800 1100 C4, C6 HL bay 2 & 3

respectively W & DC cell 2Nos. 6500 12800 7500 750 650 800 1100

C7 Hull compaction

Batching cell 1 No. 5300 24000 10500 750 650 800 1100

C8 Hull compaction

W & DC cell 1 No. 5300 23250 9000 650 750 800 900

C9 Cementation cell

Product handling cum storage

1 No. 7300 12750 10000 750 650 900 1100

C10 NSDF- ASF & Special vault

Repackaging area

1 No. 5050 8500 5300 650 650 850 900

TOTAL CRANES QUANTITY 10 NOS.

1. Design & supply of all assemblies/ components of hoisting system, CT double girder, CT

trolley, end carriages (trucks), L.T. girder, LT rails and C.T.(trolley) drives, CT rails, wall embedment plugs as per list Table -B, radio pendant & push button pendent, cabling from the panel to the crane inclusive of those to the limit switches, in-cell cable take up system (drag chain type), remote/quick electrical connectors for bridge, Crab, motors, CCTV camera system ( consisting of Dome camera ( 1 no. per crane), wiring, control panel, pan-tilt-zoom joystick & 20 inch CCTV monitor), travel limiting system (stoppers), control panel & junction boxes, radio remote control system for operation of crane, devices for emergency L.T. , C.T., hoisting and associated lifting tackles for remote removal of crab & motors.

2. Preparation/submission/approval of detailed design, fabrication/manufacturing drawings for all mechanical and electrical components & accessories of the crane. Drawing should include all details like assembly, subassembly and part drawings of all components of the crane.

3. The design and dimensions of crab of the crane shall be such that their sizes shall be grouped for interchangeability with similar group crane. The wiring diagram shall be kept similar for interchangability.

4. Design calculations of crane. 5. Preparation/submission of detailed Q.A./Q.S program for purchaser’s approval. 6. Procurement of all materials in accordance with the material specifications as given in the

approved drawings and in these tender technical specifications.

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7. Material Testing & Submission of test certificates for all raw materials procured for manufacturing of the crane as and when required.

8. Obtaining approval of the purchaser for any materials used or intended to be used as alternative to the specified materials.

9. Manufacture of the components as per approved drawings. 10. Preparation of inspection reports of all components and subassemblies at the appropriate

stage during fabrication. Submission of these reports to the purchaser as and when required during the execution of the contract for verification and records.

11. Obtaining approval of any deviations in design with necessary reasons for the same from purchaser.

12. Offering the components, subassemblies or the full equipment for inspection to purchaser’s representative as and when required by him to do so during the execution of the contract.

13. Carrying out any necessary modifications or improvements until satisfactory performance of the crane for which it is intended. Such modifications shall be carried out by the contractor at free of cost if they are required for reasons arising from poor designs, bad workmanship or non-conformity to the specifications.

14. Testing of the crane at supplier’s workshop. 15. Packing and safe crating of the equipment so as to avoid any damage during handling,

transportation and storage before installation. All components of the crane wrapped plastic wrap/sheet, protected with suitable cushion and packed in premium wooden boxes. The boxes should be designed for easy handling with fork lift. All the electrical packaging shall be suitable for protection from minor ingress of water.

16. Delivery of the equipment to WMP (FRFCF), Kalpakkam, Tamilnadu here after referred to as installation site.

17. Erection /installation of the crane at site. 18. Testing and Commissioning of the crane at site. 19. Incorporating the as built changes in the manufacturing & fabrication drawings and

submission of as built drawings (reproducible prints) in soft as well as hard copy to the purchaser (4 sets).

20. Submission of History Dockets (4 sets) consists of QA/Q.S. documents, operation and maintenance manual, design report, and as built drawings.

21. Supply of drag chain supporting rollers/ trolley incase of cranes having higher bay length is in scope of supply of the supplier. Any other accessories like rails, Girders require for movement of trolley is also in the scope of supply.

22. Offering a guarantee of the equipment as per following conditions:- a) If installation deferred due to non availability of site – 3 yrs from date of supply b) If installation carried out within 3 yrs of supply – 1 year from date of testing and

commissioning at site. This guarantee shall cover free repairs or replacement of parts, which have failed during normal operation within the guarantee period due to defective design, material of construction, workmanship etc.

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PART-II TECHNICAL SPECIFICATIONS

1. Introduction: The cranes under procurement are meant for their use inside the

radioactive hot cells as listed in TABLE- A for WMP (FRFCF), Kalpakkam where the surrounding atmosphere is highly radioactive with temperature of about 60oC. All the cranes also shall meet the requirements of decontamination with acidic/ alkaline solution/ soap solution. The special feature of this crane is that all motions of the crane are operated and maintained from outside of the corresponding cells using pendent as well as using radio remote control. There is also requirement for operation of C1,C2, C3, C4, C5 & C6 cranes from control room panel for limited operations. The cranes need to be operated from different locations around the corresponding cells as indicated in the drawings. Due to the restriction of the personal entry into the cell, the design of the crane shall be such that the assembly and disassembly of the crane shall be possible using remote handling operations. Also it is desirable to provide components of the crane as simple as possible with almost zero maintenance requirements. For installation of in cell crane from roof opening supplier shall make his own arrangements if over head EOT crane is not available. A separate area is provided for most of the cranes, where the entire crane bridge can be brought for its maintenance through a cutout in the partition wall.

2. SPECIFICATION FOR IN- CELL CRANES

2.1. GENERAL:

2.1.1. Number of cranes : 10 (TEN) Nos.

2.1.2. Type of Crane : Double girder

2.1.3. Duty of the crane : Class II

2.1.4. Type of service : In-door

2.1.5. Atmospheric condition : Normal with high humidity

2.1.6. Working condition : Radiation field having & radiations up to 1000R/hr. Components of cranes shall be suitable to withstand radiation cumulative dose upto 100MRAD.

2.1.7. Operating Temperature : 600C Maximum

2.1.8. Hoisting method : Shall be positive

2.1.9.

Safe working load : 2 Te = 2000Kgs

2.2. OPERATING SPEEDS (at rated load)

2.2.1. Long travel motion (L.T.) : 3 m/min & 1 m/min

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( using VFD)

2.2.2. Cross travel motion (C.T.) : 3 m/min & 1 m/min

(using VFD)

2.2.3. Hoisting motion : 3 m/min & 1 m/min

(using VFD)

2.2.4. Emergency Hoisting system : 0.3 m/min

2.3. Mode of Control of motions Either from -

1. Through Push button Pendent by connecting to junction box provided at various locations out side the cell using quick connectors. Their shall be interlock that at time, crane shall be operated from one single point. (additional operating point for C1, C2, C3, C4, C5 & C6 cranes shall be provided for its operation from control room using push button pendent.

2. Radio remote control for normal drive operations. Extension of receiver for operation of crane from different locations around the access corridor to be considered as indicated in drg.

3. Manual operation of crane using emergency drive arrangements provided in the crane in case of failure of LT, CT & hoist motor ( normal operations) and emergency hoist drive operations from wall EPs and crane maintenance areas. For LT & CT emergency manual drive arrangement shall be provided using chain sprocket mechanism. Hoisting emergency operations to be carried from wall EP using mechanical load positive brake.

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2.4. Mode of bridge Travel By driving guided wheels on rails.

2.5. Mode of Crab Travel By driving guided wheels on rails.

2.6. Type of end carriage wheels for L.T. bridge Flat flanged type on both side

2.7. Type of rails for bridge wheels. Square section bar.

2.8. Type of Crab wheels for C.T. Flat flanged type on both side

2.9. Type of rails for Crab wheels. Square section bar.

2.10. CRANE PERFORMANCE AND STRUCTURAL DETAILS: Refer TABLE –A as indicated in part –A of specifications.

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2.11. For maintenance during emergency and remote operations, pipe embedments are indicated in reference tender drawing. The required wall penetration plugs shall be provided along with supply of crane as per enclosed table –B. Minor variation in numbers of plugs may occur as per crane design and site specific requirements.

TABLE - B

Crane No.

Electrical Cable take up

LT emergency chain sprocket

LT limit switches Emergency hoisting

CT emergency

C1 1 2 3 ( 2 Nos. common with LT sprocket)

2 2


2 2

C2 1 2 2 + 1 wall mount

( 2 Nos. common with LT sprocket)

2 1

C6 1 2 2 + 1 wall mount

( 2 Nos. common with LT sprocket)

2 1


2 2

C4 1 1 + 1 wall mount

2 + 1 wall mount ( 2 Nos. common with LT sprocket)

2 1


2 4


2 2


2 4


2 Hoisting plugs to be used

3. REFERENCE CODES AND STANDARDS: The cranes shall comply with all currently applicable statues, regulation and safety codes relating to the design, construction and operation of cranes in the locality where the crane will be installed. No part of these specifications shall be construed to relieve the vendor of his responsibility to supply a functionally adequate crane. The crane supplied shall comply with the latest applicable Indian/American standards. Other national standards are acceptable if they are

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established to be equal or superior to the referred standards. Some of the applicable codes are listed below:

a) IS 807 and IS 3177 b) Applicable portions of American Standard Safety Code for Cranes, Derricks and

Hoists ASA-B-80 as published by ASME. c) Electrical Overhead Cranes Institute (EOCI) specifications and general

information for standard industrial service electric overhead traveling crane. d) Standards of National Electrical Manufacturers Association (NEMA) e) American Standards Association (ASA) f) American Society of Testing Materials (ASTM)

4. MATERIAL OF CONSTRUCTION: 4.1 Design requirement:

Crane Identification Number



Material Specifications

C1, C3, C5

HL bay 1, 2 & 3 respectively

Melter cell In view of the highly radioactive and corrosive atmosphere within the cell, all moving parts and those are in contact with them like wheels, rails, cable drag chain, wire rope, hook block, sprockets, gears, pulleys, lifting hook etc. shall be of suitable grade stainless steel. All stainless steel mating parts shall be properly selected and suitably heat-treated to avoid galling. They shall be made either from AISI 410/420 or AISI 304L stainless steel with a hardness difference of approximately 50 BHN between mating parts. All other non rubbing parts which is likely to exposed to surrounding atmosphere like trolley frame, outer cover of crab, girder, bridge structure etc. shall confirm to IS 2062 Gr B with their surfaces painted with corrosion resistant epoxy paint epoxy. All materials including castings and forging shall be of tested quality and conform to relevant standards.

C2, C4, C6

HL bay 1,2 & 3 respectively

W & DC cell

C9 Cementation cell Product handling cum storage


Repackaging area

C7 Hull compaction Batching cell In view of the highly radioactive and corrosive atmosphere within the cell, all moving parts and those are in contact with them like wheels, rails, hoisting wire rope, sprockets, gears, shackles, pulleys, drag chain, hook block & lifting hook etc. shall be of suitable grade stainless steel. All stainless steel mating parts shall be properly selected and suitably heat treated to avoid galling. They shall be made either from AISI

C8 Hull compaction W & DC cell

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410/420 or AISI 304 stainless steel with a hardness difference of approximately 50 BHN between mating parts. All other parts like Crab trolley frame, outer cover of crab, Girder, bridge structure, trolley for supporting the drag chain (if required) etc. shall be of stainless steel 304L. All materials including castings and forging shall be of tested quality and conform to relevant standards. Desirable material of important components:

1. Rails : SS 304 /SS304L 2. Wheels : SS 410 3. Hook : SS304 4. Gears and pinion : SS 304 / SS 410 5. Wire rope, hook block and its pulleys:

SS 410 / SS 304 6. Bevel gears : SS 410 7. Cable Drag chain: SS 304. 8. Fasteners: Suitable grade of stainless

steel.

5. DESIGN REQUIREMENT (MECHANICAL): 5.1. General Arrangement: The cranes shall be compact and shall have minimum possible

dead space to avail the reaches of the cranes to the maximum extent. The headroom of the cranes shall get accommodated such that minimum cell volume is wasted. The cranes shall be designed and manufactured for minimum maintenance.

5.2. Crane L.T. Bridge: The bridge shall be of a box type design. It shall be possible to withdraw the hook block well within the gap between two girders of bridge. The provision shall be made to facilitate easy dismantling of the bridge from the cell top using the services of cell top EOT crane available in the area for maintenance of end carriages and L.T. shaft assembly. The electrical quick connectors shall be provided to facilitate the easy maintenance of LT bridge such as quick connector for Crab drag chain, remote connector for LT motor assembly. The bridge end carriage (trucks) shall be provided with suitable jacking pads for easy maintenance of the wheel bearings, axles etc. Wheel mounting shall include safety lugs to prevent drop of more than 2.5 cm in case of failure of axle / wheel. The design of Crane Bridge and its drive unit (mechanical and electrical components) shall conform to latest IS-807 and IS-3177 standards.

5.3. Cranes C.T. Trolley (CRAB): The crab unit consisting of the CT trolley ( spit type design i.e. crab is located in the guide pins of trolley), Crab ( consisting of drives for CT & hoisting), CT limit switches, CCTV camera (1 No. of DOME type design) and remote electrical connectors. The design of crab assembly shall be designed in such a manner that it is possible to remove the whole crab unit from the crane without entering the cell by means of the out cells cranes. Since conventional hooking methods are not feasible for attaching the crab unit to the outside

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crane, suitable handling devices (Lifting tackle/yoke ) shall be supplied with which the crab can be removed out of the cell remotely.

5.4. Mechanical End Stoppers: The mechanical end stoppers (spring buffer) shall be provided

for effectively arresting the motion of bridge and trolley. They should be fitted rigidly on the gantry beams for the Crane Bridge and on the bridge girder for the trolley at all the Four Corners. The spring buffers for L.T. & C.T. shall be designed to absorb the K.E of the respective motion with rated load. The mechanical wheel stoppers are also desired for LT & CT for additional safety.

5.5. Drives For L.T., C.T. and Hoisting: 5.5.1. The drive systems for trolley (C.T.) and hoisting shall be provided on a single unit

(upper frame i.e. crab), which can be removable type. The gearboxes for these shall also be compact ( bevel –planetary gear box of SEW make shall be considered).

5.5.2. The cross travel drive (C.T. drive) shall be located suitably on the crab. It shall be designed for remote removal along with crab, reassemble, along with the required electrical remote connector, clutch, reduction gear and spring loaded coupling. Suitable yoke and remote connector shall be provided along with supply for removal of crab.

5.5.3. The bridge travel drive (L.T. drive) shall be an independent unit located suitably on the bridge. It shall be designed for remote removal, reassemble, along with the required electrical connector, clutch, reduction gear and spring loaded coupling. The coupling shall be such that after placing remotely on locating pins the engagement of coupling and connector is ensured. Universal couplings of stainless steel shall be used if necessary for transmission of power to the bridge wheels, however LT drive assembly without universal coupling shall be preferred. Design shall aim to reduce the total headroom required.

5.5.4. Suitable spring loaded couplings (Claw clutch) shall be provided to establish the joint between output shaft of C.T on removable frame to the corresponding input shaft of bevel gear box mounted on fixed frame. The design of these couplings shall be such that after placing the upper frame remotely over the fixed frame the engagement of the coupling and connector is ensured. Suitable locating pins (dowels) shall be provided to establish proper seating of upper frame over fixed frame. Any alternative suggestions by bidder also can be considered if its implementation can make the system more reliable and facilitate ease in remote maintenance.

5.5.5. L.T. and C.T. drive shall be provided with suitable clutches to facilitate freewheeling in case of emergency requirement for manual L.T and C.T. operation. Clutches shall be D.C. power operated and provided with class F insulation.

5.5.6. The drive systems (L.T., C.T. & Hoisting) shall be accommodated within the overall height of bridge and trolley.

5.5.7. Suitable remotely removable type electrical connectors shall be provided ( Dead weight type) between the separable parts of the crab viz. the upper removable frame and lower fixed frame so that the electrical connections are automatically made for drive systems on upper frame when the upper removable frame of the crab is lowered onto the fixed frame of the crab. Proper alignment between the mating parts of the connectors shall be ensured by providing necessary guide pins/rods. In case of male/female remove connectors, place in

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the crab for keeping the connector other part shall be provided. The electrical connector shall be provided with separate rugged housing along with guide rod for smooth connection/disconnection. The yoke for remote removal and handling of connector shall be provided along with supply.

5.5.8. The drive for crane bridge (L.T.) and trolley (C.T.) shall be given directly to the wheels,

which are moving on rails. Flat rails shall be provided for both L.T. & C.T. The L.T. and C.T. wheels shall be designed to avoid skewing of bridge and trolley.

5.5.9. The hoisting mechanism shall have of four-fall wire rope system and shall be designed to

avoid twisting of wire ropes and over riding of wire rope on the wire drums. The wire rope shall be of sufficient length so that minimum two rope turns shall always remain in the drum when the hook is in lower most position. The breaking loads for the wire rope shall not be less than six times the calculated load expected on the wire rope derived from rated load for hooks plus weight of the lower pulley block and weight of the rope.

5.5.10. Hoisting system shall be provided with DC Electromagnetic non fail safe type brake

along with mechanical load positive brake for emergency drive operations. The supplier shall demonstrate the reliability, safety and smooth functioning with such type of brake. In case of failure of hoisting motor it should be possible that the load can be lowered manually ( MANUAL OVER-RIDE) from side wall EPs using specially designed tools/tackles.

5.5.11. The drive unit for hoisting shall be compact and design shall be such that motors,

clutches, reduction gearbox, brakes etc. are accessible for easy maintenance.

5.5.12. Manual Operation for L.T.: There shall be a provision for manual operation of L.T. from outside the cell/ from crane maintenance area ( depending on layout of the crane) in the event of power failure or breakdown. Manual operation of LT drive shall be possible by an arrangement of endless Stain less chain (preferably of self lubricating type & of rugged duty) and sprocket arrangements ( MOC –SS). The support for the sprocket shall be taken from wall plug EPs. The Chain shall be fully supported by a SS tray. The chain sprocket shall be designed such that to avoid derailing of the chain. The strength of chain should be sufficient to carry the complete fully loaded crane without any failure. The operating point for the LT emergency shall be brought to a height by suitable for easy manual operation by person standing on floor of crane maintenance area. The cranes in which by layout the crane maintenance area is not available, the LT manual operating point shall be provided outside the wall EP plugs. The wall EP plugs for such requirement is in the scope of supply of the supplier. There will not be any movement of the chain during normal operation for crane.

5.5.13. Manual Operation for C.T.: There shall be a provision for manual operation of C.T.

trolley from outside the cell in the event of power failure or breakdown. Manual operation of CT trolley shall be possible by an arrangement of endless Stain less chain (preferably of self lubricating type & of rugged duty) and sprocket arrangements ( MOC –SS). The support for the sprocket shall be taken from end carriages such that it does interfere with

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normal operation of the crane. The Chain shall be fully supported by a SS tray running along the length of CT Bridge. The chain sprocket shall be designed such that to avoid derailing of the chain. The strength of chain should be sufficient to carry the complete trolley along with fully loaded crab without any failure. The operating point for the CT emergency shall be through wall plug EP provided in the operating gallery. The wall EP plugs for such requirement is in the scope of supply of the supplier. There will not be any movement of the chain during normal operation of crab trolley. The operating point for CT manual override shall be brought along the face of wall EP using right angle bevel gear pair arrangements. The actuators for emergency crane operation shall be designed and supplied with crane. In addition a suitable latch/hook should also be provided on crab trolley for manual push pull of crane from wall EP.

5.6. Provision for Emergency Lowering and hoisting: The crane shall be provided with

system for lowering of the load in a safe manner and hoisting the hook block to the up limit in the case of failure of the normal hoisting system. Provision of a pony motor clutch assembly along the shaft of the motor shall be there. It shall be possible to lower full load i.e. 2000 Kg at a speed of 0.3 m/minute with the help of the pony motor. The same motor will be used to lift the empty hook block also. In case the pony motor fails, provision shall be given in the hoisting arrangement to lower the load mechanically by rotating the motor shaft at a fixed location in the cell through sleeves embedded on the wall. The actuators for emergency crane operation shall be designed and supplied with crane. Full details shall be provided in the offer itself.

5.7. Hooks and Hook Blocks: The hook block shall be designed to lift the rated load

without twisting. The hook shall be capable of swiveling and designed to turn easily on roller thrust bearings. The hook shall be capable of being readily removed and replaced and fixed rigidly. The hook shall be of the single trapezoidal shank hook type having rugged construction. Hooks shall comply with the requirements of IS-3815, BS-482 and BS-2903 and material for construction of hook & total hook block assembly shall be manufactured from SS 304 or equivalent material. The hook shall have longer shank to facilitate ease in remote handling operations.

5.8 ROPE DRUM: The rope drum shall be preferable of seam less construction of MOC

AISI TP304/304L as per ASTM A312, having spiral grooves machined to suit wire rope. The drum shall have dimensions to meet IS: 3938. (In order to make hoist compact higher diameter drums may be used). The revolution of rope drum shall be on self-aligning ball bearings, which ensures smooth running. The wire drum should have flanges at both side to avoid derailment of rope. Rope drum materail shall be UT tested as per approved procedure.

5.9 Gears, Shafts and Axles: All gears and pinions shall have accurately formed

machine-cut teeth of shape and finish acceptable to the purchaser. All exposed (to cell environment) gears shall be of stainless steel of suitable grade (rolled, forged or cast) with teeth cut from the solid blanks. All exposed pinions shall be of suitable grade stainless steel forging or cut from rolled steel bars. All exposed shafts and axles shall be turned from solid rolled and forged stainless steel bars of suitable grade. All axles shall be held rigidly in

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position by arresting plates and shall be designed for easy removal. The non-exposed gears, pinions, shaft & axles can be conventional material of construction. All shafts, axles, gears & pinions etc. shall be UT tested as per approved procedure.

5.10 Wheels and Rails: Rails shall be machined square sections made of stainless steel

compatible with the materials of construction of the wheel. The rail joints shall be at an angle to avoid jerks in movement. The rails shall be fastened suitably on the gantry girder and bridge (for L.T. and C.T. respectively) at a spacing of about 500 mm staggered. The supply of gantry girder (structural steel & MOC will be as per table-B) of suitable cross section is included in the supplier’s scope. The base plate EP’s are mounted on RCC gantry over which suitable steel gantry shall be provided for mounting of LT rails.

All the wheels shall be machined from SS410 forged steel. The wheel shall be mounted in such manner to facilitate removal and replacement. The cranes wheels and crab wheels shall be designed to avoid squeing of the bridge and trolley.

5.11 Bearings: All the bearings used shall be of suitable heavy-duty adequate anti-friction

type and permanently lubricated and sealed on both sides. For LT, CT and hoisting drive self-aligned roller bearings shall be used. All the bearings shall have adequate load carrying capacity and shall mounted in such a way that they can be accessed easily for their maintenance without disturbing to the extent possible, the shafts with their gears and pinions. All the bearings shall be of genuine SKF/FAG make.

5.12 Centralized Greasing and Lubrication System: The crane shall be provided with the centralized greasing and lubrication system. The greases used shall be resistant to

nuclear radiation damage upto an accumulated dose of 108 rads. Reduction gear units used shall also be sealed and lubricated for life with radiation resistant lubricants. Lubricants of following make or its equivalent can be used: Molykote-41 grease, molykote-321 R dry lub. Molykote-710 oil and never-seize compound manufactured by M/s. Dow Corning. In order to use the radiation resistance grease / lubricant at the time of hot commissioning the additional grease / lubricant shall be provided along with cranes.

6. DESIGN REQUIREMENTS: ELECTRICAL 6.1. MOTORS:

6.1.1. All motors shall be suitable for operation using VFD drive, constant torque squirrel type induction motors. The crane could be operated with the other speed by VFD drive. Each motor shall be given a separate connection.

6.1.2. These motors shall be totally enclosed, fan cooled (IP55), rated for continuous duty and provided with class H insulation and shall be suitable for reversing and frequent acceleration.

6.1.3. The motors shall be suitable for reversing and frequent acceleration and mechanical brake. The starting torque shall be more than 200% and pullout torque of motor shall be above 250% of rated torque at rated voltage.

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6.1.4. All motors shall conform to latest IS-325 & IS 12615 and either of Siemens, Bharat Bijlee, NGEF, GEC, Kirloskar or Crompton Greaves make only. The motors shall be operating on 415 V, 3 phase, 50Hz AC electrical supply. The motors should operate satisfactorily for Voltage varition of +10% & Frequency variation + 5%. Duty of motor shall be S4 with CDF of 40%.

6.1.5. The motors shall have cast aluminum cooling fan and the terminal box shall be suitable for terminating Al conductor armored XLPE insulated cables. Motor design and construction shall be suitable for easy dis-assembly and re-assembly. The enclosure shall be sturdy and shall permit easy removal of any part of the motor for inspection and repairs. The motors shall be provided with eyebolts or other means to facilitate safe lifting.

6.1.6. All motors shall be provided with HRC fuses, contactors with suitable overload relays and safety devices for protections against overload, under voltage and single phasing. Each motor shall be provided AC4 duty contactors. Motor starter shall be of the full voltage, direct on line, air brake, single throw electromagnetic type and shall conform to IS-2959.

6.1.7. Type and routine test certificates for all motors shall be provided by the supplier in accordance with relevant IS standards.

6.1.8. The motor vibration limits shall be in accordance with normal class of IS 12075, latest edition, unless otherwise specified. The permissible noise level shall not exceed 85db.

6.1.9. The motor shall be designed such that the temperature rise determined by the thermometer , when place at hottest accessible spot in the winding shall not exceed 70 degree centigrade and when determined by resistance method shall not exceed 80 degree centrigrade as per Class –B insulation over an ambient temperature of 40 degree centigrade and altitude not exceeding 1000 meter when operation at specified voltage and frequency.

6.1.10. Motor winding shall be given special tropical and fungicidal treatment for protection against (a) tropical weather conditions (b) fungus growth and moisture (c) oil (d) abrasive and contacting dust and (e) sulphur fumes in combination with weak acid or alkali fumes respectively that are likely to be encountered in and around the power plant area.

6.2. BRAKES/ CLUTCHES: Hoisting system shall be provided with non-failsafe DCEM brake with a special arrangement for release of brake in case of emergency. L.T. and C.T. motors shall be provided with suitable clutches such that freewheeling is possible. Clutches shall also be provided with class H insulation.

6.3. MAIN ISOLATER: A suitable switch fuse unit with fuse holder for 3 phase A.C. supply for crane shall be provided along with the control panel by supplier and installed it in a dust tight metal enclosure with a dust tight door. The door should be provided with suitable interlocking mechanism to cut off the electrical supply to the crane when the door is in open position for any maintenance. The complete switch fuse unit shall be capable of AC 24 duty. Provision of RYB 25W lamp indication shall come in the crane control panel. It is desired to have single phase protection system i.e. in event of loss of any single phase;

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there will not be any power supply to electrical drive components. The switch fuse unit shall be either of Siemens, L&T, GE and ALSTOM make only.

6.4. CCTV camera system: The scope of supply includes supply of 1 No. CCTV camera system which shall consists of Dome camera (having functions Zoom, Pan & tilt) of BOSCH Make ( Model: FLEXIDOME IP indoor 4000 HD) or Equ. Make/model, in-cell & out cell wiring, electrical connectors, control panel, pan-tilt-zoom joystick (1 No. only) & 20 inch CCTV monitor (1 No. only). Supplier shall install the CCTV monitor on one of wall of operating gallery. The joy stick shall be provided with stand near cell window for ease in operation.

6.5. CONTROLS AND CONTROL SYSTEM:

6.5.1 The crane shall be designed to be operated from different locations outside the cell, control room as shown in the drawings using a bush button hand pendent. Supplier shall make only two pendents per crane. Second pendent will be kept inside control panel. The control panel shall have provision to keep the second pendent in it. The crane shall also to be operated using radio remote control from different locations outside the cell. Crane shall have a main control cabinet from where connections are run to branch boxes fixed in these locations. These branch boxes shall be provided with suitable connectors to which the hand pendant (portable control box) can be plugged in using quick connectors. The push button hand pendent shall be light in weight with 3 m long flexible cable and shall be able to connect easily at each location with suitable multi-pin quick connector of EPIC/CONTACT make. The pendent shall have in addition to control push buttons luminous indications for `power on'. `Control on', `travel limits', and `hook on'. All The CT LT & hoisting motion push buttons shall have illumination when contact is ON. The control cabinet also shall be provided with a connector for push button pendent that can be used for repairs/maintenance.

The control circuit of the crane shall be such that crane to be operated from one single point at a time. For change over from local to remote for operation of crane using radio pendent; a selector switch to be provided inside the control panel.

6.5.2 Stop, start and directional changes shall be accomplished by reversing magnetic contactors, by push buttons operating a control circuit. In all cases the push buttons shall be spring-loaded and shall return to off positions when released. The push buttons for various motion shall be have indication glow lamp in operating condition.

6.5.3 VFD: The two speeds for CT LT and hoisting shall be achieved using VFD drives. Siemens or equivalent make VFD drive to be used. The VFD shall be designed in such a way that it covers the total span length of crane and required filter circuit to be provided in case of higher cable length for smooth operation of motors.

6.5.4 All incell & outcell electrical cables i.e. control as well as power cables connecting from crane to control panel, control panel to junction box, junction box to pendent, control panel to control room, CCTV camera cables, limit switch/proximity switch from their installation location etc. are in scope of supply of supplier. All in-cell cables i.e. power as

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well as control cable shall be of radiation resistant (both inner sheath as well outer sheath) of make HELUKABEL PUR750 suitable to withstand 100MRAD radiation dose. The cable for the drag chain shall be of drag chain duty only. The cable for the camera shall be of shielded type to have minimum video signal interferences shall be included in the scope of supply. All cables shall be bunched together using SS hose clips wherever required and also all out cell cable shall be laid through conduit and fixed to the wall.

6.5.5 All supporting electrical components such as overload relays, contactors, single phase protection devices, transformers, rectifiers, fuse unit etc. shall be located outside the cell in the control cabinet for ease in maintenance. All control equipment shall be suitable for operation with 110V AC or lower AC/DC supply.

6.5.6Supplier shall provide separate isolator switch for the electrical supply to control system and shall be of AC24 duty.

6.5.7 The supplier shall provide the brake logic and push button pendent operating logic. It shall be fabricated as per approved brake logic and push button pendent operating logic.

6.6 POWER SYSTEM: Power supply of 415V, 3 phase, 4 wire, and 50Hz AC shall be provided from separate electrical panels mounted nearby control cabinet. All electrical panels shall be provided with suitable dust tight doors, having suitable interlocking devices for cutting of the electrical supply when the doors are opened. Separate isolating switches shall be provided for the main power supply and power supplies to individual motions. Pilot lamps shall be provided on electric panel for indicating 3 Phase supply.

6.7 CONTACTORS & OVERLOAD RELAYS:

6.7.1 All contactors, overload relays shall be of reputed make like SIEMENS or Equ. and rated to permit 150 switching operations per hour. Overload relays with built in SPP may be considered for acceptance.

6.7.2 Reversing contactors shall be provided with electrical and mechanical interlocks between forward and reverse contactors. Contactors shall be provided with at least 2 NO and 2 NC additional auxiliary contacts.

6.7.3 FUSES: All fuses shall be of the HRC cartridge type conforming to IS-2208 mounted on plug-in type fuse bases. All accessible live connections shall be adequately shrouded and it shall be possible to change the fuses with the current alive, without the danger of contact with live metal.

6.8 CABLES, CONNECTORS AND CONDUITS:

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6.8.1. All power and control wiring within the cell shall be carried out with PUR sheathed, PUR insulated stranded wire core cables of HELUKABEL PUR- 750 Make. The cable shall be cable drag duty (cyclic duty) and shall be of standard 1.1KV grade, flame, heat, radiation and moisture resistant insulation suitable for operation in high temperature and radioactive atmosphere.

6.8.2. All outside wiring shall be provided in rigid galvanized steel conduit with threaded type fittings, galvanized outlet and pull boxes. Pull boxes shall be located at frequent intervals to allow cable or conductor to be pulled without abrasion or injury. Conduits shall form a continuous system and shall be properly supported. The entire conduit system shall be grounded. Conduit for power and control circuits shall not be less than the size recommended by relevant Indian standards for conductors that are to be installed their in. The entire conduit system shall be installed such that any moisture will be drained away from the terminal boxes and electrical devices. Power wiring and control wiring shall be kept in separate conduits. No conduits of size smaller than 25mm diameter shall be used. Flexible conduits when used shall be of PILCA pipe or galvanized flexible conduits.

6.8.3. Suitable multi-pin remote and quick electrical connectors shall be used for easy remote /quick connection/ disconnection of various remotely/quick separable units of crane at following locations. All the remote connectors shall be dead weight type-

(i) On LT bride near LT cable take up- Quick connector

(ii) On LT drive- Remote connector

(iii) CT cable take up/ crab drives- Remote connector

(iv) Location for connecting pendent with junction box- Quick connector

The connector shall be of LAPP EPIC make. The connectors shall be enclosed with SS enclosure and insulation for connector shall be suitable for ambient conditions as specified. These connectors shall be of reputed make with proven record of satisfactory operation in radioactive cells and shall have purchaser's approval. Soldered or screwed connections shall be provided wherever it is feasible. It shall ensured that no loose connections occur inside the cell due to vibrations of the unit while in operation by employing solder lug, spring washers and terminal blocks of best quality commercially available. Separate connector may be provided for CCTV Connection if required. The connector contacts for power and control shall be segregated.

6.8.4. The cable and wires shall be of 1.1KV grade and suitably HFFR (Halogen free fire retardant) insulated and sheathed copper conductors for control circuit wiring.

6.8.5. All insulation and all clearances to the ground shall be designed so that the live points can withstand a high potential test of not less than 2500V at 50 Hz for one minute.

6.8.6. Conductor sections of main power circuit shall be selected taking into consideration simultaneous operation of the main hoist and bridge motors.

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6.8.7. All wiring shall be done in a neat and workman like manner and wherever possible shall be run in the conduits. All wiring shall be numbered properly for easy identification.

6.8.8. All outside cell electrical cables shall be either of Universal, Finolex, POLYCAB, RRCable or CCI make only.

6.9 SAFETY EARTHING: Crane structure, motor frames and metal cases of all electrical equipment including metal conduits and cable guards shall be effectively earthed with tinned copper conductor of not less than 12 SWG as per relevant standards.

6.10 LIMIT SWITCHES: Automatic reset type of limit switches/proximity switches of suitable

design shall be provided for all the motions (L.T., C.T & Hoisting motion) of the crane to control the travel limits. Long & cross travels shall have mechanical stops at travel ends in addition to the switches. It is desirable to have the limit switches on wall penetration plugs wherever possible for ease in replacement. The design of the plug for limit switch and its supply shall be in the scope of supplier. The limit switches shall be of reputed make such as Siemens, BCH or Cutler & Hammer. For hoisting rotary limit switch as well as gravity operated limit switch shall be provided.

6.11 ELECTRICAL SUPPLY LEADS: It is desirable to provide electric supply to Crane

Bridge (L.T.) and Crab (C.T) through stainless steel cable drag chain. The cable drag chain shall be supported by rollers to avoid excessive sag. These electrical cables will be carried into the cell through a 250/200 NB stepped wall penetration plug which is in scope of supply of supplier. Design of the wall penetration plug shall be finalized in consultation with the purchaser's engineers. The Cable drag chain shall be of WIPERDRIVE or ELECTROMAG make.

7. ADDITIONAL DESIGN FEATURE REQUIREMENTS: It is desired to have suitable

system on the crane hoisting unit to facilitate the indication of the actual weight i.e. being handled. The display of such load shall be preferably in digital mode and shall be provided outside the cell on the crane control panel and on push button pendent. It is also desirable to have a circuit which will trip in case of overloading of crane beyond 2000kg and indication of the same shall be given on control panel.

8. SPARES AND MAINTENANCE TOOLS: 8.1. SPARES: The bidder is requested to provide list of necessary spares for 5 years trouble

free service. However the bidder shall quote for spares as per enclosed list as Table- C. The bidder shall give the break up for cost of spares. The lumsum cost for spares may not be considered without its break up. The necessary spares may be ordered along with crane or during commissioning phase.

8.2. MAINTENANCE TOOLS: The quotation shall include the required maintenance tools

(including the tools required for remote maintenance) for crane with the list of tools. Table –C

List of spares

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Sl no Description of the item (as per specification) Qty. Unit 1. LT Motor ( Group -1) 01 NO. 2. LT motor ( Group-2) 01 NO. 3. CT Motor 02 NOS. 4. Hoist Motor 02 NOS. 5. Mechanical load positive brake 01 NO. 6. DCEM hoisting brake 02 NO. 7. LT Clutch 01 NO. 8. CT clutch 01 NO. 9. Wire rope 120 Meters 10. Limit switches LT 6 Nos. 11. Limit switches CT 6 Nos. 12. Hoisting limit switch Rotary 2 Nos. 13. Chain for CT emergency 50 Meters 14. Chain for LT emergency 50 Meters 15. Electrical connectors (hot cell) for complete

crane 1 SET

PART-III : DESIGN, DRAWINGS AND INSTRUCTION MANUAL

1. DESIGN: The supplier shall provide detailed design calculations for selection of mechanisms like electrical motors, brake, clutch, wheel, rail, hoisting rope, pulleys, hook & its bearings, gear boxes, chain, sprockets, axles etc. and structural members like main

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girder, end carriage, crab frame etc. The design calculation shall be approved before the fabrication of the crane. The supplier shall verify the design of structural members for earthquake event and the same shall be submitted for approval. The design calculations for anti-topple lugs, wheel stoppers, end buffers shall also be provided. Two copies of approved design calculations shall be provided to the purchaser.

2. DRAWINGS:

2.1. The quotations shall accompany general layout drawings of the crane based on purchaser’s Tender Drawing for 10 nos. of 2 Te capacity incell cranes.

2.2. List of applicable drawings: Crane Identification Number



Drawing No.

C1, C5 HL bay 1,3

respectively Melter cell FRFCF/43270/GA/1160

C3 HL bay 2 Melter Cell FRFCF/43270/GA/1162 C2,C6 HL bay 1,3

respectively W & DC cell FRFCF/43270/GA/1161

C4 HL bay 2 W & DC cell FRFCF/43270/GA/1163 C7 Hull

compaction Batching cell FRFCF/43270/GA/1164

C8 Hull compaction

W & DC cell FRFCF/43270/GA/1165

C9 Cementation cell

Product handling cum storage

FRFCF/43270/GA/1166


Repackaging area FRFCF/43270/GA/1167

2.3. The supplier shall furnish two sets of following drawings for each crane to get the approval of the purchaser prior to fabrication. a) General Arrangement of crane. b) L.T. bridge and end carriage: Assembly and parts details. c) Crab Assembly and details. d) Drive units for L.T and C.T: Assembly and parts details. e) L.T. drive shaft and wheels: Assembly and parts details. f) Drive unit for Hoisting: Assembly and parts details. g) Assembly and detail drawings for hook and hook block. h) Rails, gantry girder details and their fixing arrangement for L.T and C.T along with

end stopper details. i) Arrangement for cable takes up. j) Arrangement for manual L.T. operation. k) Arrangement for manual C.T. operation. l) Arrangement for manual hoisting operation. m) Limit switch arrangement and details. n) Remote lifting arrangement for crab and its details.

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o) Remote lifting arrangement for LT motor assembly and its details. p) Mechanism for LT motion manual over –ride q) Mechanism for CT motion manual over-ride r) GA of control panel s) Electrical power and control circuit diagram. t) Wiring diagram of power and control system. u) Pendent wiring diagram. v) Push button pendent layout. w) Necessary installation, maintenance and operational drawings. x) Remote lifting yoke with resting stand for crab. y) Remote lifting yoke for LT Drive assembly and its stand z) Yoke for remote removal of crab & LT drive assembly connector. aa) Tools/tackles for manual override of LT, CT and hoisting motion bb) Layout drawing for radio remote control.

2.4. The drawings shall be made using AutoCAD.

2.5. It is the responsibility of the supplier to incorporate correctly all the comments conveyed by the purchaser on supplier’s drawings. The supplier shall provide four sets of approved fabrication drawings assembly, subassembly and part drawings to purchaser for his reference throughout the fabrication, installation and commissioning of the crane.

2.6. Drawings prepared by supplier and approved by purchaser shall be considered as part of specification. However, examination and approval of drawings by purchaser shall not relieve the supplier of his responsibility for proper engineering, design, workmanship and functioning of the cranes under the contract.

2.7. If any time before the completion of work, changes are made necessitating revision of approved drawings, supplier shall make such revisions and obtain the approval of the purchaser.

2.8. Supplier shall incorporate the as built changes in the drawing.

2.9. Supplier shall also provide all drawings on CD/DVD/PENDRIVE/HARDDISC media to purchaser for his records.

3. Documentation:

3.1 Supplier shall furnish six numbers of bound copies of documents. The documents shall consist of Quality Surveillance Document, Design Documents and Operation & Maintenance manual. Quality Surveillance document shall consist of Technical Specification of crane, Purchase Order copy, amendments if any, shipping release, packing list, approved quality assurance plan, test certificates for all raw materials, test certificates for bought out items, performance test reports, internal inspection report, assembly inspection report, joint inspection report, load testing report, minutes of meeting, approved procedures for welding qualifications (WPS, PQR and WPQ) and NDT procedures (LPT, RT and UT). Design documents shall consist of design calculations for mechanisms, structural members, swing calculation & verification for earthquake event and all as built drawings mentioned in 2.2. Operation & Maintenance

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manual shall consist of manuals and instruction of crane for operation and maintenance. The catalogues/ technical literatures for the bought out components with its selection shall also be provided. Maintenance schedule and its frequency shall also be included.

3.2 The instruction manuals shall be corresponding to the equipment supplied and not be

general in nature. The supplier shall submit two preliminary instructional manuals to the purchaser before the submission of actual manuals and one approved copy will be provided to the supplier for preparing final instructional manuals.

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PART-IV: FABRICATION, INSPECTION AND TESTING

1. FABRICATION:

1.1. The materials may be cut and formed to the required shape by any process that will not unduly impair the physical properties of materials. The edges that will be exposed in the finished form shall be rounded off to a radius of at least 3mm or chamfered at 45 degrees to at least 4 mm flat. All materials shall be grounded smooth and straightened and any slag of previous molten material shall be removed prior to further fabrication or use. SS304/304L material shall be cut only by plasma torches.

1.2. MATERIAL: The supplier shall use the material for fabrication as approved in the fabrication drawings and will be as per requirement of tender technical specifications. Suitable machining allowance shall be considered for raw material.

1.3. WELDING: Welding shall conform to IS-814, IS-816, IS-823 and relevant IS code for S.S. welding. . The welding procedures and performance qualification of welders shall be in accordance with Section-IX of ASME Boiler and pressure vessel code. Electrodes for welding shall conform to IS-814 for M.S. and IS-2811 for S.S.

1.3.1. The welding procedures and welder’s performance qualification report shall be submitted to purchaser for approval. The welding shall be carried out only by the qualified welder as approved by purchaser.

1.3.2. Welding processes and filler metals:

a. Stainless steel to Stainless steel: Any inert gas shielded arc-welding process may be used with the electrodes approved by the Purchaser's representative. The electrodes to be used are E 308L type.

b. Stainless steel to carbon steel: Any inert gas shielded arc- welding process may be used but only electrodes approved by the Purchaser's representative shall be used. The electrodes to be used are E 309L type.

c. Carbon steel to Carbon steel: SMAW Welding process may be used with the electrodes approved by the purchaser’s representative. The electrodes to be used are ER 7018 types

1.3.3. All welds should be free from defects like blowholes, lack of penetration, slag inclusions, porosity etc. and the welding shall be uniform.

1.3.4. Purchaser reserves the right to check any weld by suitable non-destructive test and if any weld is found defective, supplier shall repair the same free of cost after obtaining the approval from the purchaser.

1.3.5. Weld procedures adopted shall involve least amount of warping and not detrimental to the integrity of the sections being welded.

2. INSPECTION:

2.1. The supplier shall submit detailed QAP for purchaser’s approval.

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2.2. The inspection requirements for all components/ equipment shall as per approved QAP.

2.3. The supplier shall maintain proper inspection records and make it available to purchaser’s representative whenever required. Supplier shall make necessary arrangements for the inspection by the purchaser or his authorized representative.

2.4. Supplier shall provide to the purchaser or his representative the entire necessary test certificates for the standard components and materials bought out from the market. The test certificates for mechanical properties and chemical composition of the materials to be used for fabrication /construction of the crane shall be provided. The supplier shall make arrangements to scrutinize and purchase only good and trouble free components and preferably with the approval of the purchaser.

The steel castings and forging for load carrying parts shall be tested by appropriate Dye-penetrant and ultrasonic tests for getting the defect free units.

2.5. Welds for major load bearing components like bridge girders, end trucks, trolley frames etc. shall be examined as follows:

a) All butt welds of major load bearing members shall be100% radiographed.

b) All butt, T-joints and fillet welds shall be checked by dye penetrant test for root and subsequent each pass of welding.

c) For SS304L plate material used for welding application like manufacturing of rail, girder shall qualify for IGC practice A and E.

2.5. Purchaser reserves the right to inspect any material or equipment furnished or used by supplier under the contract and to reject any, which is found defective in workmanship or design, or otherwise unsuitable for the use and purpose intended, or which is not in accordance with the intend of contract.

2.6. Should purchaser waive the right to inspect any equipment, that waiver shall not relieve supplier in any way of his responsibility and obligations under the contract.

2.7. Purchaser reserves the right to call for certificates for all material and equipment at any stage of manufacture.

2.8. In the events of purchaser’s inspection revealing poor quality of goods, purchaser shall be at liberty to specify additional procedures if required to ascertain supplier’s compliance with the equipment specifications.

2.9. Even though purchaser or his representative carries out inspection, such inspection shall not however relieve supplier from his responsibilities for furnishing the equipment conforming to the requirement of the contract.

3. TEST CERTIFICATES AND TESTING OF CRANE:

3 .1. TEST CERTIFICATES.

3.1.1. Following test certificates shall be furnished by the supplier and approved by the purchaser.

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a) Manufacturer’s test certificates for mechanical properties and chemical compositions for material of structural steels, hooks, hoisting rope, pulleys, rope drum, wheels, gears and pinions, shafts and axles etc.

b) Functional tests for all equipment.

c) IGC A & E test certificate for SS304L plates used for welding.

d) Radiography test reports of butt welds and T-joints.

e) Test reports of DP inspection of fillet, butt and T-joint welds.

f) Rated and overload deflection test of the crane.

g) Insulation test for all electrical equipments and continuity test for all cables.

h) Type and Routine tests for motors.

i) Test certificates for brakes and clutches.

j) Test certificates for other bought out components.

k) Test certificates for all UT tested components.

3.1.2. In the absence of test certificates from the manufacturer of the materials the material shall be tested as per the specifications and approved by the purchaser prior to the starting of fabrication.

3 .2. TESTING OF CRANE:

3.2.1. Before shipment, the crane shall be carefully fitted and shop assembled, clearly match marked to facilitate ease in assembly at the site. The shop operational and running tests for machinery assembled on the bridge structure shall be conducted for all mechanical and electrical parts and automatic devices to demonstrate that the crane is in satisfactory operating condition. Supporting arrangements shall be provided in a manner to allow free movement of hook for determining high hook elevation and hook lift. The scheme for Remote maintenance of the crane and manual operation for L.T., C.T. & Hoisting shall be demonstrated at supplier’s works itself.

3.2.2. The following tests on complete crane in the presence of purchaser’s representative shall be carried out at manufacturer’s works.

a) Material inspection, visual inspection and dimensional checks shall be done.

b) Rated load test: Checks for functioning of motions, travel limits, interlock operations, brake and clutch operations, position accuracy of drive mechanisms at rated load shall be conducted in addition to checks for specified speeds at rated load. The maximum deflection with rated load shall not exceed 1/1200 of the span.

c) 25% over load test:

1. The maximum deflection shall not exceed 1/1000 of the span.

2. Functioning of travel limits shall be checked.

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3. Operating speeds shall be checked.

4. Hook shall be tested as per relevant IS standard.

d) The scheme for remote maintenance of the crane.

e) Arrangement for manual L.T., C.T. & Hoisting operation.

3.2.3. Following tests on the crane shall be carried after erection at site.

a) Test for proper functioning of the crane.

b) Test for manual L.T., C.T., and hoisting arrangement.

c) Test for demonstration of roll out maintenance of the crane.

d) Remote removal of crab & bridge of crane. Balancing of lifting yokes.

e) Rated load test: After erecting the crane at site, the crane shall be tested at the rated load. Checks for functioning of all motions, travel limits, interlock operations, positioning accuracy of drive mechanisms at rated load shall be conducted in addition to the checking of specified speeds at rated load. Maximum deflection of the bridge with the rated load shall not exceed 1/1200 of the span.

f) In case of any variations in the test results from those mentioned in 3.2.2. (b), reasons for these variations shall be detailed, and if necessary, the 25% overload testing shall be carried at site to check for the integrity of the crane.

3.2.4. All the tests shall be carried out as per latest IS-3177 unless otherwise specified.

3.2.5. No distortion, permanent strain, damages or deformation of any part of the equipment to be supplied under this specification shall occur as a result of the above testing.

3.2.6. The scheme for remote maintenance of the crane shall be tested at site.

3.2.7. The supplier shall arrange free of cost the required testing and inspection instruments for use at ex-works and at site.

3.2.8. Noise level of crane shall be within 85 DB from 1 meter of crane.

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PART-V: PACKING, TRANSPORTATION AND PLACE OF DELIVERY

After carrying out the tests at manufacturing works as specified in 3.2.2 PART-IV, and after match marking, the crane shall be carefully disassembled into major sub-assemblies and then properly packed, crated and protected from damage during transport, transit and storage at site. The packing shall include adequate cushioning, blocking, bracing, skidding, hoisting and tie down provisions. All machined parts shall be protected with anti rust grease. All components of the crane wrapped plastic wrap/sheet, protected with suitable cushion and packed in premium wooden boxes. The boxes should be designed for easy handling with fork lift. All the electrical packaging shall be suitable for protection from minor ingress of water. LT & CT girders of the cranes shall also be packed in wooden boxes.

Supplier shall be responsible for any damage to the equipment during transport, transit and storage at the site. The supplier without any extra cost shall supply any short supply inside the intact package. The intact packages shall be safely transported to the following destination:

Asstt. Stores Officer,

WMP, FRFCF, IGCAR

Kalapakkam,

Tamilnadu, India

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PART-VI : INSTALLATION AND COMMISSIONING

1. The supplier shall install the cranes at the required area of WMP, FRFCF, Kalapakkam as indicated in tender drawing in consultation with purchaser’s site representative. Supplier is advised to visit the site and get him self fully acquainted with all the conditions at site. Ignorance of site conditions shall, in no case whatsoever be the basis for claim for extra payment

2. Temporary electric power 440 Volts, 3 Phase, 50 Hz and 230 Volts, single phase, 50 Hz will be supplied free of cost subject to the following conditions-

a. Supplier shall make his own arrangement for supply, erection and dismantling on completion of the work, of his temporary distribution system required to take power from the purchaser's supply points.

b. Purchaser will supply this power to the supplier at a point within 100 meters of the location of work place.

c. Purchaser will not be held responsible for the consequences of any unintentional interruptions in power supply

3. Contractor shall at his own cost, make arrangements for transport of his personnel to and from the site. Neither living accommodation nor space for labor colony will be provided by purchaser for installation contractors. It shall be supplier's responsibility to make all accommodation arrangements.

4. All handling equipment, scaffoldings, tools and tackles etc. required for the erection work shall be arranged by the supplier. Safety procedures prevalent at site shall be complied in total and instruction in this regard from time to time by Project Manager or his engineer shall be followed in all respects. Supplier shall cooperate with other contractors for the use of purchaser's facilities. Insurance of supplier’s personnel working at site for installation purpose shall be taken care of as per stipulation of Government of India. Purchaser shall not be held liable for any damage to person or property resulting from the use of construction tools and equipment furnished, rented or loaned to the contractors by the purchaser. Contractor shall be solely responsible for all injury, loss of life to his persons and for any other damage due to any cause in any way connected with carrying out this contract. Contractor shall indemnify purchaser in respect of all claims brought against the purchaser by any body in this regard.

5. All efforts will be made to make it available services of cell top EOT crane in the area for handling equipment of hot cell crane for its installation. However this cannot be guaranteed and supplier shall not dependent on these services in any case.

6. The supplier at all times shall work in coordination with purchaser’s engineering staff and offer them all facilities to become familiar with the erection, operation and maintenance of the equipment. Contractor shall work in harmony with other contractors at site in such a manner to enable the other work to be performed without any hindrance

7. After installation, the crane shall be commissioned by the supplier and handed to the purchaser in complete working condition. Before handing over all the tests (full load

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test, overload test, travel limits, hook approaches etc.) as desired at site shall be carried out and demonstrated in presence of the purchaser's representatives.

8. Installation and commissioning of the complete crane at site shall be done as per the agreed time schedule between the supplier and purchaser. The complete responsibility for the safe transportation of the crane to site and its installation and commissioning shall rest with the supplier.

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PART-VII CONFIDENTIALITY CLAUSE

(1) Confidentiality: No party shall disclose any information to any third party

concerning the matters under this contract generally. In particular, any information identified as “Proprietary” in nature by the disclosing party shall be kept strictly confidential by the receiving party and shall not be disclosed to any third party without the prior written consent of the original disclosing party.

(2) This clause shall apply to the sub-contractors, consultants, advisors or the employees engaged by a party with equal force.

(3) “Restricted information” categories under Section 18 of the Atomic Energy Act, 1962 and “Official Secrets” under Section 5 of the Official Secrets Act, 1923.

(4) Any contravention of the above-mentioned provisions by any contractor, sub-contractor, consultant, advisor or the employees of a contractor will invite penal consequences under the aforesaid legislation.

(5) Prohibition against use of BARC’s name without permission for publicity purpose: The contractor or sub-contractor, consultant, advisor or the employees engaged by the contractor shall not use BARC’s name for any publicity purpose through any public media like Press, Radio, T.V. or Internet without the prior written approval of BARC.

(6) Police verification certificate: Supplier persons involved in the installation work at site will require police verification certificate (PVC) and personal government photo identity card. Supplier shall kept ready all these documents before commencement of installation work. No excuse will be considered in delay of getting such document for getting timely start of installation work.

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PART-VIII DELIVERY SCHEDULE, GUARANTEE, FACTORY REPORT,

SUB-CONTRACT AND GENERAL INSTRUCTIONS. 1 Delivery Schedule:

1.1 The crane shall be designed, fabricated, assembled, load tested and delivered at site in 24months time from date of purchase order. The supplier shall take all the necessary steps to meet delivery schedule.

1.2 The supplier shall install the cranes at the required area as specified in the tender technical specifications Table-A in consultation with purchaser’s site representative.

1.3 Installation and commissioning of the complete crane at site shall be done in 6 months time from the date of getting clearance for start of installation and commissioning from site representative/ indenter. The complete responsibility for the safe transportation of the crane to site and its installation and commissioning shall rest with the supplier. The necessary loads for load testing of crane shall be arranged by the purchaser at site. However, the supplier shall bring necessary instruments for conducting testing of crane at site.

2. GUARANTEE:

2.1 Supplier shall guarantee that the goods furnished by him shall be in full accordance with the requirements of the specifications and are new and of high quality. Supplier shall also provide the warranty that the goods are free from defects in design, materials or workmanship.

2.2 The supplier shall indicate clearly the terms covered under guarantee/warranty and its period from the date of satisfactory commissioning and handing over of the crane. The guarantee/warranty shall be as per following clauses- a) Installation deferred due to non availability of site – 3 yrs from date of supply b) If installation carried out within 3 yrs of supply – 1 year from date of testing and

commissioning at site.

2.3 If, within the expiry of the above stipulated warranty/ guarantee period, the subject goods or any part thereof are found defective because of poor design, workmanship or materials, supplier shall at his own expense, repair or furnish and install replacement parts of proper design, workmanship and materials approved by the purchaser. The guarantee period for replaced parts of repair works shall be the same as above.

3. FACTORY REPORT: The bidder shall provide the description and details of company structure, design department, fabrication units and quality surveillance department. This should include the facilities and equipment available for the design, manufacture, supply and erection of cranes of similar nature and capacities. Any special features of the cranes manufactured and special facilities available with the manufacturers for the design and manufacture of the cell cranes shall be indicated. The bidder should also provide the list, with reference, orders of the cranes of similar kind and capacities to the government

33

organizations especially to the units of Department of Atomic Energy. The bidder shall submit the factory report comprising all above information along with the tender.

4. SUB CONTRACTS: The supplier shall not sub contract any part of the work without a written consent from the purchaser. The supplier shall be responsible to the purchaser for all the work of subcontractor if allowed by purchaser.

5. GENERAL INSTRUCTIONS:

5.1. The bidder shall give the cost structure and technical details strictly as per the format as given in our tender document (Annexure-A & Annexure-B) failing which the offer may not be considered. Any information (commercial or technical) if bidder wants to add can indicate in the appropriate annexure for which additional sheets can be attached. The bidder shall note that the cost figures shall not be revealed anywhere in the tender document except in annexure-A.

5.2. The purchaser reserves the rights to place the purchase order for cell crane on any party based on the technical evaluation, vendor evaluation and cost comparison.

5.3. The bidders shall provide the details in vendor evaluation pro-forma as given in Annexure-C.

34

ANNEXURE – A COST STRUCTURE PERFORMA

1. Ex-Works cost of 10 Nos. cranes as listed in table-A of Tender technical specifications including cost of gantry girder, rails and rail fixing clamps, bolts etc.

(Note: Separate cost of each crane should be indicated in the tender )

(Note: Payment against Delivery of crane will be given on pro-rata basis ).

2. Packing and Forwarding charges ( @ % of ex-work)

3. Total Ex- Work Cost of cranes ( 1 +2)

4. Excise duty ( Exemption certificate will be provided by DAE)

5. ST/ VAT

6. Transportation charges (@ % of ex-work)

7. Cost for Installation and commissioning of 10 Nos. of cranes including cost for installation of crane gantry girder and power & control cables as per TTS.

(Note: Separate cost of I & C of each crane should be indicated in the tender. Payment against installation & commissioning charges for commissioned cranes will be given on pro-rata basis).

8. Cost of spares as per listed in TABLE -C

(Note: Separate cost for each spare shall be indicated clearly)

9. Service tax, if any on installation and commissioning

10. Any other taxes/ duties (specify clearly)

11. Delivery period in months

12. Installation and commissioning period in months

13. Validity period of the quotation. (120 days Minimum )

14. Guarantee/ Warranty period. a) Installation deferred due to non availability of site – 3

yrs from date of supply b) If installation carried out within 3 yrs of supply – 1 year

from date of testing and commissioning at site.

Note: Price escalation for value of PO will not be considered.

35

ANNEXURE – B INFORMATION REGARDING CONSTRUCTION OF THE CRANES, TO BE SUPPLIED BY THE SUPPLIER/ BIDDER

Please follow the notes carefully as given below:

1. Provide details separately for LT, CT and Hoist 2. The specification for all components shall be provided. 3. The layout of the cranes shall be as per the purchaser’s Tender Drawings. 4. The information asked for as detailed below and any other missing

information should be clearly indicated in the tender. Additional information supporting the points as asked below may be provided on separate paper and to be submitted along with tender. Any special features of the crane offered also shall be clearly indicated.

5. All the dimensions shall be in Metric Units Bidder has to provide following technical Information along with their bids for technical evaluation. Following information shall be separately provided for crane i .e. C1 to C10.

1. SPECIFICATION OF THE CRANE

1.1. GENERAL

1.1.1. Number of cranes

1.1.2. Type of crane

1.1.3. Duty of the crane

1.1.4. Type of service

1.1.5 Safe working hoisting load in addition to dead weight for hoist.

1.1.6. Atmospheric condition

1.1.7. Hoisting method

1.2. OPERATING SPEEDS (at rated load)

1.2.1. Long travel

1.2.2 Cross travel

1.2.3 Hoisting

36

1.3. CRANE PERFORMANCE AND STRUCTURAL DETAILS (ref: tender drawings)

1.3.1. Span (A)

1.3.2. Total lift

1.3.3. Distance between the bottom of the crane rail on the longitudinal crane gantry girder to the bottom of top RCC slab (Head room available) (c)

1.3.4. Bridge wheel base (P)

1.3.5. Trolley wheel base (Q)

1.3.6. Longitudinal approaches of the crane

L1 (mm)

L2 (mm)

1.3.7. Transverse approaches of the crane

C1 (mm)

C2 (mm)

1.3.8. End clearance between the crane bridge and walls (J)

1.3.9. Distance between ground level of cell to topmost position of hook (E)

1.3.10. Distance between ground level of cell to lowest bottom of L.T. bridge (L)

1.3.11. Minimum clearance above the crane (T)

1.3.12. Distance between the center line of the crane rail to the adjacent wall (H1 & H2)

1.4 Cable take up arrangement for L.T. bridge

1.5 Cable take up arrangement for C.T. Crab

2. BRIDGE CONSTRUCTION

2.1 Type of girder construction

2.2 Type, size and section modulus of end truck (carriage) construction

2.3 Material specification of girder and end trucks

2.4 Size and section modulus of the girder

2.5 Distance between two girders for double girder bridge.

2.6 Safety factor used in the design

37

2.7 Designed maximum deflection of the bridge girder for i) Rated load ii) 25% excess load

2.8 Does the bridge construction conform to IS-807 (Yes/No)

2.9 Whether all butt and T joint welds of major load bearing component would be radio graphed (Yes/No)

2.10 Whether all welds would be dye penetrate tested (Yes/No)

2.11 Whether all supplier’s site inspection reports could be made available to the purchaser (Yes/No)

2.12 Whether spring loaded buffers will be provided on bridge for mechanical stopper.

3. TROLLEY CONSTRUCTION

3.1. Type and construction

3.2 Whether trolley and crab are as separate unit for remote handling

3.2. Material specification

3.3. Size of trolley

3.4. Whether spring loaded buffers will be provided on trolley for mechanical stopper.

4. WEIGHTS, LOADINGS AND DESIGN CONSIDERATIONS

4.1. Bridge wheel loading on the crane gantries

4.2. Trolley wheel loading on the bridge girders

4.3. Total crane weight

4.4. Total trolley weight

4.5. Maximum weight of the single unit for handling during transportation, storage and installation

4.6. Minimum safety factor used in the design of the crane

4.7. Minimum impact factor considered in the design of the crane

5. RAILS DETAIL

5.1. BRIDGE RAILS

5.1.1. Type and weight of the rail per meter

38

5.1.2. Size of the rail

Top width (W1)

Bottom width (M)

Height (W2)

5.1.3. IS standard or other standard to which they conform to

5.1.4. Material Specification

5.1.5. Fixing arrangement of the rails and spacing in between successive mountings

5.1.6. Whether wheel stoppers for bridge will be provided on rails?

5.2. TROLLEY RAILS

5.2.1. Type and weight of the rail per meter

5.2.2. Size of the rail

Top width (W1)

Bottom width (M)

Height (W2)

5.2.3. Material specification

5.2.4. State to which IS standard the rails conform to

5.2.5. Fixing arrangement of the rails and spacing in between the successive mountings

5.2.6. Whether wheel stoppers for trolley will be provided on rails?

6. CABLE TAKE UP

6.1. CABLE TAKE UP FOR L.T. BRIDGE

6.1.1. Type

6.1.2. Details of Cable Take up

6.1.3. Mounting arrangement for cable take up. (Roller/trolley etc)

6.1.4. Insulation specification

6.2. CABLE TAKE UP FOR C.T. CRAB

6.2.1. Type

6.2.2. Details of Cable Take up

6.2.3. Mounting arrangement for cable take up.


39

7. MECHANICAL DETAILS

7.1. WHEELS

7.1.1. BRIDGE WHEELS

7.1.1.1. No. of wheels

7.1.1.2. Material specification

7.1.1.3. Diameter

7.1.1.4. Flange dimensions (Projection outside the rail on each side)

7.1.1.5.

Maximum wheel load with impact factor and without impact factor

7.1.1.6. Dimensional details of bridge end stoppers (wheel stopper)

7.1.1.7 Hardness of wheels in BHN

7.1.2. TROLLEY WHEELS

7.1.2.1. No. of wheels

7.1.2.2. Material

7.1.2.3. Diameter

7.1.2.4. Flange dimension (projection outside the rail on each side)

7.1.2.5. Maximum wheel load with and without impact factor

7.1.2.6. Dimensional details of trolley end stoppers (wheel stopper)

7.1.2.7. Hardness of wheels in BHN

7.2. WHEEL AXLES FOR BRIDGE AND TROLLEY

7.2.1. Type


7.2.3. Size

7.3. Bearings for bridge wheels, trolley wheels, main and aux. hoisting units and their hook blocks, rope drives and all gear boxes

7.3.1. Type

7.3.2. Make (SKF/ FAG)

7.3.3. Lubrication particulars including the scheme of centralized lubrication for the complete crane

7.4. HOISTING METHOD FOR HOIST

40

7.4.1. Whether wire-rope hoisting will be provided? (Yes/No)

7.4.2. Type of rope

7.4.3. Rope Specifications

7.4.4. Material of construction for rope

7.4.5. Minimum breaking load

7.5. HOISTING DRUM FOR HOIST


7.5.2. Design Specifications

7.6. HOISTING WIRE ROPE GUIDE (Scheme)

7.7. GEAR DRIVES FOR LT, CT, AND HOIST

7.7.1. Type

7.7.2. Make

7.7.3. Material specification of gears, pinion and shafts

7.7.4. Lubrication type and specification

7.7.5. Does it conform to any relevant standards, and if so, specify the applied standard

7.7.6. Hardness of gears and pinions in BHN

7.7.7. Gear box reduction ratios: LT, CT and Hoist

7.8. HOOK FOR HOIST

7.8.1. Type


7.8.3. Whether the hoist hook can swivel freely under load, and whether it can be locked remotely at four positions (900 apart)

7.8.4. Whether long shank hook will be supplied

7.8.5. Does it conform to any relevant standards and if so specify applicable standard.

7.8.6 Type of the hook block supplied

7.9. TYPES OF REMOTE COUPLINGS FOR

7.9.1. Long Travel

7.9.2. Cross Travel

7.9.3. Hoisting

41

7.9.4. Material specification for coupling

8. ELECTRICAL DETAILS

8.1. MOTORS

8.1.1. Motors for L.T, C.T and Hoist

8.1.1.1. Type of motor

8.1.1.2. Make

8.1.1.3. No. of motors

8.1.1.4. Power rating (voltage, current, frequency, no. of phases and wattage in Kw)

8.1.1.5. Rating (duty)

8.1.1.6. No. and specification of bearings used per motor

8.1.1.7. Class of insulation

8.1.1.8. Earthing detail

8.1.1.9. Do they correspond to latest IS-325 (Yes/No)

8.2. BRAKES FOR HOISTING

8.2.1. Type

8.2.2. Make

8.2.3. Design value of holding torque in % full load torque

8.3. LIMIT SWITCHES FOR LT, CT AND HOISTING

8.3.1. Type

8.3.2. Make

8.3.3. Mounting Details

8.4. PENDANT AND IT’S CONTROL SWITCHES

8.4.1. Type and Make

8.4.2. No. of pendants to be provided(minimum 2 pendent is required for each crane)

8.4.3. Material specifications

8.4.4. No. of switches per pendant

8.4.5. Whether mechanical and electrical interlocking is provided

8.4.6. Arrangement to avoid simultaneous operation from different pendent (Arrangement for energizing only one pendant at a time to execute crane operation)

42

8.5. TRANSFORMERS FOR POWER AND CONTROL CIRCUITS, FOR BRAKE SUPPLY, FOR LT, CT AND HOISTING

8.5.1. Power Rating

8.5.2. Voltage and current rating

8.5.3. Type

8.5.4. Make

8.5.5. Earthing Details

8.6. Isolators And Fuse Holders For Main Isolators for L.T, C.T and hoisting, for control circuits

8.6.1. Type

8.6.2. Make

8.6.3. Current rating (Amps)

8.6.4. Type and current rating of the fuses

8.7. OVERLOAD PROTECTION FOR LT, CT AND HOISTING MOTORS AND BRAKE CIRCUIT

8.7.1. Type

8.7.2. Make

8.7.3. Range of rating

8.7.4. Mounting details

8.7.5. Conform to what standard

8.8. SINGLE PHASE PROTECTION FOR ALL MOTORS

8.8.1. Type

8.8.2. Make

8.8.3. Voltage / current rating

8.8.4. Power rating

8.8.5. Mounting details


8.9. ELECTRICAL PANEL FOR LT, CT AND HOISTING

8.9.1. Type

8.9.2. Make

8.9.3. Size

43

8.9.4. Whether door is interlocked


8.9.6. Earthing detail

8.9.7. Any other special features

8.10. CONTACTORS FOR LT, CT AND HOISTING MOTORS

8.10.1. Type

8.10.2. Make

8.10.3. Specification

8.10.4. Voltage and current rating

8.10.5. Max. no. of operations/ hour


8.11. PILOT LAMPS & SUPPLY POINTS

8.11.1. Whether pilot lamps are provided for indicating the 3-phase supply on control cabinet. Indicating lamp for control panel ON.

9. Make of In-cell electrical cables

10. Make of Out cell electrical cable.

11. SPECIAL FEATURES TO FACILITATE REMOTE Handling

11.1. Scheme for maintaining drives for L.T., C.T & Hoisting.

11.2. Scheme for maintaining L.T. shaft bearings and couplings.

11.3. Scheme for maintaining L.T. & C.T. wheels assembly.

11.4 EMERGENY OPERATIONS

11.4.1 Whether provision for remote manual operation for L.T., C.T. and Hoisting will be made? (Yes/No)

11.4.2 Scheme in brief for remote manual operation for L.T. in case of emergency.

11.4.3 Scheme in brief for remote manual operation for C.T. in case of emergency.

11.4.4 Scheme in brief for remote manual operation for hoisting in case of emergency.

11.4.5 Whether Non failsafe brake DCEM will be provided for hoisting

44

11.4.6 Whether Mechanical load positive brake to provided inside gear box of hoisting for emergency operation. Provide details

12 Details of VFD drives for speed control of motors TYPE make model

13. CCTV Camera system

13.1 Details of DOME PTZ Camera Type, make, model etc.

13.2 Whether camera will be part of crab. Provide details.

14. Radio remote pendent Make Model Type etc.

15. Whether the supplier/ bidder will conduct and provide test certificates for all the tests specified in the tender specifications (Yes/No)

16. Any other remark the supplier/ bidder would like to add

Index

45

Notes for the Bidders

Sr. No. Description Page No.

1 Price Bid & Validity of the offers 46

2 General Conditions 46

3 Vendor Qualification Criteria 46

4 Documents Required from the Bidders 48

Annexure-I Vendor Evaluation Performa 50

Annexure-II Schedule of Deviation 52

Annexure -III Performa for Past Experience of Similar Orders Executed 53

Annexure-IV Assets & Liabilities of the Firm 54

Annexure -V Qualification & Experience of Key Personnel 55

Annexure -VI Organization & Structure

56

Annexure -VII List of Typical Plant & Machinery

57

Annexure -VIII List of Machinists, Qualified Welders & Fabricators

58

Notes for the Bidders

1 Price Bid & Validity of the offers:

46

Commercial bid shall be submitted separately as per instructions of Directorate of

Purchase & Stores. The offer shall be valid for minimum 120 days from opening of

the tender.

A pre-bid meeting shall be arranged to explain the entire requirement in detail & to

address the queries of the bidders. Bidders should nominate technical representative

for the meeting. No Technical clarification shall be entertained after the pre- bid meeting.

2 General Conditions:

(a) Work should be carried out strictly conforming to the material specification as given

in of this tender specification. Deviations, if any, should be clearly indicated by the

supplier in their offer as per annexure II.

(b) The bidder shall procure the items strictly as per technical specification of the item

.The test certificate of such purchase items must be reviewed and certified by the

purchaser and/or its representative before the delivery of these items to bidder’s stores.

3 Vendor Evaluation Criteria:

(a) The offers only from manufacturers/ Fabricators shall be accepted. The bidder

shall clearly indicate whether they are manufacturer/ fabricator or trader of the

indented items.

(b) The firm shall have Quality Management System conforming to National/ International

standards.

(c) The manufacturer/Fabricator should have experience in manufacturing the tendered

items of the similar quality and should have supplied such items in last 7 years.

3.1 Financial Evaluation Criteria:

a. The bidder should have satisfactorily completed following similar works (i.e.

design, fabrication, installation& commissioning of incell cranes) based on

certification of performance by clients during last 7 years as follows:

Three works, each costing not less than Rs. 2.60 Cr.

or

Two works, each costing not less than Rs. 3.25 Cr.

or

One works of value not less than Rs 5.20 Cr.

b. Average annual turn-over of the bidder in last three financial years shall not be less

than Rs. 6. 5 Cr. ending March 31st 2015.

c. The firm should have bank solvency of Rs. 2.60 Cr.

d. The firm should not have incurred loss in more than two years during the last five

years & financial net worth of the firm should not be negative.

e. The firm should not be under liquidation, court receivership, or similar

proceedings. A self-certified statement by the firm should be furnished.

The bidders not qualifying the financial criteria will not be considered for technical

evaluation.

3.2 Technical Evaluation Criteria:

47

a. Organizational structure w.r.t design, drafting, engineering planning, procurement

manufacturing/production and quality assurance.

b. Adequate experience in design, fabrication, installation& commissioning of incell

cranes.

c. Understanding of incell crane functioning and remote maintenance design

features.

d. The manufacturer/Fabricator should have experience in manufacturing the tendered

items of the similar quality and should have supplied such items in last 5 years.

e. Experience in design &fabrication of mechanical load positive brake for hoisting

operation.

f. The vendor shall have a well laid out machine shop with adequate space. The machine

shop shall have adequate plano millers, shaper / milling machines, lathe machines,

welding facility. The vendor shall submit a detailed list of heavy machinery indicating

type, capacity, duty, year of manufacture & valid recent calibration certification. The

vendor shall have a manufacturing capacity to meet the delivery schedule required for

this work. The vendor shall submit past records of meeting delivery schedule for job of

similar nature. The vendor shall have adequate handling facility on shop floor.

g. Implementation and experience of relevant codes as listed.

h. Existence of quality control system along with qualified NDT personnel and

availability of in house facility for NDT.

i. Skilled man power in design, fabrication, installation& commissioning.

j. The vendor shall have qualified engineers with experience for design and qualified

drafting personnel for drafting work.

The vendors will be evaluated based on points rating criteria related to all above

points as per following table. The decision of BARC will be final.

Sl. No. Criteria Maximum Marks Marks Obtained

1. Financial Criteria 20

2. Experience in Similar Jobs Executed 20

The manufacturer/Fabricator should have

adequate experience in manufacturing the

tendered items of the similar quality design,

fabrication, installation& commissioning of

incell cranes and should have supplied such

items in last 7 years.

3. Performance of Works (Time Overrun)* 20

4. Performance of Works (Quality) 15

5. Personnel & Establishment 10

48

6. Plant & Equipment 15

Note: The minimum qualifying points shall be 70% marks (in total) & 60% marks

against individual criteria.

4 Documents Required from the Bidders:

The firm should submit the following documents as documentary proof for meeting

the above requirements:

i. List of similar jobs/orders i.e. design, manufacturing & testing with high precision

requirements executed for government & private organizations as per Annexure-III.

ii. Financial turnover statement for the last three years ending March 31,2015 or 2016

which so ever be latest (refer Annexure-IV)

iii. List of qualified & experienced key personnel as per Annexure-V.

iv. The profile of the organization with the organization chart & the total technical/non-

technical staff as per Annexure-VI.

v. List of machining/ fabrication facilities, installation/erection capabilities, quality

control/testing facilities as per Annexure-VII.

vi. List of qualified welders, fabricators, machinist as per Annexure-VIII.

vii. Schedule of Deviation as per Annexure- II.

viii. National / International standard for Quality Management System.

ix. Audited balance sheet and profit & loss a/c for the last five years.

x. Statement showing the net worth of the firm.

xi. Declaration or self-certified statement that the firm is not under liquidation, court

receivership or similar proceedings.

xii. Performance certificates from the users/ clients for similar jobs executed.

xiii. The Time Over-Run (TOR) for similar works will be calculated as per following table:

Sl.

No.

Parameters Score, if TOR = Max

Marks 1.0 2.0 3.0 >3.5

1. Without levy of compensation 20.00 13.34 6.67 0.00

20.00 2. With levy of compensation 13.34 6.67 0.00 -6.67

49

3. Levy of compensation not decided 13.34 6.67 0.00 0.00

TOR = AT/ST, where AT: Actual Time; ST: Stipulated Time

Marks for value in between the stage indicated above are to be determined by straight

line variation basis.

Notes: 1. The bidders/suppliers shall indicate the above information (agreements with other

firms).

2. No part bid for part supply will be accepted.

xiv. In the event of the ordered quantity is split among bidders, the bidders shall accept part

order.

xv. List of testing facilities available in-house with the bidder.

xvi. List of sub-vendors.

xvii. Copy of QA Plan approved by purchaser/TPI for similar orders executed in recent past.

Offer not accompanied with any of the above documents will be treated as incomplete and

liable for rejection without any further correspondence.

50

ANNEXURE-I

VENDOR EVALUATION PROFORMA

(To be filled in and submitted along with the tender)

Reference Tender Enquiry No. Date:

Quotation No. Date:

1. Vendor Details :

(a) Name

(b) Address (Office & Works)

(c) Telex

(d) Contact Person

(e) Details of ownership of premises

(Only if not owned by company)

2. Registration Details:

Registration No. :

(a) Small Scale Industry

(b) Directorate of industries

(c) Others

3. Organization Details :

(a) Nature (proprietary, partnership, private

limited, public limited, state/central

government undertaking)

(b) Top management (name, qualification and

position)

(c) Date of incorporation (include all details in

case of sister organization, if any)

4. Performance of preceding three years with

profit and loss account

(a) Year

(b) Capital

(c) Turnover

(d) Profit/loss

5. Current year performance:

a) List the orders already executed.

b) List the orders in hand, their value and

anticipated date of completion.

51

6. Details of Facilities Available:

(a) Floor space

(b) Key departments

(c) List of machines, equipment etc. available

(d) No. and details of welding sets

(e) No. and details of qualified workers

(f) Man power available

(g) Quality control facilities available

Instruments, Qualified operators Facilities

available from other sources

7. Documentation:

(a) Reference standards specific to tender

enquiry

(b) Plant standards availability with each

departments duly updated

(c) Drawing availability for purchaser’s

retention

(d) Procurement of materials with emphasis on

test certificates for purchaser’s verification

(e) Availability of inward inspection

(f) Availability of process inspection

(g) Availability of final inspection

(Yes / No)

8. Work Experience:

Whether Cranes of similar nature (cell crane) have been manufactured earlier? If yes for whom?

(Yes / No) Details

9. Time Over-Run (TOR) for similar works carried

out in past

52

ANNEXURE-II

Schedule of Deviation

1. Whether vendor fully agrees to comply with the Drawings and Technical Tender

Specifications : YES/ NO

1.1 If yes , put the official seal and signature :

1.2 If not please indicate the deviation clearly point wise and put the official seal and

signature :

53

ANNEXUR- III

Performa for Past Experience of Similar Orders Executed

The following information should be provided in the format given below for each

reference assignment for which your firm, either individually as a corporate entity or

as one of the major companies within an association has been primarily

responsible to render the services.

Description of Job:

Schedule Time

Period: Contract

Value (Rs):

Name of the Client:

Address of the Client:

(with name, telephone & fax no. of

contact person)

Start Date

(Month/Year)

Completion

Date:

(Month/Year)

Narrative description of the Project with the name of activities carried out by your

professional staff under mechanical (machining/fabrication) etc. can be attached.

List of design codes & standards used:

Any other relevant information:

Important Notes:

• Bidders may use separate sheet for more details.

• Two performance certif icates from users/clients for already completed

similar work shall be submitted along with the offer.

54

ANNEXURE-IV

Assets & Liabilities of the Firm

Assets & Liabilities

(In Rs Crores)

2013-2014 2014-2015 2015- 2016

Total Assets

Current Assets

Total Liabilities

Current Liabilities

Profits Before Taxes

Total Annual Turnover

• In case of a consortium, annual of the LEAD PARTNER only will be considered.

Hence bidders shall indicate details of the lead partner only. Bidders shall also

indicate details of the consortium partner separately.

• Please enclose audited balance sheet and profit & loss a/c for last five years

55

ANNEXURE- V

Qualification & Experience of Key Personnel

Sl.

No.

Position & total number

on companies rolls

Experience Qualific

ation

Area of

Expertise/

Experience

1. Team Leaders -Nos.

2. Project Coordinator (S)/

Project Manager-Nos.

3. (a) Design Engineer or

equivalent-Nos.

(b) QA Managers or

equivalent-Nos.

4. Production Engineer or

equivalent-Nos.

5. Planning Engineers/QA

Engineers-Nos.

6. Specialist in Assembly

& Testing-Nos.

7. Support Staff-Nos.

(Draftsman/Supervisors

/Fabrivators/ Welders

etc.)

8. Any other information

56

ANNEXURE- VI

Organization & Structure

Please indicate below or attach the organization chart showing the company structure

including communication & responsibilities, structure of engineering group, production

group, erection group (project group), finance group, QA group, and the positions of

Directors & relevant key personnel (by name, educational qualification & experience),

specially bring out the line of reporting.

ANNEXURE-VII

57

List of Typical Plant & Machinery

A. Machining / Fabrication

Bidder to indicate separate lists of equipment / machinery owned by him and

available to him for this project

B. Erection/ installation

Bidder to indicate separate lists of equipment / machinery owned by him

and available to him for installation of the machine.

C. Quality Control/ Testing

Bidder to indicate separate lists of equipment / machinery owned by him

and available to him for testing of the machine.

Note: Bidder to indicate complete list of equipment for Machining/ Fabrication

/ Erection & Testing required for completing the tendered works.

58

ANNEXURE- VIII

List of Machinists, Qualified Welders & Fabricators

(Employed in service since last three years)

Sl.

No.

Name

Age

Qualification

Experience Nature of

Work

Handled

Previous

Employment

Project

Handled In

Organization

Previous

(1) (2) (3) (4) (5a) (5b) (6) (7) (8)

Tender Technical Specifications for 2 Te In-Cell Crane...

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