SATISH DHAWAN SPACE CENTRE SHAR

SOLID PROPELLANT PLANT

File No: SHAR/SPP/2015002267

TENDER SPECIFICATIONS FOR

175t/25t FLAMEPROOF EOT CRANE
 BID QUALIFICATION CRITERIA FOR SUPPLY OF 175t/25t EOT CRANE
Bidders who are qualifying/meeting following Technical and Financial capabilities are
eligible to participate in the bid for supply of 175t/25t EOT crane. Bidder shall furnish all the
requirements asked in this criteria with documentary proof and submit along with quotation.
Bids of the parties which are not meeting the following criteria will not be considered for
evaluation and will be rejected without seeking any further clarifications.

I. Technical Qualification Requirements:

The bidder should meet the following technical qualifying requirements a nd

shall submit relevant certificates to establish his credentials.

1. The Bidder should be an organization with experience in having executed contracts

for design, engineering, manufacture, supply, erection, testing and commissioning of
Double girder EOT cranes & Hoists Package for last 25 years in India.

2. The firm should have successfully completed Design, Manufacture, Installation, Testing
and Commissioning of at least 5nos. of double girder EOT cranes of capacity 200t and
above and Span equal to 20m and above during last 7 years ending 31.12.2014.
Bidders have to provide relevant certificates from the Owners (end users) along with
the submission of bid for consideration of bid document.

3. The firm should have successfully completed Design, Manufacture, and commissioning
of EOT cranes with VVVF (VFD) drive & control systems at least 10 nos. of cranes
and at least one crane of capacity not less than 150t in last 10 years.

4. The firm should have successfully completed Design, manufacture and establishment of
fail safe mechanisms & controls like Emergency disc brake on rope drum (actuated in
case of failure in power transmission line), wire rope spooling monitoring and
redundant (double) wire rope reeving system at least in 2nos. of EOT cranes in last
10years.

5. The firm should have experience and knowledge in the Design and manufacture of EOT
crane with dual drive hoist (Twin load path). It is preferable to have completed
realization of such cranes.

6. The firm should have successfully completed Design, manufacture, and establishment
of at least 05 nos. of EOT cranes (not less than 100t capacity) with twin motor with
planetary gearbox system for Hoist mechanism for last 10 years.

7. The firm should have successfully completed Design, manufacture, and establishment
of at least 05 nos. of EOT cranes (not less than 100ton capacity) for ladle cranes (hot
metal handling cranes) for reputed steel mills for last 10 years.

8. The firm should have facility to full load test and over load testing of 200t EOT crane
(hoist and cross travel) at their factory.

9. The firm should have successfully completed Design, manufacture and establishment
Page 1 of 3
 of high capacity EOT cranes (100t and above) to the satisfaction of reputed third party
inspection agencies like M/s MECON and M/s M.N.Dastur.

10. Bidder shall furnish the details of their factory like manpower, machinery, quality
system etc., for department to access their capability. Bidder shall submit above
information in the format given in “Questionnaire” attached as Annexure to this BQR.

II. Financial Qualification Requirements:

The bidder should also meet the following financial qualification requirements:
2.1 The Bidder should have annual turn over of not less than a value of Rs. 10 crores
per year last three financial years ending 31-03-2014.
2.2 Firm should have undertaken and successfully completed following value of works
related EOT cranes at least in last 05 (Five) years :
Single work of EOT cranes not less than : Rs.10 Crores.
(or)
Two works of EOT cranes not less than : Rs.5 crores (each)
(or)
Three works of EOT Cranes not less than : Rs.4 crores (each)
2.3 Bidder should possess a current Solvency Certificate from Nationalized Bank for an
amount of not less than 10 crores.
2.4 IT/ TDS certificate shall be submitted with Loss & Profit.
2.5 Bidder shall submit audited statement of financial status for last 03 years.

III. The following documents shall be submitted along with the application for
prequalification of Bid:
1. Firm establishment certificate and nature of work (for Sl no.1).
2. Detail of work of similar type completed during the last seven years ending 31.12.2014
( for Sl. No.2).
3. Satisfactory work Completion certificates from the clients, with the work order copies
(for S.Nos 2 & 3).
4. Performance Report of EOT cranes established (with years of service) from End users,
with addresses and contact person with phone numbers.
5. Documentary evidence (Technical details & drawings) for fulfilling special technical
conditions (Sl. no. 2, 3, 4 & 5).
6. Copy of audited Balance Sheets for last three years.
7. IT / TDS certificates for last three years.
8. Current Solvency Certificate.
9. List EOT crane projects ( for capacity 100t and above / Span 20m and above)
completed for last 10 years with PO copies.

Page 2 of 3
 10. List, value and work order copies of total projects under Execution with Purchaser
name and address.
11. Duly filled “Questionnaire” with signature, name, phone no and company seal.
12. Structure and Organizational Chart
13. List of personnel with qualification & experience in the firm in the areas of design,
production, quality, safety, administration etc.,
14. List of Machinery & Equipments to be used for the work.
15. Any other relevant information which add value to above.

IMPORTANT NOTES :

1. Bidder shall furnish all the above details fully and explicitly.
2. Please note that the “BID” without above mentioned the documents/information in
support of the eligibility criteria will be summarily rejected.
3. No further clarifications will be seeking in this regard.

IV. Bid Selection Procedure and Process of BID Qualification

Step - 1: Short listing based on documents submitted, satisfying the all eligibility criteria
given above by the firm or individual along with their Bid / application. (Non-
submission of any document as given in above list within stipulated time leads to
rejection of Bid)

Step - 2: Subsequently Bidder’s competency, their technical achievements and financial status
will be evaluated suitable for his project. Feedbacks from Bidder`s clients will be
verified.

Step – 3: Visit to sites/EOT Cranes by technical team (ISRO or Third party) where Bidder has
established above mentioned capacity EOT cranes.

Step - 4: If required to visit will be made to their factory/ firm by technical team (ISRO or
third party) for accessing the capability of manufacturer.

Step - 5: Mean while technical Bids will be opened and scrutinized for meeting all technical
specification and supply conditions.

ISRO - SHAR reserves right to verify the information / data furnished by Bidder. If the
same is found as fault or with any deviation the bid will be rejected.

Only those Bidders who are found suitable & meeting all the above qualification
Criteria/requirements will be finally qualify for opening the Price Bids for evaluation.

Page 3 of 3
 Annexure to Bid Qualification

QUESTIONNAIRE FOR DESIGN, MANUFACTURE, TESTING AND ERECTION & COMMISIONING OF

HIGH CAPACITY EOT CRANES
(INFORMATION TO BE PROVIDED BY BIDDERS)

Name & Address of EOT Crane supplier:

Phone : Mobile : Fax :

Email :

Sl.
Items/ Information Specification/ details of items Remarks
No.
Type of Industry (SSU, Medium, Govt, etc.,)
1.
2. Year of Establishment
Annual Turnover (in Rs. lakhs) for last
3.
three years year ending up to 31-03-14
3.1 Turn over – 2013-14
3.2 Turn over – 2012-13
3.3 Turn over – 2011-12
Orders executed during last 03 years,
capacity of EOT Cranes, references are is
to be mentioned. (Separate sheet can
attached for this)
4. a. 2013-14

b. 2012-13

c. 2011-12
Quality Certification of company
5. (ISO, TUV, etc.,)

Page 1 of 6
 Annexure to Bid Qualification

Nos. of EOT Cranes of capacity 200t and

above and Span :20m and above
6.
manufactured during last 10 years ending
31.12.2014
No of EOT Cranes of capacity not less than
100t with SIEMENS VVVF (VFD) drive &
7. control systems produced in last 10 years.

No. of EOT Cranes of capacity not less than

8. 100t supplied with Emergency Rope drum
caliper brake.
No. of EOT cranes produced (not less than
100 ton capacity) with twin motor with
9.
planetary gearbox system for Hoist
mechanism for last 10 years.
No. of steel mill cranes ( not less than 100 ton
10. capacity) produced for molten metal ladle
handling in last 10 years.
11. Shop floor Area Covered

No of Employees (Supplier shall mention

contract personnel separately)
a. Engineers
12. b. Supervisors
c. Technicians
d. Quality control engineers
Administrative staff
Raw Material Sourcing:
a. Steel Plates
b. Rolled sections, Flats
13.
c. Forged Rods, Blanks
d. Round bars (for Axles)
e. Seamless pipes

Page 2 of 6
 Annexure to Bid Qualification

Sources of Bought out components:

a. Electric Motors
b. Brakes Flameproof
14. c. Gearboxes
d. Couplings
e. Limit switches
f. Wire ropes
Details regarding out sourcing, if any, of
15. manufacturing and fabrication works.

Handling facility available:

a. Over head /Gantry crane details
16. (capacity, span, lift).
b. Mobile cranes

Load testing Facility Available:

a. Maximum weight available.
17. b. No. of weights
c. Total test load available.

Welding /Fabrication Workshop (Type/

capacity/ Quantity of machines shall be
provided)
a. MMAW machines
18. b. GMAW machines
c. Gas cutting m/cs
d. Plasma cutting m/cs
e. Welding Fixtures

Fixtures available for Welding of Girders of

19.
span more than 20m.

Page 3 of 6
 Annexure to Bid Qualification

Welding Professionals:
a. No. of welders (MMAW)
Qualification details
Qualified by
b. No. of welders (GMAW)
20.
Qualification details
Qualified by
c. No. of welders (TIG)
Qualification details
Qualified by
Details of Welding Inspection Equipment &
welding inspector available with supplier
21. ( LPT, UT, MPT, X-ray, etc)
Any out sourcing can be mentioned.

Forming Facilities available (with brief

specification of each machine)
a. Shearing Machine
22.
b. Cutting machine
c. Bending machine

Machining Facilities available (with brief

specification of each machine)

a. Turning Lathe (Conventional/CNC)

b. Milling Machine (Conventional/CNC)
c. Gear cutting/ hobbing machines.
23.
d. Gear Grinding machines
e. Drilling Machine (Conventional/CNC)
f. Cylindrical Grinding Machine
(Conventional/CNC)
g. Any other machines

Page 4 of 6
 Annexure to Bid Qualification

Details of Inspection facilities / Instruments

available
24. (Brief description & specifications shall be
provided)

If third party inspection services are taken

for manufacturing of EOT Cranes give
25.
details.

Range of Capacity of EOT Cranes

manufactured, till now (list with brief specs,
26.
& customers shall be provided)

Maximum capacity of EOT Crane

manufactured with dimensions, type,
27. quantity, customer, and purpose of EOT
Crane.

Maximum dimensions of EOT Crane

manufactured with capacity, Span, quantity,
28.
customer, and purpose of EOT Crane.

Special purpose EOT Cranes

manufactured, if any, capacity, dimensions,
29.
and customer

Design facility available:

a. Drafting & Modeling software
packages
30. b. FEM software
c. Other Softwares
d. Design engineers (with qualification
& experience)

Page 5 of 6
 Annexure to Bid Qualification

Painting facility available

a. Sand/ Abrasive blasting facility.
31.
b. Painting equipment
c. Make of paints generally used.
General stock level of Raw
materials/brought out items in the factory:
1. Structural steel plates etc.,
32.
2. Alloy steel round bars
3. Bought out items
4. Paints, etc.,
Any awards or recognitions obtained
33.
through product excellence
Collaborations with other reputed
manufactures and OEMs with product
34.
details and Name of Principal supplier,
country of origin etc.,
Any other relevant information in design,
35.
manufacture and testing of EOT Cranes
List of documents enclosed with this
36.
questionnaire
Any other information like to add (separate
37.
sheet can be attached)

Signature of competent person

Name :
Designation :
Date : Company seal :

Page 6 of 6
 SATISH DHAWAN SPACE CENTRE SHAR
SOLID PROPELLANT PLANT

Ref: SHAR/SPP/2015002267

TENDER SPECIFICATIONS OF 175t/25t EOT CRANE

Facility : Propellant Machining Facility - II

Capacity Crane Duty

Sl. Span Height of Lift Quantity
Type of crane of crane Travel class of
No. (m) (m) ( No)
(ton) (m) crane

Double Girder Class - II

MH – 22.50m
1 Flameproof 175t / 25t 21.0 32.00 of 01
AH – 24.50m
EOT Crane IS 3177

175t/25t EOT crane shall be supplied, transported, erected and

commissioned as per the Technical Specifications, Terms & Conditions given in
following pages of this document.
 Ref : SHAR/SPP/2015002267

CONTENTS OF BOOKLET

Sl. No Contents Page No.

Technical Specifications cum Compliance statement,
1 Terms & conditions of supply including codes 1 to 44
and standards.
Annexure – 1A to 1D :
2 Figures, EOT Crane Clearance diagram, Location of 45 to 48
VVVF room and dimensions.

Annexure – 2 :
3 49
Schematic of Pendant Button operating station
Annexure – 3 :
4 Quality Assurance, Inspection and Testing plan for 50 to 60
EOT Cranes
Annexure – 4 :
5 61
Price format for Spare parts for EOT crane.
 TECHNICAL SPECIFICATIONS OF
175t/25t FLAMEPROOF EOT CRANE

SECTION – I

GENERAL SPECIFICATIONS
SDSC SHAR Page:1 of 41
175t / 25t FLAMEPROOF EOT CRANE
SPP
SPECIFICATIONS CUM COMPLIANCE STATEMENT

Bidder shall completely fill the following format of technical specifications & supply conditions with
mentioning required details. Bidder can add more information and details, if required, by attaching seperate
sheets, by giving point no. of this format. Inadequate /incomplete, ambiguous, or unsustainable information,
A against any of the clauses of the specifications / requirements shall be treated as non-compliance to tender
and quotation will be rejected. Generalized statements like crane shall be manufactured "as per your
specifications" or "as per IS standards" or "as per enclosed specification" is not acceptable and Bidder shall
submit all the specifications by filling in the following FORMAT only, otherwise it is not valid.

Bidder shall submit complete information asked in Qualification Criteria and Questionaire for qualifying for
B bid with all informations, certificates and earlier references of manufacture should be enclosed. The offer
meeting all the requirements & conditions in all respects will only be considered for further processing.

Deviations with respect to specifications given below are not acceptable. However Bidder can submit /
C
suggest improvements, if any, seperately by indicating the clause no. in this specifications.

Contact Person :
NAME & ADDRESS
D
OF THE Bidder : FAX No :
Mobile No : Email :
Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
1 SCOPE OF SUPPLY

Design, detailed engineering, manufacture, inspection, shop testing, supply,

erection, commissioning & performance proving of Heavy duty 175T/25T
1.1
capacity, Flame proof, Top running, double girder EOT Crane as per following
specifications and IS 3177, IS 807 & relevant codes & standards.

Supply & Erection of Bridge gantry rail along with its accessories for bay length
1.2
of around 32.0meter. (Gantry girder is in the scope of Department / Purchaser).

Supply & erection of Drag chain power cable system for EOT crane as per the
1.3
specifications mentioned.
Main Hoist (175t) shall be provided with dual rope reeving system i.e., two
independent wire ropes shall be provided with balanced reeving system, wire
1.4
rope spooling & monitoring as per the specifications mentioned in this
document.

VVVF panels shall be erected in a separate room at ground level and cabling
1.5 must be done to the EOT crane at gantry girder height of 19m as per clerance
diagram enclosed.

The scope of work shall also include procurement of all materials including
importing of components (from other countries) required for completion of the
1.6
work, coordinated planning for manufacture, inspection, painting, load testing at
supplier works.

Packing, marking, loading on Trucks/ Trailers and safe transportation of EOT

1.7
crane & other parts / items / accessories from supplier site to SHAR site .

Erection, testing & commissioning of EOT crane shall be done as per the
1.8 Technical Specifications, conditions given below and also in accordance with
latest editions of IS: 3177, IS: 807 & relevant codes and standards.
SDSC SHAR Page:2 of 41
175t / 25t FLAMEPROOF EOT CRANE
SPP
SPECIFICATIONS CUM COMPLIANCE STATEMENT

Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
Main hoist drive system shall be designed to provide assurance
that a failure of single component of hoist mechanism (Motor, Gearbox,
brake, coupling, wire rope) would not result in loss of load and uncontrolled
movement of the lifted load. This can be accomplished by the application of
dual hoist drive unit described below.

1.9 Dual Hoist Drive with two gearboxes and rope drum (Twin Load path) :
The dual-hoist drive shall have rope drum, two parallel shaft helical gear
trains ( on each side of drum), two drive motors (each gearbox driven by
motors) and at least two holding brakes located on input shaft of geartrain
and realted couplings. This shall ensure two independendant load paths for
main hoist drive and each of two independant load paths shall be capable of
driving & holding the rated load of 175t.
Supplier shall arrange "Third party inspection Agency " for design
verifications, approvals, inspection during manufacture, load teasting,
and certfying the EOT crane as per QAP.

1.10 Arranging the third party inspection is in the scope of supplier for the entire
scope of work as given above and as per QAP enclosed. Bidder shall engage
TPIA - Third Party Inspection Agencies like M/s Mecon,(or) M/s M.N.Dhastur
only. The finalization of third party agency shall be done on mutual agreement
between ISRO and Bidder.
2 Quantity of Crane : 01 No. (One)
3 Usage of EOT crane
This Heavy duty EOT crane is used for handling of
hazardous / dangerous materials like rocket motors,
propellant containers, delicate flight hardware etc., for
positioning and assembly during process operations.
Failure of EOT crane & its components during handling
3.1 Application
may result in loss of life and property. Hence Bidder
shall design, manufacture and erect the crane with
emphasis on quality, reliability and safety and shall
ensure smooth & reliable operation of crane with long
service life.
This heavy duty EOT crane will be put to use for 365
Usage period & Days’ intermittent duty (Class II duty as per IS3177)
3.2
desired life of crane with CT, LT and Hoist movements. EOT Crane shall
be designed for minimum life of 30years.
4 Hazardous area conditions
The EOT crane shall be equipped with flame proof electrical systems suitable
4.1 for operating in hazardous area classified as Zone 1, Gas group IIA / IIB, T4 as
per relevant IS 5572 / IEC standards.

VVVF panels shall be provided in a separate room at the ground level and
4.2 cabling must be done to the EOT crane which is at a height of ~19m. The
VVVF panels shall be suitable for normal atmospheric conditions.

Operating environment is Indoor, near to sea (i.e.,

Operating saline atmosphere), with ambient temperature of 50ºC
Environment of and with relative humidity of 95%. Weather conditions
5
Crane / Weather are tropical. Bidder shall consider above while design
conditions of EOT crane, electricals, painting of crane & related
parts.
SDSC SHAR Page:3 of 41
175t / 25t FLAMEPROOF EOT CRANE
SPP
SPECIFICATIONS CUM COMPLIANCE STATEMENT

Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
6 MAIN PARAMETERS OF EOT CRANE

Double girder, Flameproof, Indoor, Heavey duty EOT

6.1 Type of Crane
Crane

Structures : Class-II duty as per IS 807

Class & duty of EOT
6.2 Mechanisms : Class -II duty as per IS3177
Crane
Main Hoist Gearboxes: Class IV duty of IS:4137-1985

EOT Crane capacity (in 175t (Main Hoist)

6.3
ton) 25t (Auxiliary Hoist)

6.4 Span 21.00 meters

6.5 Lift Height

Above FFL - 17m , Below FFL - 5.50m,

6.5.1 Main Hoist (meters)
Total : 22.50m

Above FFL - 19.00m , Below FFL - 5.50m,

6.5.2 Auxilary Hoist (meters)
Total : 24.50m

6.6 Operation Speeds ( meters/minute)

Main Hoist with dual Main speed : 2.0 m/min & creep speed: 0.2m/min with
6.6.1 load path (four motors all motors running--Main speed :1m/min & creep speed
& two gearboxes) :0.1m/min when half the motors are running.

6.6.2 Auxilary Hoist 2.5 m/min in main speed, 0.25 m/min in creep speed.

6.6.3 Cross travel 6.0 m/min in main speed, 0.6 m/min in creep speed.

6.6.4 Long travel 6.0 m/min in main speed, 0.6 m/min in creep speed.

Side clearance
(Distance from centre
6.7 400mm (minimum) on both sides.
of gantry rail to nearest
obstruction)

Head room available

(Vertical distance from
6.8 top of gantry rail to 6.00 meters (maximum) (Refer clearance diagram).
lowest overhead
obstruction)

Distance from floor to

6.9 ~ 19.00 meters
top of gantry rail

6.10 Bay length in meters ~ 32.00 meters

SDSC SHAR Page:4 of 41
175t / 25t FLAMEPROOF EOT CRANE
SPP
SPECIFICATIONS CUM COMPLIANCE STATEMENT

Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE

DSL side :
6.11 Main Hook : around 2.00m
Aux. Hook : around 3.50m
Hook Approaches
(Refer Clearance
6.12 diagram) (supplier shall Non-DSL Side Main Hook : around 3.20m
optimise these values) Aux. Hook : around 1.70m

CT DSL side : not more than 4 m (LT forward side)

6.13
Non DSL side : not more than 4m (LT reverse side)

6.14 LT wheel base as per IS807 / shall not be less than 1/5th of span.
shall be as minimum as possible for having optimum
LT hook approaches for better utilization of crane &
6.15 Width of Crane building.
Max. Width of crane around 8.00m.
6.16 Main Hoist Drive
Main hoist drive system shall be designed to provide assurance
that a failure of a single component in hoist mechanism would not result
in loss of load and uncontrolled movement of the lifted load. This can be
6.16.1 accomplished by the application of dual hoist drive units. The wire rope
drum, hook, hooknut, and load block structure are exempted from this
requirement. Supplier shall accomplish above failure proof design feature as
described below.
Dual Hoist Drive with two planetary gearboxes, 4 drive motors and rope
drum (Twin drive Load Path) : The dual-hoist drive shall have rope drum,
two parallel shaft helical planetary gear trains (on each side of drum), four
drive motors (each gearbox driven by two motors) and at least two brakes
per motor located on input side of each gearbox and related couplings. This
shall ensure two independendant load paths for main hoist drive and each of
two independant load paths shall be capable of driving & holding the full rated
load. Each gear box train shall be sized for the total full-load drive
torque with appropriate service factor as per IS4137. All motors shall be driven
through two/four VVVF drives with syncronization with proper control &
interlocks. There shall be two independent wire ropes, each shall be capable of
holding the rated load. Refer Schematic arrangement given in Fig .1. Supplier
can suggest & design alternate configuration to meet above safety,
6.16.2 redundancy, and reliable Main Hoist system with optimum hook
approaches.

Motors and gearboxes shall be rated such that each set of motor and Gearbox
will take full rated torque at rated speed i.e., 2m/min

In case of any problem & failure in one load path, easy & safe switch over to
second/redundant load path shall be done smoothly without free fall and heavy
jerks. Proper arrangement shall be made for safe & reliable mechanical
decoupling of defective drive system.

Proper Electrical and drive interlocks shall be provided betwee motors and
brakes such that drive system is safe gaurded without damage, incase of failure
in one load path and to overloading of other load path.
SDSC SHAR Page:5 of 41
175t / 25t FLAMEPROOF EOT CRANE
SPP
SPECIFICATIONS CUM COMPLIANCE STATEMENT

Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
Service brakes shall be located on Input shaft of gearbox. 2nos. of Imported
6.16.3
flameproof brakes per motor shall be provided.

6.17 Auxiliary Hoist Drive ( conventional hoist system)

Single motor with one Horizontal, foot mounted, parallel shaft Helical gearbox
6.17.1
of standard make mentioned in this specification.

Two service brakes (Imported, flameproof brakes ) must be provided on either

6.17.2
side of input shaft of gearbox.

6.18 LT Drive
LT drive shall be provided with twin drive system at two corners of crane.
Horizontal foot mounted helical gearboxes, motors and thruster brakes shall be
6.18.1 used.
Drive size shall be selected such that Crane can be moved by two motors
drives with one VFD.
Each corner drive components shall be easily accessible and shall be designed
6.18.2
with inter changeable components.
Wherever applicable the driving pinions shall not interfere with the removal of
6.18.3
wheels.
Number of wheels for 8Nos or 16Nos. & Drive wheels : 50% of total wheels
6.18.4
LT drive based on design.

Diameter of wheels for

6.18.5 Not less than 710 mm.
LT drive

6.19 CT Drive
CT drive shall be provided with sufficient no. of drive systems / central drive.
6.19.1 Helical parallel shaft gearbox, motor and imported thruster brakes shall be
used.
All the drive components shall be easily accessible and shall be designed with
6.19.2
interchangeable systems. (If twin drive is selected for CT)

Wherever applicable the driving pinions shall not interfere with the removal of
6.19.3
wheels.
Number of wheels for 4Nos or 8nos.,and Drive wheels : 50% or 25% of total
6.19.4
CT drive wheels based on design
Diameter of wheels for
6.19.5 Not less than 630 mm.
CT drive

Maintenance of CT Maintenance platform shall be provided for CT drives

6.19.6
drives covered with chequered plate.

Type of bearings for Anti-friction, Heavy duty Double row Spherical Roller
6.20
LT/CT wheels Bearings

Type of mounting of
6.21 "L" type brackets with fit bolts and locknuts.
LT/CT wheels
SDSC SHAR Page:6 of 41
175t / 25t FLAMEPROOF EOT CRANE
SPP
SPECIFICATIONS CUM COMPLIANCE STATEMENT

Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
Total Weight of EOT
6.22 Crane (tons) Bidder to Specify

6.23 Weight of trolley (tons) Bidder to Specify

Weight of each Bridge

6.24 Girder (tons) Bidder to Specify
Weight of each End
6.25 Carriage (tons) Bidder to Specify

Weight of Electricals
on top of crane Bidder to Specify
6.26
Weight of electrical
Panels in room (tons) Bidder to Specify

6.27 LT wheel load (tons) Bidder to specify

6.28 CT wheel load (tons) Bidder to specify

Size of Cross Travel

6.29 Crane rails not less than CR-100 as per IS 3443
Bridge Girder Rail

Size of Crane gantry

6.30 rails (for Long Travel) - Crane rails not less than CR-100 as per IS 3443
Scope of Crane Bidder
 TECHNICAL SPECIFICATIONS OF
175t/25t FLAMEPROOF EOT CRANE

SECTION – II

MECHANICAL DESIGN AND DETAILS

SDSC SHAR Page:7 of 41
175t / 25t FLAMEPROOF EOT CRANE
SPP
SPECIFICATIONS CUM COMPLIANCE STATEMENT

Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
7 MECHANICAL DESIGN AND ELEMENTS' DETAILS

The design of components shall be done on the basis

of ultimate tensile strength, the value of stress factor
used shall be the product of the basic stress factor and
the duty factor for the appropriate mechanism class as
mentioned in IS:3177.
7.1 Factor of Safety

The design of all mechanical components shall be done

as per IS:3177 & as per this technical specifications
and also on the basis of minimum ultimate tensile
strength with factor of safety of not less than 5.

The stresses in all components of hoist mechanism and gearboxes should not
7.1.1 exceed 66% of yield point (proof stress) of the material for the component
under break down conditions of motor i.e. pull out torque of motor.

All mechanical components in Hoist (vertical load path), shall be designed for
7.1.2 infinite fatigue life. Fatigue analysis shall be based on the crane maximum rated
load.
Materials with less than 15% elongation shall not be used for any of
7.1.3 mechanical load bearing component except for electrical motors, panels and
hydraulic components.

Stress Concentration factors shall be considered in mechanical design for

7.1.4 calculating working stresses and also combination of stress concentration
factors shall be considered at required conditions.

No cast iron part should be used as load bearing member on the crane except
7.1.5 for electrical equipment. Similarly wood or combustible material and Bush
bearing should not be used in any part of the crane.

Main Hoist : Ramshorn type hook with swiveling anti-

friction thrust bearing and safety latch as per IS:5749.
7.2 Hoist hook type
Aux. Hoist : Single Point hook with swiveling anti-
friction thrust bearing and safety latch as per IS 3815
& relevant standards.

The hooks shall be free to swivel on antifriction roller thrust bearing of

7.2.1 adequate capacity and so constructed as to exclude dirt and also shall
be provided with a means for lubrication.

Number of falls for Main Hoist : ~ 16 (8 + 8).

7.3
Hoist Aux. Hoist : ~ 8

7.4 ROPE DRUM

Rope Drum shall be of welded / fabricated type of IS:2062 steel with duly stress
7.4.1 relieved. Rope drum shall be designed as specified in IS:3177 in general.
Allowable stress in drum shall not be more than 1/5th of UTS.

7.4.2 Rope drum diameter shall be minimum 40 times the diameter of wire rope.
SDSC SHAR Page:8 of 41
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Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
Fleet angle of wire rope from drum to sheave shall not be more than 2.5 deg
7.4.3
and drawings & calculations shall be provided in this regard.
Drum grooves shall be helical and machined with smooth surface finish. Drum
7.4.4
grooves shall be dimensioned as per IS3177.
Length of the drum shall be sufficient to accommodate the rope in one layer of
the rope requisite for the specified lift and in addition rope drum shall be
provided with not fewer than three dead turns at each anchored end and at
7.4.5
least one spare groove at the other end when hook is at full height of lift
condition. Grooves shall be finished smooth and shall be rounded at edges &
corners.

Rope dead ends shall be clamped with minimum three clamping wedges with
7.4.6 two numbers of bolts on each clamp. The bolts shall be at the centre of
clamp and shall be wire locked.

7.5 MAIN HOIST WIRE ROPE - Double rope reeving system

The design of the rope reeving system shall be such that a single rope
7.5.1 failure will not result in the loss of the lifted load. A load balance
sytem shall be provided on each rope system.

Reeving system shall be divided into two separate load paths so that either
7.5.2 path will support the rated load and maintain vertical alignment in the event of
rope breakage or failure in one rope system.
Upper block assembly and lower load block assembly shall be designed
7.5.3 such that the sheaves will be contained & maintain vertical balance of load
in the event of failure of single wire rope.
Dual rope reeving system shall be designed such that the bottom load block &
7.5.4 hook shall follow a true vertical path ( true vertical lift) during hoisting and during
with No load & Full load conditions.
During hoisting & lowering hook block shall not oscillate/ rotate without load or
7.5.5
with load.
i). Sensing and automatic signaling of excessive rope load/displacement to
either side shall be provided.
ii). Provision, tooling and procedure shall be provided for adjustment of
7.5.6
wireropes to take equal load.
iii). The vertical displacement of the load, following a rope failure, shall be
minimized.
In the event of a hook over travel, where the lower block contacts the
7.5.7
crane trolley structure, the ropes shall not be cut or crushed.

The wireropes shall be of M/s USHA MARTIN make, Non-rotating type,

7.5.8 Galvanized, Powerform, 35x7 construction, core : IWRC, RH, Regular lay,
preformed, Minimum tensile strength / Grade : 1960MPa.

Minimum factor of safety of 10 shall be provided for wire rope of Main Hoist on
7.5.9 Minimum Breaking Strength (MBS) of rope with two ropes combined together.
With single rope the factor of safety shall be 5 on the MBS of main hoist rope.

7.5.10 No joints shall be used for wire ropes under this specification.
SDSC SHAR Page:9 of 41
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Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
Auxillary hoist wire rope shall be single path & conventional reeving system
with true vertical lift as per IS3177. Wire rope shall have factor of safety of 6
on Minimum Breaking Strength (MBS). The make wirerope shall be of M/s
7.5.11
USHA MARTIN only. Wire rope shall be Non-rotating type, Hotdip Galvanized,
35x7 construction, Core : IWRC, RH, Regular lay, preformed, Minimum tensile
strength/Grade : 1960MPa.

7.6 ROPE SHEAVES

7.6.1 Design of sheaves in general shall be as per IS:3177.

7.6.2 All sheaves shall be of forged steel only.

All sheaves shall be mounted on special roller type sheave bearings.Grease

7.6.3 lubricated sheave bearings should be provided with individual grease
lubrication fittings and shall be easily accessible for maintenance.

Sheave diameters (at the bottom of groove) shall be minimum 29 times rope
7.6.4
diameter. Sheave fleet angle shall not be more than 2.5 degrees.
Equalizer sheave diameter (at the bottom of groove) shall be minimum 18 to
7.6.5
20 times the diameter of wirerope for Aux Hoist.

The equalizer sheave /Equalizer Bar shall be mounted above the trolley floor
and shall be easily accessible for maintenance from the floor of the trolley.
7.6.6
Equalizer Bar / sheave shall be made in such a manner that it can
turn or swivel to align itself with the pull of the ropes.

Equalizer sheave /Bar shall be arranged such that reeving equalization

shall not be restricted under normal operating conditions. Adequate free
7.6.7
movement to compensate for operational block swing and/or normal rope
stretch shall be provided.
Sheave grooves shall be machined smooth and support wire rope uniformly at
7.6.8
least 136° angle of contact over its circumference.

All Sheaves shall have guards, which fit closed to the flange having a clearance
7.6.9 not more than 1/3rd rope diameter between sheave and inside of guard, to
prevent the wire rope from leaving the sheave grooves.

All the upper block sheaves shall be mounted above the trolley platform for
7.6.10
ease of maintenance and inspection.

7.7 GEARBOXES

Hoist drive shall be provided with two parallel shaft

helical planetary gearboxes each driven by two
A) Main Hoist (Twin
motors. Standard make, Crane duty, Horizontal foot
drive & Dual load path)
mounted, Parallel shaft, Helical Gearboxes shall be
7.7.1 used.

Standard make, crane duty, parallel shaft, Helical,

B) Aux. Hoist horizontal foot mounted gearboxes shall be used for
Aux. hoist motion.
SDSC SHAR Page:10 of 41
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Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
Helical parallel shaft, Crane duty, gearboxes, shall be
used for CT & LT drives. LT drive shall be of
Gear Boxes for CT & horizontal foot mounted gearboxes.
7.7.2
LT drives Travel drive gearbox ratings for bending strength and
pitting resistance shall be based on 2 times rating of
AC motor.

Heavy duty, and crane duty gearboxes of Elecon /

Shanti/ GREAVES (Premium transmission) /
Flender/ DB-Radicon / Sumitomo / Renold only.
7.7.3 Make of Gearboxes Other make & Own make gearboxes are not
acceptable. Bidder shall confirm the acceptance.
Tender will be rejected for not meeting this
requirement.

1) Gearboxes selection shall consider starting torque

of motor (i.e., 2 times the Full load torque) of selected
motors.
2) The gearing shall be designed for strength,
durability, and momentary high overloads which
includes the loads imposed during starting,
braking and failure of components.

Torque & Power rating 3) Due consideration shall be given for braking torque
7.7.4 of Gearboxes / Pinions on input shaft of Gearboxes.
/ Gears / Shafts
4) The stresses in all components of hoisting
machinery and gearboxes should not exceed 66% of
yield point of the material for the component under
break down conditions ( Pull Out Torque) of motor.

5) In design of gearboxes, due consideration shall be

given to creep speed and also ramping down of rated
speed (rpm) to zero speed through VVVF drives.

Drawings and dimensional details of gear boxes, selection criteria, power rating
& torque rating calculations, bearing details, data sheets from gearbox
7.7.5
manufacturer shall be submitted for TPIA / Purchaser (SDSC SHAR) approvals
during design engineering phase.
Main hoist gearboxes shall be designed & manufactured as per class '4' duty
7.7.6
of IS:4137.

7.7.7 Gearboxes with parallel shaft helical gearing shall be used for all motions.

7.7.8 All pinions shall be integral with shafts.

7.7.9 All gear teeth shall be helical and with helix angle not less than 15°.

7.7.10 All gears shall be of forged alloy steel preferably case hardeneing steels.

Gear teeth shall be cut in metric module system. All gear teeth shall be profile
7.7.11
ground to smooth with less error & for low noise while running.
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Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
All gear boxes shall be totally enclosed and splash or forced lubrication system
shall be provided. Gearboxes shall have sufficient heat radiation area to
7.7.12
maintain lubricant at temperatures below maximum operating
temperature
Vertical Gearboxes shall have an oil pump lubrication system when
vertical gearing exceeds of two reductions. Tubing/ Piping for gearbox
7.7.13 lubrication shall be provided with SS316/SS304 and must be properly clamped.
No hoses shall be used. Visual indicator for oil flow shall be provided in line.

Gearboxes shall have fill and drain connections, BREATHERS, lubricant

7.7.14 level indicator, and shall have good accessesibility for checking, maintenance
and oil filling.
For all gearboxes lubrication shall be esured even at creep speed of motor and
7.7.15
from the intial start of motion (i.e. main or creep).
The casings of gearboxes shall be made from structural steel (IS:2062) or cast
7.7.16
steel.
Fabricated gearbox housings shall be made of minimum 10 mm thick steel
7.7.17
plate. All fabricated gearboxes shall be duly stress relieved.

Gearbox cover shall be split horizontally at each shaft centre line and fastened
7.7.18 and arranged so that the top half can be removed for inspection and repair
without disturbing the bottom half.

Radial clearance between the gear box inner surface and the outside diameter
7.7.19 of the gears shall be at least 1 ¼ times the depth of the largest gear tooth
inside gear box or 20 mm whichever is higher.

No oil leakage is allowed from gearboxes. Oil drip pans shall be provided
7.7.20
around the gearbox.

Sufficient clearance need to be maintained between gear of one stage to pinion

7.7.21
of next stage of non meshing sets to avoid interference.

The noise level at gear box must not be more than 75-80 dBA measured at a
7.7.22 distance of 1m from the direct vicinity of the gear box. This is very important for
all the gearboxes, and any gearbox making more noise is liable to be rejected.

Realiable oil seal arrangement i.e., preferabley double stage oil sealing
7.7.23
arrangment shall be provided for shafts of gearboxes.

7.7.24 Open gears should not be used in any drive / motion.

7.8 Drive Shafts (LT & CT)

7.81 Shafts shall be of 45C8 forged steel or alloy steel.

Torsional deflection of the shafts at torque corresponding to 1.33 motor rated

7.8.2
torque during acceleration shall not exceed 0.10deg./meter of shaft length.

7.8.3 Shaft supports on plummer blocks of SKF / FAG / TIMKEN make only.
SDSC SHAR Page:12 of 41
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Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
7.9 Brakes

Imported Flameproof thruster drum brakes shall be used for all drives / motions
in EOT crane. Make of brakes shall be M/s Pincsh Bubenzer-Germany, M/s
SIBRE-Germany, M/s Galvi-Italy, M/s Wittonkramer-UK , M/s SIME-GKN
Stromag-France. Thrusters for all brakes shall be Explosion proof (Ex d),
ATEX/ PTB Certified, Make of thrusters : EMG, Germany or Brook crompton,
UK. ATEX/ PTB/ Exproof Certificates for brakes & thrusters shall be submitted
7.9.1 for Approvals.

Brakes shall be mounted on the input pinion shaft of the gear boxes.

Brake performance certificate, test certificate, and Exproof (ATEX) Certificate

shall be provided from original manufacturer of brakes.

Two nos. of imported electro hydraulic flameproof

MAIN HOIST BRAKES
thruster drum brakes per motor with Manual release
2 brakes per motor.
and antiwear compenstor shall be provided (the second
7.9.2
brake is for redundancy). Minimum time lag shall be
Aux. Hoist : 1 motor
provided between two brakes of main hoist and Aux.
and 2 brakes.
Hoist as per standard.

Torque rating of each thruster brake shall be minimum

2 times motor full load torque. Torque adjusting
7.9.3 Brake Rating Hoist. provision shall be available in the Brakes. Selected
Brake shall have sufficient margin with maximum
catalogue torque rating.

Hoist components and brake shall be selected such

that the braking distance for lowering motion shall be
Braking distance/brake
7.9.4 as IS3177 with one brake at full rated speed.
path for hoist
Necessary calculations shall be submitted in this regard
during design phase.

Imported, flameproof Electro hydraulic thruster drum

7.9.5 Brakes for CT & LT brakes of above make, as per clause no 7.9.1, shall be
provided.

Brake drum size and thermal rating shall be selected such that with the duty
7.9.6 cycle mentioned, the surface temperature shall not exceed "T4" classification
of hazardous area.

Braking torque shall be checked so that it is capable of

Brake rating for CT arresting the motion within a distance in meters equal
7.9.7
and LT motions to 10% of speed when travelling with rated load at
rated speed, provided there is no skidding.

Brake manual release mechanisms shall be

provided to permit drive movement during
Manual release for
7.9.8 power stoppage. Manual release shall be of self-
Brakes
reset type and operative only when held manually in
the release position.

No oil leakage is allowed from thruster brakes. Oil drip pans shall be provided
7.9.9
under thrusters.
SDSC SHAR Page:13 of 41
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Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
shall be made from forged / cast steel / SG iron.

Drums shall be completely machined to smooth surface

and Statically & dynamically balanced.
7.10 Brake drums
Hardness of surface of finished drum shall be 38-43
Rc.

Width of the brake drum shall be 10mm more than the

width of the brake shoes.

All the gearboxes, motors, brakes, bearing pedestals,

7.11 Mounting of equipment etc. shall be mounted on machined and levelled
surfaces.

7.12 Couplings

Couplings between Flexible Full / half geared couplings. Make of

7.12.1
motors and gearbox Couplings shall be of FENNER/ELECON/ Shanthi

Flexible Couplings
Drum/ Barrel couplings of M/s Malmedie, Germany
between gearbox and
shall be used for Main hoist . Selection criteria, service
rope drum for main
factor (as per ISO-M8 class), Torque rating, drawing
hoist ( For dual load
shall be submitted for approval.
7.12.2 path/ twin drive)

Flexible Couplings Drum/ Barrel couplings of M/s Malmedie, Germany

between gearbox and shall be used for Aux hoist . Selection criteria, service
rope drum for Aux. factor (as per ISO-M8 class), Torque rating, drawing
hoists shall be submitted for approval.

All Couplings selection shall be based on the manufacturer's rating and

applicable service factors for heavy duty cranes compared to the applied
7.12.3
torque on the coupling and as per IS3177. Consideration shall be given to
motor starting torque, gear ratio, dynamic effects, brake torque etc.,

Motor shafts shall be connected to gear extension shafts through flexible /

shock absorbing couplings. Geared couplings shall be used between gearbox
output shaft and intermediate shaft or end shaft and also for connecting
7.12.4 intermediate lengths of long travel and cross travel shafts. Between
intermediate shaft and end shaft and between end shaft and wheel axle, any
other special coupling which can give better and more reliable service may be
used after obtaining specific approval of the Purchaser (SDSC SHAR).

7.13 Track Wheels

All crane wheels shall be of double flanged with straight tread, with 12° taper
7.13.1 flanges, and accurately machined. Drive wheels shall be precision machined
and matched in pairs with minimum deviation.
All crane wheels shall be made from forged steel C55Mn75 and minimum
7.13.2 surface hardness shall be 350 BHN for a case depth of 10mm. The wheels
shall be capable of taking up misalignments in span as specified.
SDSC SHAR Page:14 of 41
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Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
General design & sizing of wheels shall be as per IS:3177.Crane wheels of
minimum 630mm dia for cross travel and minimum 710mm for long travel shall
7.13.3
be used. Necessary sizing & contact stress calculations as per IS:3177 shall
be submitted.

Galvanized, high tensile fasteners of tensile quality not

less than 8.8 shall be used in crane parts, except for Fit
bolts of Girder. Make of all fasters shall be of M/s TVS
/ M/s UNBRAKO
7.14 Fasteners
Maximum combined stresses induced in the fasteners
by normal operating loads (but not including
pretensioning loads) shall not exceed 20% of the
ultimate strength of the fasteners.

7.15 Lubrication of Crane

Semi centralized lubrication system shall be provided for all mechanixms in

7.15.1 EOT crane with easy approach for all pedastal bearings, couplings, wheel
bearings, gearboxes etc.,

Wheel bearings shall be provided with suitable gearing points on both the sides
7.15.2
of wheel and shall be made approachable.

Trunion of wheel bogies shall be provided with suitable greasing points for both
7.15.3
the sides of the pins.

Suitable provision shall be provided for lubrication of hook and sheave

7.15.4
bearings.

7.15.5 Hoisting ropes shall be lubricated with lubricant approved by rope manufacturer.

Adequate provisions/arrangements shall be made to prevent lubricants

7.15.6
falling from the crane.

All keys where ever used should be of parallel keys as

per IS:2048 (Couplings / gear boxes / motor shafts)

7.16 Keys & Keyways Material of keys shall be 45C8 or alloy steel.

Proper fits and tolerances shall be used between key

and key ways, such that key should not get loosened in
service life. Key end arrestors shall be provided.

Ball and roller antifriction bearings of approved make

SKF/ TIMKEN/ FAG/ INA only shall be used throughout
the drives except where specified otherwise.
7.17 Bearings
Rated life of ball and roller bearings shall be not less
than total life (B10 or L10) in working hours not less
than 20,000 hrs .
SDSC SHAR Page:15 of 41
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Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE

Main hoist gearbox's bearings shall be selected based

on rated life given in class 4 duty of IS 4137.

Special consideration shall be given to bearings

which operate at low speeds. Certified
confirmation of the bearing's capacity at low
Bearings speeds must be obtained from the
(Continued from manufacturer during design phase.
previous page)
All bearings shall be provided with proper
lubrication or means of lubrication. Mounting fits,
tolerances and clearances shall be as recommended
by the bearing manufacturer.

Life of bearing shall be calculated in accordance with

bearing manufacturer’s recommendations.

All bearings housings shall be of STANDARD MAKE

(SKF/FAG/TIMKEN) and made of cast steel or wrought
steel or fabricated steel bolted to a rigid portion of
crane structure by at least 4 bolts. Housings shall be
7.17.1 Bearing Housings
split on the shaft centre line to permit removal of the
shafts. The underside of the base of each bearing
pedestal shall be machined and shall bear upon a
machined surface. Standard make Bearing housings.

Hoist Drum Wire Rope mis-spooling monitoring in Main Hoist Motion of

7.18
EOT crane :

In Mian hoist motion of EOT Crane, wire rope spooling monitoring shall be
provided. The wire rope spooling monitor is an electro-mechanical assembly
that senses improper or mis spooling of wirerope from drum grooves. Improper
spooling is sensed prior to wire rope damage. Since, wire rope damage and
loss of the load can result, if improper wire rope spooling is detected, the wire
rope spooling monitor actuates the Failure Detection System (i.e., limit switches
) and stops main hoisting motion.
 TECHNICAL SPECIFICATIONS OF
175t/25t FLAMEPROOF EOT CRANE

SECTION – III

STRUCTURAL DESIGN AND DETAILS

SDSC SHAR Page:16 of 41
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Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE

8.0 STRUCTURAL DETAILS OF EOT CRANE

The crane should be rigid, robust and of sturdy

Design of structural construction. The design of all structures shall be Class
8.1
work of Crane II as per IS:807 and as per this technical
specifications.
For welded construction such as that of bridge girders and carriages, trolley
8.2 frames, rope drums, gearboxes etec., all steel plates shall confirm to IS:2062 or
its equivalent.

8.3 Unless otherwise specified, only bolted or welded joints shall be used.

8.4 Black bolts shall not be used in the main structures of the crane.

All the bolts, nuts, washers etc., shall be heavy duty galvanized and shall be
8.5
protected against corrosive environment.

All the structural plates used in fabrication of Girders,

8.6 Material of structurals Trolleys and End carriages, machine bases shall be of
minimum 10 mm thick of IS 2062 Gr. B.

Covering chequered Trolley and platforms shall be covered with Chequered

8.6.1
plates plates of minimum of 6mm thick.

Shall be of double Girder Box Type construction having

Maximum rigidity.

For box plate girders in addition to the required full-

length diaphragms, short diaphragms shall be inserted
where required to transmit the trolley wheel load to the
8.7 Girders
web plates and to limit the maximum stress in the
trolley rail within safe permissible stress.

Girders shall be cambered and amount equal to the

deflection caused by the dead load plus one half of the
live load and the trolley.

Deflection shall not be more than 1/1000 of span in

8.8 Deflection of Girders mm with safe working load, with trolley stationed at mid
span and excluding deflection due to dead load.

No splice joint is permitted. Girder is to be of single

8.9 Girder Joints piece only. Number of weldable butt joints along the
total length of the girder should not exceed two.

For Box Girders Span to Depth ratio shall not exceed

Ratio of span to depth
8.10 18. Other ratios for construction of girder shall be
of Girder
maintained accordingly as per standard.

Local buckling of top flange and compression members

Local Buckling of top
8.11 shall be considered and necessary calculations shall be
flange
submitted for approval.
SDSC SHAR Page:17 of 41
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Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
End carriage shall be fabricated as solid box section
8.12 End Carriages made from rolled steel plates IS:2062, except for
essential openings which shall be reinforced.

End ties for cranes with more than four bridge wheels shall be of
8.12.1
rigid type. End ties shall be constructed of box sections in structural steel.

Equalizer bridge trucks shall be incorporated into the end carriage

design to promote equal sharing of bridge wheel loads, and equalizer
8.12.2
pins shall be provided between the equalizer trucks and equalizer beam
and/or the rigid bridge frame structure.
End ties shall be designed to resist the loads due to crane
8.12.3
movement and the load combinations as per IS807 & IS3177.

A rail sweep shall be provided in front of

8.12.4 Rail Sweeps. each outside wheel. The rail sweep shall
project below the top of the bridge runway
rail.
A rigid frame analysis shall be used to determine the proportions of the
8.13
loads resisted by the end ties and by the girders.

End ties shall be designed to accommodate up to 6mm difference in

8.14 elevation of the bridge rail between any wheels or pair of wheels without
exceeding allowable stresses.

8.15 Details of Bogie joint of End carriages shall be provided along with quotation.

Lubrication of Bogie joint pins shall be from a centralized or semicentralized

8.16
lubrication points.
Fit Bolts ( as per IS:3640) with property class 5.6 and
Structural bolted
reamed holes shall be used for all structural joints
8.17 Joints/ Girder to End
between girder & end carriages, wheel L - bracket &
carriages
end carriages etc.,
8.18 Trolley

The trolley frame shall be built up of rolled sections and plates to form a rigid &
8.18.1 robust structure and shall be arranged to afford maximum accessibility to
mechanical and electrical parts placed on it.

The trolley frame shall be of rigid construction such that lifted loads do not
8.18.2
cause deflections that impair the proper operation of machinery.

No parts shall be mounted under the trolley except for the gravity limit switch
8.18.3 weight. Top pulley block and all other pulleys, equalizer bars, fitments shall be
mounted on the top of trolley platform only.
Trolley shall be designed such that at the highest position of hook there shall be
8.18.4 a clear distance of 700 mm between the lowest point of trolley obstruction and
the highest point of bottom block.

Safe access for maintenance and removal of all mechanical and electrical parts
8.19
must be ensured without any additional scaffolding.
SDSC SHAR Page:18 of 41
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Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE

All parts requiring replacement or inspection or lubrication shall be easily

8.20
accessible without the need for dismantling of other equipments or structures.

All electrical cables on trolley shall be so laid that they are not liable to be
8.21
damaged and can be easily inspected and maintained.

Full length chequered platform of width 750mm shall be

provided for both bridge girders in order to access for
LT drive and CT cable track for maintenance and with
hand rails of height 1000mm. The platforms shall be
jointed to Girders with fasteners.
8.22 Platforms
Additional maintenance accesss platforms on four
inside corners of the girder shall be provided between
inside faces of girder for repair & maintenance inner LT
wheel bearings & mountings of End carriage. These
platforms must not hinder with the CT hook
approaches.

Hand rails along girder Handrails of 1000mm height shall be provided along
8.22.1
platform the length of the girder near to platform.

Hand rails for around Handrails of 1000mm height shall be provided on all
8.22.2
trolley the four sides of the trolley.

Maintenance of CT Maintenance platform shall be provided for CT drives

8.23
drives and shall be covered with chequered plate.

Chequered plate of 6mm shall be used all over trolley

Top chequered plate of except for openings required for the ropes for bottom
8.24
trolley block etc., to pass. All the mechanical and electrical
equipment shall be placed above trolley top only .

Full length wearing plate of minimim 10mm should be

8.25 CT rail wear plate
provided under the trolley rails.

All bridge and trolley rails required to transmit

8.25.1 Rails vertical down and horizontal loads due to
operation, and shall conform to the IS3443.

CT Rails shall be made continuous by welding standard

lengths. Welding shall be done as per standard
8.26 CT rail welding
procedure approved by Third Party Inspection Agency
and Purchaser.

CT & LT Crane rails shall be clamped to the girders

with double bolt clamping plates. The rail clamps shall
8.27 CT & LT rail clamping
be spaced not more than 450mm apart. Rail clamps
shall be of Make : M/s GANTREX only.
SDSC SHAR Page:19 of 41
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Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
CT & LT Rails shall be prevented from creeping in the
Rail stoppers /Wheel
8.28 longitudinal direction by welded rail stops and Wheel
ramps
ramps.
Suitable jacking pads should be provided on end
8.29 Jacking pads carriages and trolley for jacking up the crane & trolley
for changing track wheels & bearings .
Safety pads shall be provided under the end carriages
and crab to prevent the crane/ trolley from falling more
8.30 Safety Pads
than 25mm in the event of breakage of a track
wheel/axle or bogie pin.

8.31 End Buffers

8.31.1 Spring buffers are to be provided on four ends of the bridge and trolley.

Buffers shall be rigidly bolted in place preferably along the Centre line of crane
8.31.2
rail or trolley rail as the case may be, such that the bolts are not in direct shear.

Buffers shall be designed to absorb the kinetic energy released at 50% of the
8.32 full load rated travelling speed, the average rate of deceleration not exceeding
5.0 m/s² at 50% of the rated travelling speed.

Metric Component All components including fasteners should be in metric

8.33
Systems system only

Bolts in rotating parts shall be locked with spring

8.34 Locking of All fasteners washers & lock nuts. All couplings & brake drums shall
be provided with "Fit" type bolts.

NDT of Butt joints of All butt joints shall be 100% radiographed or Ultrosonic
8.35
girders tested for both compression and tension joints.

Toe gaurds shall be provided for all openings, on trolley

8.36 Toe gaurds and on bridge platforms with minimum height of
100mm.

Parts of steel frames carrying machinery should be

Mounting of machinery
provided with doubling plates (including stiffners) of
8.37 on machined bases on
adequate thickness welded and machined to true
trolley / LT
surface.

Welded snugs shall be fitted against against the feet of all pedestals,
8.38 gearboxes, brakes etc., except motors. Motors shall be provided with alignment
screws for side alignment.

8.39 Ladders

Approach ladder shall be of staircase type. Ladders shall be provided from

8.39.1
catwalk to end carriage and to LT platforms in all four corners.
SDSC SHAR Page:20 of 41
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Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
Approach ladders to be provided for reaching the trolley at two locations along
8.39.2
the span of the girder.

Guards: All the moving parts couplings, shaft should

be duly covered with guards as per safety norm. Proper
Protection Gaurds for guard / cover / tray to prevent falling of bolts from
8.40
rotating equipment coupling etc should also be provided, wherever
required. The covers shall be strong enough to take
person weight ~ 100 kg.

Fasteners for pedestal blocks, motors, gear boxes etc., shall be easily
8.41 removable from the top of platform. Studs or body bound bolts shall not be used
as fasteners for mechanical items except for fixing covers.
 TECHNICAL SPECIFICATIONS OF
175t/25t FLAMEPROOF EOT CRANE

SECTION – IV

ELECTRICAL DESIGN & DETAILS

SDSC SHAR Page:21 of 41
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Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
9.0 ELECTRICAL DESIGN AND DETAILS

All Electrical equipments shall be supplied for tropical

and humid climate (Temperature of 50°C & RH not
less than 95%) . De-rating of drive motors, power
cables etc., shall be done for ambient temperature of
50°C.
Electrical equipment
environment Flame proof electrical fittings and controls shall be
9.1 selected, assembled and tested as per relevant Indian/
IEC standards like IS:5571, IS:2148, and IS:5780.
However for control circuit, intrinsic safe modules of
make : M/s. P&F shall be used.

The Electrical equipment shall conform to IS3177 and also to the latest Indian
electricity rules and regulations as regards safety requirements, earthing and
other essential provisions specified therein.

The power available at 415 Volts, 3phase, 4 wire, 50

Hz near by the Crane panel. The power and control
equipment selected shall be suitable for operation on ±
9.2 Power supply condition 10% variation in the voltage and ± 3% variation in
supply frequency. Power source available to tap for
protective panel (where main power source is located
approximately 50m distance).

Power Supply for

9.3 3 phase, 415 V, 50 Hz / A.C + 10%
motors

1 phase, 110 Volts AC, only for switchgears inside the

9.4 Control voltage
panel
For Push buttons,
9.5 Indication lamps, limit 24V, Intrinsic Safe Package Supply, Make : M/s P&F
switches in the field
(top of the crane) and
Under slung HPMV 4nos of 400watts, well glass flame proof lights shall be
9.6
lights. provided.

All cables for LT and CT are to be routed through IGUS

9.7 DSL for LT & CT
chain (plastic) with guided cable tray only.

Panels: (Non FLP), Make: M/s Rittal only. (Located in separate room at ground
9.8
level, suitable air conditioned units shall be part of the VFD panel).

9.8.1 Individual panels (nos.) to be provided as follows:

9.8.2 Protective panel – 1 No. (One)

9.8.3 Main Hoist panel - 2 or 4 Nos. (as per design).

9.8.4 Aux hoist panel – 1 No. (One)

SDSC SHAR Page:22 of 41
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Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE

9.8.5 CT panel - 1 No. (One)

9.8.6 LT Panel - 2 Nos. (One)

9.8.7 Individual isolating switch (with SDF) to be provided for each panel.

9.8.8 Individual Power Contactors are to be provided for each motion for controlling.

9.8.9 Panel lighting shall be provided and it shall be CFL or LED lamps only.

All the Panels shall be provided with space heaters to avoid moisture
9.8.10
condensation.

Rubber mats of 2mx1m shall be provided before the all panels such that
9.8.11
persons stand on rubber mats during maintenance.

The bottom most row of equipment mounted inside the panel excepting terminal
9.8.12 strip shall be at least 350mm above the panel bottom cover to facilitate
inspection and repairs.

A minimum clearance of 250mm shall be provided between the terminal strip

9.8.13
and the panel bottom cover to facilitate cabling.

Power terminal blocks shall be separated from each by means of replaceable

9.9
insulated spacers.

All the power terminals are to be selected for connecting the ring type lugs (in
9.9.1
both panel and FLP junction boxes)

All the power terminals and live parts are to be covered with proper terminal
9.9.2
covers.

9.9.3 Group terminal markers to be used for the clear identification.

All the power and control terminals are to be provided with suitable terminal
9.9.4
numbers.
Mounting of panels Panels are to be mounted on the floor with required
9.10
and resistance boxes anchored Bolts and nuts.

9.11 Switchgears Make: SIEMENS only

AC4 Duty

9.12 Contactors The contactors shall be able to withstand their rated

current for one second without welding / fusing of the
contacts

Manually operable
TPNSFU with Semi
9.13
conductor fuses
To be provided for all panels except protective panel.
SDSC SHAR Page:23 of 41
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Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
Hoist, Aux hoist, CT and LT power supply to VVVF
drives to be routed through Semi conductor fast acting
9.14 Fuses
Fuses of adequate rating only. Semi conductor fuses
shall have a indicator for fusing.

Make: M/s Siemens

Qty: as per design 6 Nos. (shall be wired for individual
panel)
9.15 SMPS Input voltage – 110V / 230 V AC

Output voltage – 24 V DC

Current rating – as per the circuit load

9.16 Terminal blocks and labels

9.16.1 Terminal blocks shall be of 750 Volts grade of the stud type and shrouded.

9.16.2 Insulating barriers shall be provided between adjacent terminals.

Provisions shall be made for label inscriptions for the easy identification of
9.16.3
terminal blocks.

Labels shall be of acrylic sheet with white engraving on black background /

9.16.4
computerized labels.

ON/OFF/TRIP inscriptions shall be clearly marked over the individual panel with
9.16.5 clear marking of direction of the operation of handle apart from the standard
marking provided by the switchgear manufacturer.

Enamel Danger plates / stickers of size and descriptions as recommended in

the relevant IS, shall be provided on the Panel inscribed in Hindi and English
9.16.6
languages. The same is to be indicated in panel G.A dwgs after PO and before
proceeding for fabrication.

To be provided for the motor which is not powered viz.

9.17
VVVF drive. (ie., all thruster brakes).
Motor protection circuit
breaker (MPCB) MPCB to be selected with 2 nos. of NO and NC points
9.17a as auxiliary contacts and preferably one no. of alarmn
contact.

Safety in arrangements

Minimum clerance to be maintained as follows (IS 60947-1)

between phases - 25 mm
9.18
between phases and neutral - 25 mm

between phase and earth - 25 mm

between neutral and earth - 19 mm

SDSC SHAR Page:24 of 41
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SPP
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Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
All the live parts to be covered properly in order to avoid possibility of in advent
touching.

9.18 All the joints / tapping points of the terminal blocks / terminals shall be suitably
cont. shrouded to prevent accidental contact.

All the switchgear and termincal blocks to be covered with suitable electrical
protective cover.

VVVF Drives

The power/current rating of VVVF drive shall be one step higher than the
selected rating of motor.

Main Hoist – as per design 2 or 4 nos.( Capacity of drive shall be suitable to

motor kW selected)
9.19
Aux Hoist – 1 No.

LT – 2 Nos.

CT – 1 No. Depending on drive motors.

Drive shall be supplied with 20 % additional DI / DOs for future usage.

VVVF Drives shall have PROFINET Communication facility.

Make of VVVF drives : M/s. SIEMENS only.

9.20 For Hoist motions, Control shall sense sufficient motor torque (or current)
before releasing holding brakes (i.e., torque proving).

The Control circuit shall be so designed as to ensure that brakes for all motions
are applied near about zero speed of rotation.
Suitable input and output chokes are to be provided for
controlling the harmonics from VVVF drive to source for
all VVVF drives.
Input and output THD should not exceed 5 % and individual Harmonics
9.21
chokes should not exceed 3 %.
It needs to be demonstrated at site during erection and
commissioning.

Both control and lighting transformers can be located

outside the panel with suitable enclosure for ventilation.
9.21a Transformer
Transformer terminals are to be covered with hylum
sheet or acrylic sheet to prevent from inadvertant /
accidental contact.

9.22 DBU Suitable size and rating of DBU for all the above drives.
SDSC SHAR Page:25 of 41
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Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
Dynamic braking resistors of suitable capacity/rating
shall be provided to all VVVF drives. For Hoist motions
DBRs shall be sized for a minimum of 150% of
motor full load torque and it shall not be less than the
torque limit setting of the VFD in the hoisting
direction.

Dynamic braking Necessary forced cooling needs to be planned.

9.23
resistors Controlling of the cooling fans needs to be linked with
control supply ON.
The DBR panels shall be designed such that during
maintenance activities the entire door has to be dis-
asssembled for enabling the better access to the
components inside the panel.
Each motion shall have its individual panel.
Each side of the LT platform 2 Nos. of 1 phase, 230
Volts AC FLP switch cum socket with plug top and 1
No. on the Crab.
9.24 Power Sockets outlets
2 Nos. of 230 V AC power sockets with ON / OFF
switch shall be provided inside for the all the panels
except protective panel.
Separate control is required for the following:
Under Slung Lights (In pendent)
9.25 Isolating Switches Socket outlets on the Crane platforms (In protective
panel)
Control circuits (In pendent)

Training shall be offered for our engineers by M/s

Training on Siemens Siemens about operation, maintenance and trouble
9.25.1
Drives shooting of VVVF drives during commissioning of
Crane.
9.26 MOTORS

Crane duty Motors suitable for Inverter Operations shall be as per IS3177.

Flameproof (Zone 1, Gas group IIA/IIB, T4).

Squirrel cage induction motors kW rating as per IS3177

Temperature classification - T4.

Class of insulation - Class F

For accepting the input from VVVF drives, 60% CDF, min of with 300 starts per
hours, IP55, and Pull out torque of not less than 2.75 times of nominal value
and specifically designed for crane duty application .

All the motors shall be housed with inbuilt thermistor and it is to be linked with
VVVF drive for necessary protection like switch OFF the motor in case of
increase in surface temperature more than T4 classification of hazardous area.
SDSC SHAR Page:26 of 41
175t / 25t FLAMEPROOF EOT CRANE
SPP
SPECIFICATIONS CUM COMPLIANCE STATEMENT

Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
The Motors shall have preferably ZZ type bearings.
No of motors required
Main Hoist Motion - 4 Nos. (as per design, required power/torque capacity )

Aux Hoist Motor -1 No.

Long travel - 4 Nos. (as per design)
Cross travel - 1 or 2 Nos. (as per design)
The Motors shall have both side extended shaft
In cases where sufficient clearance is not possible in front of terminal box for
facilitating maintenance / cable connections, terminal box shall be provided on
the top of the stator frame.
Hoist and Aux hoist motors shall be 8 pole with ~750
rpm speed.
9.27 Speed rating of Motors
Long Travel and cross travel motors shall be 8 poles
with ~ 750 rpm.

Bidder shall provide following details of motors like:

No. of motors

Power of motor

Frame size
Details to be provided
related to motor make
9.28
selection and
calculations duty : Crane Inverter duty,

no. of starts/hr (300 starts/hr)

CDF : 60%
No. of poles :8

amb.temp : not less than 50 deg C

Current drawn by Maximum Current drawn by all motors with full load
9.29
motors should not exceed 80% of the full load rated current.

Torque Rating of Motor full load torque rating shall be min. 120% of
9.30
motors calculated rating on full load.

Imported Electro Hydraulic flame proof Thruster Drum

Brakes for

Main Hoist motion - 2nos. Per motor

Aux. Hoist Motor - 2 nos.

9.31 Brakes
CT Motors - each one no. per motor.
LT motors - each one no. per motor.

Rating, duration and frequency of operation shall be

mentioned in quotation.
SDSC SHAR Page:27 of 41
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Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
Main Hoist motors - one no. per motor

Aux Hoist Motor -1 No.

Shall have FLP / Intrinsic safe hollow shaft

incremental encoder for better dynamic performance.
The same to be used to achieve vector control mode of
9.32 Encoders for motors operation.

All Encoders shall be of Flameproof / Intrinsic safe in

nature.

Encoders' signal shall be of intrisic safe only. Screened

cable as per manufacturer recommendations shall be
used for all encoders.

9.33 Pendant Push button station

Floor operated pendant (Push Button Station) shall be provided with 3-way
Selector Switch for selecting the hoist motors.

PBS shall be provided with push buttons for controlling crane motions:

Main Hoist motion UP / DOWN - Main speed & Creep speed

Aux. Hoist motion UP / DOWN - Main speed & Creep speed

Cross Travel motion Right / Left - Main speed & Creep speed (with 5Hz)

Long Travel motion Fwd / Rev - Main speed & Creep speed

Pendent Shall be provided with Key way switch Lockable at OFF (for Control
ON command),

Emergency OFF (Lockable) ( One more emergency OFF shall be planned in

Bridge platform).

Crane ON indication Lamp – Powered through Intrinsic Safe circuit.

PBS shall also provide with 2-way Switch for Under Bridge Lights.

At least 30 % Spare Core shall be provided in PBS.

All push buttons at Push button station are to be powered through Intrinsic safe
module only apart from other control elements like limit switch, over speed
switch, etc..,

Number and arrangment of push buttons and indication lamps in Pendant

shall be as per the Annexure - 2A

Selector switches shall be of semi flush mounted type.

9.34 Selector switches
Only the front plate and operating handle projecting.
SDSC SHAR Page:28 of 41
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SPP
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Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
Interlocking is to be carried out for selection of
command for all the motions.

Pendent level: Hard wired interlocks are to be

provided at push button station. For example when
Main Hoist UP motion push button is pressed Hoist
Creep / Hoist Down (Main and Creep) motions should
not be activated even if pressed and Vice versa.

9.35 Interlocks
Auxiliary contactor level: Hard wired interlocks are to
be provided such that when Aux.contactor operates
with respect to the motion selected, remaining Aux.
contactors with respect to other Aux. hoist motions
should not be operated.

In the VVVF Drive: It is to be programmed such a way

only one motion has to be selected for operation at a
time in the VVVF drive.

1. Selection of Hoist motor / each load path.

2. Rotary limit switches i.e hoist and lower, Gravity limit

switch
Main Hoist VVVF drive 3. Wire rope mis-spool limit operation
ON command is to be
9.36
interlocked with the 4. Auxilary Hoist operation
following.
6. Thruster Brakes' MPCB condition.

7. Provision shall be made for two extra interlocks for

future usage.

1. Rotary limit switches i.e. Aux hoist and lower

operation limit.

2. Gravity limit switch

Auxiliary Hoist VVVF
drive ON command is
9.37 3. Main Hoist operation
to be interlocked with
the following.
4. Thruster Brakes' MPCB condition.

5. Provision shall be made for two extra interlocks for

future usage.

1. Right and Left limit switches for respective motion

of the drive.
Cross Travel VVVF
drive ON command is 2. Brakes' MPCB condition.
9.38
to be interlocked with
the following. 3. Provision shall be made for two extra interlocks for
future usage.
SDSC SHAR Page:29 of 41
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SPP
SPECIFICATIONS CUM COMPLIANCE STATEMENT

Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE

1. Forward / Reverse limit switches for respective

Long Travel VVVF motion of the drive
drive ON command is
9.39
to be interlocked with 2. Brakes' MPCB condition.
the following.
3. Provision shall be made for two extra interlocks for
future usage.
Indication lamps shall be provided for all 3 phases for
the protective panel.

Control ON / OFF (based on the pendent push button

control) indication lamps shall be provided on the
protective panel.
Indicating lamps shall be of Cluster LED type only,
provided with translucent lamp covers.
9.40 (a) Indication lamps
Lamps and lenses shall be easily replaceable from the
front.

Cluster LED module shall be suitable for direct

operation on 230 V, 50 Hz AC in general except the
indication lamps planned in push button station.

Indication lamps in push button station to be powered

viz. Intrinsic safe relays only.
All wiring for power, control, lighting etc., (which is not
running in the IGUS cable drag chain) shall be carried
out with 1.1.K.V grade XLPE Armored copper
conductor cables.
All wiring for power, control, lighting etc., (which is
running in the IGUS cable drag chain) shall be carried
out with 1.1.K.V grade flexible copper conductor
cables.
Minimum size 4 mm sq. in power circuit and 2.5 mm sq
in control circuit.

All wiring to be done neatly through perforated trays

Power and Control from the protective panel / VVVF panel to the top
9.41
Cables junction boxes fixed in suitable places.

Wiring shall be neatly bunched, adequately supported

and properly routed to allow easy access and
maintenance.
Wires shall be identified by numbered ferrules at each
end.
The ferrules shall be of the ring type and of non-
deteriorating material.

Cable tags to be provided for cable connections as per

circuit diagram.
SDSC SHAR Page:30 of 41
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Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
The crane rails, structures, motor/brake frames, metal
enclosures of all electrical equipment, conduit and trays
shall be effectively grounded with double earthing and
shall be connected to building earth through gantry
9.42 Earthing
rails. The laying of Earth strip from Gantry rail to Earth
pit ( which is around 10meter away from the crane
bay) outside the building is in the scope of EOT
Crane's supplier.

Labels of permanent nature to be specified.

Identification of Circuit
9.43
& Cables All power and control cables, etc are to be tagged at
both the ends.

FLP junctions Boxes are to be planned for inter facing

the connections between field connections and panel
connections. Sufficient space to must be available for
the maintenance.
9.44 Junction Boxes (FLP) The probable locations of the JBs are
Crane LT Girder
Crane Platform
Crane Trolley / crab

Rotary Limit Switch – 1 No. To be linked with the hoist

Limit Switches for Main motors and linked to the control circuit according to the
9.45 operational requirement) (For hoist and lower limit).
Hoist

Gravity Limit Switch – 1 No.

Limit Switches for Aux Rotary Limit Switch – 1 No. (For hoist and lower limit)
9.46
Hoist
Gravity Limit Switch – 1 No.
Limit Switches for CT
9.47 Lever type - 2 Nos. for CT & 2 Nos. for LT
& LT
 SECTION – V

OTHER SPECIFICATIONS AND TERMS &

CONDITIONS OF SUPPLY OF
175t/25t FLAMEPROOF EOT CRANE
SDSC SHAR Page:31 of 41
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SPP
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Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE

PAINTING OF CRANE : Total painting thickness, DFT, shall be 200

10
microns. (DFT shall be measured at the time of final inspection)

The entire surface of fabricated materials, girders,

frames, platforms, trolley, end carriage, wheels etc.,
10.1 Surface Cleaning are to be sand / grit / abrasive blasted to white metal
finish (SA 2½ quality) and cleaned properly off rust,
grease & dirt.

Painting with Epoxy Two coat of epoxy primer (Apcodur CP 680 of M/s
10.2 Primer (Total thickness Asian Paints or equivalent) shall be applied to a Dry
of 80 microns) Film Thickness (DFT) of 80 microns.

Two coats of epoxy paint of Golden Yellow color

(Apcodur CF 693 of M/s Asian Paints or equivalent)
Painting Epoxy Paint shall be applied to a Dry Film Thickness (DFT) of 80
10.3 (Total thickness of 120 micron and 40 micron for first and second coats with
microns) proper drying in between coats. Final touching shall
be done after erection & commissioning at site.
Painting quality shall ensure austhetic looking of crane.

Not less than 200 microns. This will be tested during

Total paint thickness
10.4 stage inpsections and final inspection at supplier
including primer
works.

In addition if any intermediate cleaning required between successive coats of

10.5 paint are to be carried out as per the recommendation of paint manufacturers
and as per the instruction of the Purchaser (SDSC SHAR).

Interior of all gear box housings shall be sand blasted and painted with two
10.6
coats of oil resisting durable paint.

INFORMATION/DOCUMENTS TO BE SUBMITTED ALONG WITH

11 QUOTATION (offer will be rejected unless these information / documents
are submitted)

Bid Qualification Record (BQR) with duly funnished information, as given

11.1
"Appendix" along with this Specifications

Questionnarie, attached with BQR, duly filled by Vendor given along with the
11.2
"Appendix" of this specifications.
Technical Specifications with Point-wise Specifications to all points as given in
this "Specification cum Compliance Statement" (given in this FORMAT).
11.3
Deviations, if any shall be mentioned clearly in a separate sheet. (See. II in
page 1).

GA drawing showing full details of crane, with dimensions, span, height of lift,
end clearances, head room, overhead clearance, hook approach limits,
11.4
weights, wheel loads, major components and general arrangement of main
Hoist Drive etc..

11.5 The bidder shall quote separately for erection and commissioning of Crane.
SDSC SHAR Page:32 of 41
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Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
DESIGN APPROVALS:

DRAWINGS /DOCUMENTS (EACH 3 COPIES) TO BE SUBMITTED AFTER

12 PLACEMENT OF ORDER FOR APPROVALS.

[ Note : It is the responsibility of the supplier to get the drawings /

documents approved from Third Party Inspection Agency (TPIA) ]

Bidder shall submit following list of Three sets (03 sets) of drawings/
calculations / documents (in 03 -three sets) for approval before manufacture of
12.1 crane within 4 weeks after placement of purchase order. (12.5 to 12.40).
Note: It is the responsibility of the supplier to get the drawings/ documents
approved from TPIA/ Purchaser (SDSC SHAR).

At the same time, Supplier shall be responsible for proper submisssion of

12.2 following drawings & calculations along with technical specifications to Third
party Inspection Agency (TPIA) and obtain design Approvals from them.

If the drawings and other particulars are returned by the Purchaser (SDSC
SHAR), because they are incomplete or faulty, the Bidder shall make the
necessary correction / modifications and resubmit the drawings and
12.3
calculations within a reasonable time, but in any case, should not exceed two
weeks from the date of receipt of purchaser’s / third party inspection agency's
comments.
Design of load bearing structures shall be as per IS 807 and drive mechanisms
12.4 as per IS 3177 and Main Hoist Gearboxes as per IS4137 and also as per
technical specifications in to consideration.

General Arrangement (GA) drawing of crane to scale with dimensions, Bill of

12.5
materails, Boughtout items, makes, weight breakups and wheel loads.

12.6 GA Assembly Drawing of Trolley with all components.

GA Drawing of individual drive mechanisms for Main Hoist, Aux. Hoist, CT and
12.7
LT. G.A drawing of Main Hoist drive shall be submitted.

General Arrangement drawing of Dual wire rope reeving with dimensions and
12.8
rope equlizer assembly.

Design & Constructional Drawings of Girder, end carriage, and trolley their
12.9
connections with bill of materials.

Sub-assembly drawings for rope drum assembly, wheel assemblies, hook

12.10
blocks etc.,

GA drawings, details and selection criteria, design calculations for gear boxes
12.11
with manufaturer's data sheets as per this specifications and conditions.

LT rail arrangement (on Gantry Girders) drawing to scale with Bill of Materials
12.12
(BOM).

12.13 Bridge Girder CT rail arrangement drawing to scale with BOM.

SDSC SHAR Page:33 of 41
175t / 25t FLAMEPROOF EOT CRANE
SPP
SPECIFICATIONS CUM COMPLIANCE STATEMENT

Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE
Sizing calculations for selection of Machine elements like wire rope, hook
12.14 blocks, cross head, sheave pins, rope drum, couplings, wire rope pulleys,
shafts, bearings etc.,

Calculation for bridge girder with deflection & camber, trolley frame, end
12.15
carriage, with weight breakup.

12.16 Calculations for selection of wheels & wheel bearings.

12.17 Calculations for selection of CT & LT rails.

12.18 Calculations for drive shafts and plummer block bearings.

Quality Assurance Plan for total crane manufacture, erection & testing as given
12.19
in Annexure - 3.
Delivery schedule of EOT crane in the form of Bar chart indicating different
12.20
stages.

12.21 Selection of keys, key ways & couplings

12.22 Selection of bearings for EOT Crane.

12.23 Selection of sheaves & sheave pin with calculations.

12.24 Calculations for selection of wheel bogie connecting pins.

All the componets of crane which are lifted for erection shall be design
12.25 checked for erection / lifting loads and necessary Calculations shall be
submitted.

Calculation for selection of motors, brakes, drives, cables and switch gear with
12.26 manufacturer datasheets & Exproof certificates. All Motors' torque and speed
curves shall be submitted for approval.

Electrical circuit diagrams of EOT crane with individual drive circuits, control
12.27
circuit, and with interlocks' circuits.

GA drawings of Protective Panel and other panel and inside components

12.28
arrangements

12.29 Wire rope spooling monitoring G.A drawing and electrical circuit.

12.30 Lubrication arrangement of EOT crane with points indicated in drawing.

Bidder shall give the break-up weights of crane as mentioned below

12.31
during final design :

Weight of each bridge girder as assembled and ready for erection, with and
12.32
without mechanical and electrical components.

12.33 Weight of each end carriage as assembled and ready for erection.

12.34 Weight and name of individual heaviest mechanical components.

12.35 Total weight of structural, mechanical and electrical components separately

SDSC SHAR Page:34 of 41
175t / 25t FLAMEPROOF EOT CRANE
SPP
SPECIFICATIONS CUM COMPLIANCE STATEMENT

Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE

12.36 Total weight of crane including electrical equipment.

12.37 Weight of trolley structure ready for erection shall be provided.

12.38 Total weight of trolley including electrical equipment.

List of Manuals / drawings/ documents/ certificates to be submitted at the

13 time of inspection of crane at supplier's works and also at the time of
commissioning at ISRO, SHAR

QAP/shop Inspection report document showing Third party design approvals,

manufacturer test certificates., all stage & final inspection reports, load test
13.1
reports as per QAP and TPIA report on final inspection at works & TPIA
clearance report.

Test certificates of all items like raw materials, hooks, wire ropes, motors etc
13.2 and for all crane parts certified by "Competent person of third party agency"
as per QAP & standards.

13.3 4 sets of Crane operation & maintenance manuals

13.4 2 sets of spare parts manuals

13.5 2 sets of Gearbox spare parts and service manuals shall be provided.

4 sets of all as built Drawings of all systems of crane as mentioned above

13.6 aprroval drawings that have been finally approved by TPIA / Purchaser (SDSC
SHAR).

Manufacturer installation & maintenance manuals, test certificates and

13.7
Warranty / Guarantee Cards for all Bought-Out-Items.

13.8 Trouble Shooting Chart for Main and all Sub-Systems.

13.9 Lubrication schedule, diagram with details of lubrications.

13.10 Final test certificate of EOT crane from TPIA with inspection report

Final as built drawings of crane and machinery, Maintenance & spare part
13.11 Manuals, test certificates shall be supplied in soft form in the forms of DVDs
and Memory stick in the latest software format.

14 Tolerances on Crane dimensions and manufacturing :

Bidder shall ensure that the crane shall be manufactured as per the
tolerances specified below. Final inpection reports shall be submitted in
drawing format.

14.1 Span over LT wheels + 4mm maximum

14.2 Diagonal on wheels ± 5mm maximum

< 1/1000 of wheel gauge (measured at every 1m

14.3 Parallelism of Girders
interval)
SDSC SHAR Page:35 of 41
175t / 25t FLAMEPROOF EOT CRANE
SPP
SPECIFICATIONS CUM COMPLIANCE STATEMENT

Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE

14.4 Verticality of Girders < 2mm (measured at every 1m interval)

Verticality of End
14.5 < 1mm (measured at every 1m interval)
Carriages

14.6 Trolley wheel gauge ± 2mm (measured at every 1m interval)

14.7 LT wheel alignment ± 1mm (maximum)

Difference in height
14.8 <1/1000 of wheel gauge maximum at 1m interval
between trolley rails

CT Rail alignment w.r.t

14.9 ±1 mm (measured at every 1m interval)
Girder centre

Tilt of wheels ( both

14.10 < D/ 1000mm where D = diameter Of wheels
horizontal & vertical)

CT/LT wheel
14.11 <2mm (measured at all wheels) Wheel alignment
displacement

CT / LT wheel
14.12 less than 0.1 mm in diameter of wheel
diameter variation

Squareness of Girders
14.13 within 1.60mm ( for wheel base of ~4000mm)
to End carriages

14.14 Hoisting speed +10% -5% of specified speed.

14.15 Lowering speed +20% -5% of specified speed

14.16 Travelling speed +10% -5% of specified speed.

INSPECTION & TESTING DURING MANUFACTURE & SHOP TESTING OF

15
CRANE

Supplier shall obtain all design/ drawings approvals

DESIGN / DRAWINGS
from third party inspector (TPIA) before starting
APPROVALS &
crane's production. Crane & components shall be
15.1 CERTIFICATE from
manufactured & inspected as per the approved
TPIA before crane
drawings only. All inspection/test repots shall be made
manufacture.
with respect to approved drawing with ref. no.
SDSC SHAR Page:36 of 41
175t / 25t FLAMEPROOF EOT CRANE
SPP
SPECIFICATIONS CUM COMPLIANCE STATEMENT

Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE

INSPECTION and testing shall be carried out as per

QAP enclosed here with in Annexure-3. Supplier shall
hold the manufacturing at specified "HOLD" places and
QAP & Third party call for inspection. The Schedule of Inspections shall
15.2
agency be strictly adhered to and shall be witnessed by THRID
PARTY and/or ISRO. All the critical inspections and
load testing shall be done in the presence of Third
Party and /or ISRO.

Raw material identification for structures, wheels, hoist

mechanisms, Gears, load pins etc., shall be done by
Raw materials
Third party inspectorate and/or department. Raw
15.3 identification &
material test certificates, traceability of materials with
stamping
identification marks shall be made available during
identification.

All Butt Welded Joints (both compression & tension

flanges / web joints) shall be subjected to 100% X-Ray
Welding inspection &
15.4 Testing and X-Ray Films to be produced for TPIA
Testing
and/or ISRO/SHAR for evaluation and shall form part of
the quality (QA) documentation submitted to purchaser.

Inspection of Bridges, End Carriages, trolley, rails

Inspection major parts gauge, Wheels and Measurement of Camber,
15.5
and records mechanical assemblies checking as per QAP. Reports
shall be made in drawing format.

Inspection of Span & Diagonal Dimensions (Minimum

~10Kg pull should be applied while checking),
Dimensional inspection
Checking bridge & end carriages' squareness,
15.6 & alignment checking
Checking of Wheel Alignments, Mechanical drive
& records
Assemblies alignment and Pulley blocks alignment.
Reports shall be made in drawing format.

The crane hook should be tested and certified by the dock labor board / govt.
15.7
Approved test house for twice its SWL and test certificate should be provided.

No load test, Full load tests and Deflection

15.8 Load tests
measurement as per as per QAP and as per IS: 3177.

Test at OVER-LOAD (125% SWL) capability Check

15.9 Load tests and Permanent Set Measurement as per QAP and as
per IS 3177.

The equipment shall be despatched only after

satisfactory performance testing/ inspection at
15.10 Clearance for despatch
supplier's works and on written clearance from ISRO &
TPIA.

Testing the extra safety features in EOT crane i.e. performance & interlock
15.11
checking of twin hoist system.
SDSC SHAR Page:37 of 41
175t / 25t FLAMEPROOF EOT CRANE
SPP
SPECIFICATIONS CUM COMPLIANCE STATEMENT

Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE

16 ERECTION & COMMISSIONING OF EOT CRANE

Fully in the supplier's scope. Inspection and testing

16.1 At ISRO- SHAR works
during/after erection shall be as per QAP.

Before erection, supplier shall submit detailed erection

Erection Plan & plan and procedure along with erection loads on
16.2
Procedure building & also on parts being lifted shall be submitted
for approval.
Supplier shall depute adequate qualified personnel i.e.,
Two Engineers/supervisor/ foreman, (one for
16.3 Erection Supervision mechanical and one for electrical), fitters, riggers, and
electricians and helpers for carrying out quality
erection work at our site within schedule.
Initial unloading of EOT crane parts shall be done by supplier. Equipment
16.4 support ( with available equipments if any) will be spared for unloading like
Mobile crane / Forklift / Pick & carry mobile crane (Hydra).

Material (lifting
Fully in the supplier's scope. All lifting machines /
equipment, lifting
16.5 tackles used shall be tested & certified as per
tackles, etc) required
standards before their usage for lifting crane.
during erection.

Department shall provide suitable hooks on the roof in the facility for lifting of
crane components. Supplier can use these hooks for lifting of crane
components during erection of Crane. The capacity & location of erection
16.6 hooks shall be given by manufacture during detail engineering. However the
lifting machinery ( power winch, pulley blocks, wire ropes, lifting gear, etc.,) and
accessories are in the scope of supplier. All lifting machines/tackles' Test
certificates shall be furnished.
Initial filling of lubricants and spare parts required for commissioning at site
16.7
shall be provided by the supplier.
No Load test, Full load test and overload test (for
125%SWL) shall be done as per QAP and as per
Performance Proving &
IS3177. Proving out for the Crane’s Capacity and
16.8 Smooth running of
Smooth Functioning of the Crane at Full load (SWL)
EOT crane
and Over load (125%SWL) shall be the responsibility of
the supplier.

To be inspected and certified by "Competent Person of

Third party Inspection Agency " as per Industrial Laws
Test/Clearance
16.9 and shall provide Certification from Third Party
certificates for crane
Inspection Agency for final clearance & regular usage
of EOT crane .

17 MAKE OF THE BOUGHT-OUT ITEMS

GEAR BOXES and Elecon /Shanti /GREAVES(Premium transmission) /DB-

17.1
Geared Motors Radicon/ Renold/ Sumitomo/ Flender.
SDSC SHAR Page:38 of 41
175t / 25t FLAMEPROOF EOT CRANE
SPP
SPECIFICATIONS CUM COMPLIANCE STATEMENT

Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE

Structural Steel All the structural raw materials (plates, angles, beams)
17.2 Materials Plates, rolled shall be NEW and of reputed make of M/s SAIL / M/s
sections JINDAL/ M/s ESSAR/ M/s TATA STEEL / VIZAG-RINL

Forged steel materials SAIL / JINDAL / TATA STEEL / ESSAR / VIZAG-RINL

17.3 wheels, shafts, keys, / SUNFLAG STEEL / TIMKEN / Mahindra Ugine Steel
gears (MUSCO) / BHARTH FORGE

17.4 Wire Ropes M/s. Usha Martin only.

17.5 Bearings SKF / FAG / TIMKEN / INA

Imported flameproof Pintsch BUBENZER / SIBRE / WITTON KRAMER /

17.6
Thruster Brakes GALVI/ Sime GKN Stromag

17.7 Hooks EEK / Hercules/IRZAR/ Shilpa Udyog

FENNER / Elecon / Shanti / Renold

17.8 Couplings
Drum/Barrel coupling - Malmedie, Germany

SAIL / IISCO / JINDAL / ACCELOR / TATA STEEL /

17.9 Rails
ESSAR
17.10 Paints Asian Paints / Berger
All Electrical Switch
17.11 M/s Siemens
gear

17.12 Flame Proof Motors M/s. Siemens / Bharat Bijilee / Crompton Greaves

17.13 VVVF Drives M/s. Siemens only.

17.14 Pushbutton switches M/s Siemens

17.15 Limit switches M/s. Sterling controls / Speed-O-Control / Electromag.

LT power & control

17.16 M/s. Lapp / Universal / Nicco / Finolex / RPG / Uniflex.
cables

17.17 Panels M/s. Rittal

17.18 Terminal Blocks M/s. Elmex / M/s. Connectwell

M/s. Hubner / P&F (Flame Proof / Intrinsic safe)

17.19 Encoders
Hollow shaft type Encoder can be planned.

17.20 Junction Boxes (FLP) M/s. FCEG / BALIGA

Junction Boxes (Non-

17.21 M/s. Rittal
FLP)

17.22 Intrinsic Safe realys M/s P&F only

17.23 UB lights M/s Baliga

SDSC SHAR Page:39 of 41
175t / 25t FLAMEPROOF EOT CRANE
SPP
SPECIFICATIONS CUM COMPLIANCE STATEMENT

Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE

Other reputed and reliable makes of bought out items will be conisdered during
17.24 detail engineering with submission of technical details, references and
credentials. However about other makes final decision is of SDSC SHAR.

18 General TERMS & CONDITIONS during Supply and Installation :

In the design of Crane, all Indian standards, all safety regulations as applicable
under provision of factory Act, Indian Electricity rules etc. as prevailing in the
18.1
country / State of Andhra Pradesh (site of installation) shall be taken into
consideration.
Arrangements shall be made by the supplier for the inspection and testing of
the crane during different stages of its manufacture starting form the raw
18.2 materials till the completion of the crane by the SDSC,SHAR and/or Third Party
Agency at the suppliers site as per the QAP schedule.

18.3 Dimensions of all parts used on crane shall conform to metric standards.

No cast iron part should be used on the crane except for electrical equipment.

18.4 Similarly wood or combustible material and Bush bearing should not be used in

any part of the crane. Open gears should not be used in any drive / motion.
Assembly at site is to be kept as minimum as possible to enable early
18.5 commissioning of the crane. Welding of crane at site is to be avoided as far as
possible.
The supplier should satisfy himself about the site condition beforehand to avoid
18.6
any difficulty during erection and commissioning of the crane
Supplier shall submit complete erection plan with details of erection loads &
18.7 pattern of wheel loads that will act on building civil structure, erection
procedure, material handling procedure etc.
During the erection, testing and commissioning of the crane at site in
Sriharikota, the supplier has to make his own arrangements for boarding,
18.8 lodging, transportation of his men and materials. However, hostel
accommodation may be provided by the purchaser (SDSC SHAR) on
chargeable basis, if available.
Free electricity and water will be provided by the purchaser for the erection,
testing and commissioning of the crane at the site.
18.9
Supplier shall make his own arrangements for welding and gas-cutting works if
any, that are required for erection and commissioning of Cranes.

For unloading the crane parts at site (in respective building) material handling
18.10 support like Forklifts (~12 ton cap.) and mobile crane (~20 ton/50ton cap.) will
be provided by department at free of cost.

A toolbox containing all necessary tools as given in Page no. 40 required for the
18.11
maintenance of the crane should be from part of supply along with the Crane.
SDSC SHAR Page:40 of 41
175t / 25t FLAMEPROOF EOT CRANE
SPP
SPECIFICATIONS CUM COMPLIANCE STATEMENT

Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE

SDSC, SHAR / Third Party Inspection Agency (TPIA) shall have the right of
inspection and supervision of the manufacturing process adopted by the
supplier for the manufacture of equipment at various stages through their
authorized representatives. In case the manufacturing process adopted is not
18.12
found suitable and commensurate with the desired quality of the equipment, the
Supplier will be advised to adopt the correct manufacturing process which will
be binding on the supplier. SDSC, SHAR’s decision regarding the quality of
work and its acceptability shall be final and binding on the Supplier.

Bidder should quote separately for spares as considered necessary

for two years of normal operation of crane as given in Annexure-4. Bidder
18.13 can suggest any extra spare parts with cost in this regard. However, purchaser
may use his discretion in selecting/removal of spares at the stage of
ordering.

19 COMMERCIAL TERMS & CONDITIONS :

Delivery Schedule : 12 months for total work. The crane shall supply the
19.1 crane within 10 months from date of Order and shall be erected &
commissioned with in 2 months from date of supply.

19.2 Supply Prices shall be F.O.R Sriharikota.

All Taxes (like sales tax, VAT, service tax etc.,) and duties applicable shall be
19.3
indicated clearly in quotation.

Excise duty (ED) exemption Certificate will be issued by the Department for the
final product. (Hence, ED shall be NIL). Also Octroai exemption will be provided
19.4.1
by department on request from supplier. ED exemption will not be provided for
input materials.

Customs duty (CD) exemption certificate shall be issued by the purchaser for
the imported components used for this EOT crane. Hence, details of items, qty
19.4.2
and cost of the imported items shall be mentioned in the quotation. Bidder shall
provide necessary details accordingly for availing CDEC.

Liquidates Damages (LD): In case of delay in fabrication, supply, testing and

19.5 commissioning beyond the stipulated delivery period LD will be levied at 0.5%
per week or part thereof subject to a maximum of 10% of total order value.

Guarantee period shall be for a period of 12 calendar months, commencing

from the date of acceptance & taken over by the purchaser at our site. During
19.6
this period any defect noticed on design, materials, workmanship shall be
replaced/rectified by the supplier at free of any cost.

Performance Bank guarantee (PBG) for 10% of total cost of the crane shall
19.7 be provided by the Vendor for a period of 12 months from the date of
commissioning and acceptance of the crane at purchaser’s site at Sriharikota.
SDSC SHAR Page:41 of 41
175t / 25t FLAMEPROOF EOT CRANE
SPP
SPECIFICATIONS CUM COMPLIANCE STATEMENT

Bidder OFFER /
Sl.No. DESCRIPTION ISRO SPECIFICATION
ACCEPTANCE

Payment Terms in three stages. Vendor shall comply with following

19.8
payment terms only :

Advance along with

19.8.1 30% of supply value against Bank guarantee
Order

Payment after crane

19.8.2 60% of Supply value along with taxes & duties.
receipt at site

Balance Payment after

10% of Supply value + 100% TPIA charges + 100%
completion of erection
19.8.3 erection & commissioning charges against submission
& commissioning &
of Performance Bank Guarantee as per clause 19.7.
acceptance

Validity of Offer shall be minimum period of 120 days from the tender due
19.9
date.

Date : Signature & Office Seal of the bidder

 42

List of Tools to be supplied along with the crane (Ref : 18.14)

Sl.
Description of Item Units Required Qty
No.
Double end Spanners from 10-11 to 36-41
1 (set of 13nos.) of make : M/s Snap On / Set 01
Taparia)
Ring Spanners from 10-11 to 36-41 (set of
2 13nos.) Set 01

Heavy duty socket spanner set with

T-handle, Ratchet and Extension rod with ¾”
3 drive or 1” drive from 20mm to 55mm. Set 01
(1 set – 10 nos.)

4 Heavy duty single end spanners of size 55 Nos. 01

Screw driver set

a) Flat – 300mm long No 01
5
b) Star – 300mm long No 01

6 Adjustable spanner of 12” or 300mm length No 01

7 Cutting plier ( Size ~10” length) No 01
8 Locking / Grip plier ( Size ~10” length) No 01
Circlip plier
9 a) External Circlip plier ( Size ~10”) No 02
b) Internal Circlip plier ( Size ~ 8”) No 02
Special tool driver kit suitable for SIEMENS
10 Nos. 01
Drives
Nut driver kit suitable for selected terminal
11 Nos. 01
blocks inside the panel
Calibrated steel tape of 30m length of
12 Nos. 02
reputed make.
13 Suitable hydraulic jack capacity 50t. Nos. 02
 43

CODES AND STANDARDS FOR 175t / 25t FLAME PROOF EOT CRANE
The design, manufacture and testing of the crane shall conform to the latest editions of the
following codes and standards wherever applicable:
Code of Practice for Design, Manufacture, Erection and Testing
IS:807
(Structural Portion) of Cranes and Hoists.

Code of Practice for Design of Overhead Traveling Cranes and

IS:3177
Gantry Cranes other than Steel Works Cranes.

Code of practice for Heavy duty electric overhead traveling cranes

IS:4137
including special service machines for use in steel works
IS:2062 Steel for general structural purpose.
Code of welding practice for Industrial cranes, Mill cranes and other
ANSI/AWS D14.1
material handling equipment
IS:800 Code of practice for use of structural steel in general building
construction.
IS:3681 Gears tooth form and modules.
Code of Practice for Selection of Standard Worm and Helical Gear
IS 7403 : 1974
Boxes
IS 4460 : Parts 1 to
Gears - Spur and Helical Gears - Calculation of Load Capacity
3 : 1995
IS:1835 Steel Wires for Ropes
IS:6594 Technical supply conditions for steel wire ropes and strands.
IS:2266 Steel Wire Ropes for General Engineering Purposes.
IS:2363 Glossary of terms relating to wire ropes.
Selection, installation, maintenance and technical supply conditions of
IS:3973
wire ropes.
IS:3443 Crane Rail Sections
IS:5749 Forged Ramshorn Hooks
IS:3815 Point Hook with Shanks for General Engineering purpose
Code of Practice for Use of Metal Arc Welding for general
IS:816
Construction in Mild Steel.
IS:823 Code of Practice for Use of Metal Arc Welding of Mild Steel.

Qualifying Tests for Metal Arc Welders (Engaged in Welding Structures

IS:1181
other than pipes).

Code of Practice for Oxy-Acetylene Welding for Structural Work in Mild

IS:1323
steel.
IS:325 Three Phase induction Motors.
IS:4029 Guide for Testing Three Phase induction Motor.
 44

ANSI/ASME B30.2 Safety Codes for overhead and Gantry Cranes.

Degrees of protection provided by enclosures for low voltage switch
IS:2147
gear and control gear.
IS:5571 Guide for selection of electrical equipment for hazardous areas

Classification of Hazardous Areas (Other than Mines) for electrical

IS:5572
installations.

IS 2148 : 1981 Flameproof enclosures for electrical apparatus

IS 2206 : Specification for Flameproof Electric Lighting Fittings

IS 5780 : 1980 Specification for Intrinsically Safe Electrical Apparatus and Circuits.

Classification of maximum surface temperature of electrical equipments

IS:8239
for use in explosive atmosphere.
IS:1554 PVC Insulated (Heavy Duty) electric cables.
IS:2208 HRC cartridge fuse links up to 650V.
IS:2959 Contactors for voltage not exceeding 1000V AC or 1200V DC
Air-break switches, Air-break dis-connector, Air-break switch dis-
IS:4064 connector and fuse combination for voltages not exceeding 1000V AC.
or 1200VDC.
General requirements of switch gears and control gears for voltages not
IS:4237
exceeding 1000V AC.
IS 8623 : 1993 / IEC Specification for Low-Voltage Switchgear and Control gear Assemblies
Pub 439-1 : 1985 - Part 1 to Part 3
IS 13947 : Part 4 : Specification for Low-Voltage Switchgear and Control gear - Part 1 to
Sec 1 : 1993 / IEC Part 5 : Suppliers and Motor-Starters - Section 1 : Electromechanical
Pub 947-4-1 : 1990 Contactors and Motor Starters
Code of Practice for Selection, Installation and Maintenance of
IS 10118 : 1982
Switchgear and Control gear
Part I : General
Part II : Selection
Part III : Installation
Part IV : Maintenance
Use of Welding in Bridges and Structures Subject to Dynamic Loading -
IS 1024 : 1999
Code of Practice
SECTION – VI

ANNEXURES
 Annexure – 1A

Pedestal bearing Pedestal bearing

Rotary limit switch Rotary limit switch

Rope drum

Overspeed sensor Overspeed sensor

Planetary gear box 1

Planetary gear box 2

Drum / barrel coupling

Top pulley block

Encoder 4
Encoder 1

Brake 1 Brake 2 Brake 5 Brake 6

Motor 1 Motor 4
Encoder 2

Encoder 3
Motor 2 Motor 3

Brake 3 Brake 4 Brake 7 Brake 8

Fig 1 : 175t Main Hoist Configuration, Dual drive and Twin load path. 45
 EOT CRANE CLEARANCE DIMENSIONS – 175t / 25t FLAMEPROOF EOT Crane
(Top running, Double Girder, Flameproof EOT crane)

Refer Annexure – 1A (Fig) for details

All Dimensions are in meters

Rated
Facility Span
Sl.No SWL A B C D F G H P N M X Y
Name (S)
In tons

Propellant Not more

MH– 175t
01 Machining 21.0 m 6.0m 2.20m 1.70m 2.0m 0.1m 0.4m 0.3m 19.00m ~ 6.0 m than ~ 3.0m ~ 3.0m
AH – 25t
– II 8.0m

Height of Lift (m)

Main Hoist Auxiliary Hoist

I J K L

17.0m 5.50m 19.00m 5.50m

Note :

1. The above dimensions are indicative only. EOT crane supplier shall work out the exact dimensions by keeping the view
to minimize the end hook approaches and head room and shall provide the same in Cranes GA, drawing along with
quotation.
2. EOT Crane span & lift are subjected minor changes which shall be accommodated by supplier during detail engineering.

48
 Annexure – 2

SCHEMATIC OF PENDANT PUSH BUTTON OPERATING STATION

No. of
Selector Indication
Crane Motion / Requirement push
Switch lamps
button
1&2
Selection of Hoist 3-way Selector
1 - -
Motor switch
2
Main UP 1
Main DOWN 1
Hoist - -
Creep UP 1
Creep DOWN 1
Main UP 1
Main DOWN 1
Aux. Hoist - -
Creep UP 1
Creep DOWN 1
Main Right 1

Main Left 1
Cross Travel - -
Creep Right 1
Creep Left 1
Main Forward 1

Main Reverse 1
Long Travel - -
Creep Forward 1

Creep Reverse 1

Emergency Stop with Lockable Key - 1 -

Control ON - 1 -

Control OFF - 1 -

Control ON Indication lamp - 1

Push Button for Bell (Flameproof bell) - 1 -

Two way
UB lights - -
selector switch

49
 Annexure - 3
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE

Agency
Type / Extent

Performed

Witnessed
Sl. Components/ Characteristic to Method of of Ref. Acceptance Format of
Category Remarks

Verified
No Operations be checked check check Document Norm record

A B C D E F G H I J K
i) Identification of Raw All raw materials shall be offered with test certificates for identification for Crane manufacture Component Stamping on All materials shall be Identified by
materials structural before start of fabrication. Stamping shall be done for verification at later date. Specs./ IS 2062/ parts & Third
H 1 - _
plates, forged steel IS1570/ En steels Identification Party Agency . (HOLD)
material, Alloy steel etc., record

1 STRUCTURAL WORKS : BRIDGE GIRDERS, END CARRIAGES, CRAB FRAME, DRIVE BASES & PLATFORMS ETC.
1.1 Chemical composition/ Major T.C. Correlation One per Approved Approved Material T. C. /
Mechanical Properties (if not available heat drawings/ drawings / Tech. Supplier's Test 3,2 - 1
then test) Specs./ IS 2062 Specs./ IS 2062 Report Reports / TC review by TPIA .
Materials -
1.1.1 Plates/rolled sections Lamination /Internal Major Ultrasonic 100% ASTM A-435 ASTM A-435 Supplier IR For a l l plates of thickness > 20mm,
defects Testing 3,2 - 1 UT qualification ( volumetric test) 50

1.2 Welding Welding procedure & Critical Test piece visual One for ASME Sec.IX ASME Sec.IX WPS/ PQR
Welders qualification. & physical test. each format 2 - 1
position
a) Welding quality & Visual & IS:3658 & IS:3658 & Visual inspection & Use weld
Surface defects Critical 100% Supplier’s IR 2 - 1
Load Bearing Butt D.P. Test AWS D14.1 AWS D14.1 gauges for measurement of weld
1.2.1 welds (both tensile and size
compression) b) Sub surface defects ASME Sec.VIII ASME Sec.VIII
Critical Radiography Supplier’s IR 2 1 - Review of radiography films by I.A.
100 % Div I DivI

Legend
1 Third Party Inspection Agency (TPIA) Place: Signature of Crane Vendor
2 Vendor (Suppliers) Date: with Designation
3 Sub Vendor / Item Supplier
 Annexure - 3
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Agency
Type / Extent

Performed

Witnessed
Sl. Components/ Characteristic Ref. Acceptance Format of
Category Method of of Remarks

Verified
No Operations to be checked Document Norm record
check check

A B C D E F G H I J K
1.2.2 Other than load Surface defects & Size Major Visual & DPT 100% Use weld gauges for
Bearing Butt welds & Visual measurement of weld size
fillet welds check &
DP test IS:3658 IS:3658 Supplier’s IR 2 - 1
10%
random

1.2.3 Bridge Girder & End Visual, & Welding Major Visual & Visual Component Component Supplier’s IR Use weld gauges for
H Carriage inspection Measurement welding quality 100% DPT- drawing AWS drawing/ AWS measurement of weld size
before closing the box 2 1 -
random of D14.1 D14.1 (HOLD)
10%

1.2.4 Final Welding Visual Inspection Major Inspection of 100% Specification/ AWS D14.1 Supplier’s IR Visual final welding inspection by
Inspection Welding quality AWS D14.1
2 - 1
TPIA
51
1.2.5 Final Inspection of Dimensional , Camber , Major Measurement 100% Tech. Tech. Supplier’s IR Measured Dimensions shall be
fabricated components straightness, level, tolerances as Specification/ Specification/ marked on component drawing.
Girders, End carriages, Parallelism, verticality, per Component Component 2 - 1 Review of reports at next stage by
Trolley, LT drive frame, etc., specifications drawing/IS drawing/IS 807 TPIA. (HOLD)
etc.., 807

2.0 ROPE DRUM Fabricated/ Material composition/ Major T.C. Correlation One per Spec/drawing/ Spec/drawing/ Material T. C. /
Reports / TC / pressure test
Heavy duty Seamless pipe Mechanical Properties (if not available heat ASTSM A106/ ASTSM A106/ Supplier’s Test 3,2 - 2, 1
reports review by TPIA
UTS, YS, % elongation then test) IS 2062 IS 2062 Report
Welding Joint quality & Measured Dimensions shall be
2.1 ROPE DRUM joint Critical Visual/DP 100% Component ASME Sec.VIII Supplier’s IR
Welding / Seamless pipe
Weldment defects
Test/RT/ UT drawing Div I 3/2 2` 1 marked
on component drawing.
Examination of RT films by TPIA.
Stress relieving Major Verification 100% Mfg’s std. Stress relieving Supplier’s IR
3/2 2 1
chart

Legend
1 Third Party Inspection Agency (TPIA) Place: Signature of Crane Vendor
2 Vendor (Suppliers) Date: with Designation
3 Sub Vendor / Item Supplier
 Annexure - 3
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Agency
Type / Extent

Performed

Witnessed
Sl. Components/ Characteristic Ref. Acceptance Format of
Category Method of of Remarks

Verified
No Operations to be checked Document Norm record
check check

A B C D E F G H I J K
3.0 Material composition/ Major T.C. Correlation One per Spec/drawing/ Spec/drawing/ Material T. C. / Reports / TC to be
Mechanical Properties (if not available heat IS 2062 IS 2062 Supplier’s Test 3,2 - 2, 1
UTS, YS, % elongation then test) Report review by TPIA

3.1 Gear box Housings Stress relieving Major Verification 100% Mfg's std. Stress relieving Supplier's IR SR chart will be reviewed by TPIA.
2 - 1
chart
Fabricated
3.2 Surface defects & Major Visual/DP Test/ DPT 10% IS:3658/ IS:3658/AWS Supplier's IR Measured Dimensions shall be marked
dimensional check Measurement random & Component D14.1 on component drawing
2 - 1
100% drawing
visual
a) Platform Dimensional
4.0 Minor Measurement 100% Component Component Supplier's IR
b) LT Frame Conformity/
Critical drawing/ Mfr’s drawing/ Mfr’s
c) Hand Rails Visual checking / dimension TC/ Industrial TC/ Industrial 2 - 1 52
d) chequered Plates Mfr’s TC s / others standards standards
at random

5 MECHANICAL COMPONENTS – GEAR BOXES

MH, AH , CT & LT Input 1) UT volumetric test for wrought or
5.1 Material composition/ Major Correlation with 100% Specification Component Mfr's TC/
shafts, Gears , Pinions, forged materials as per ASTME
Mechanical properties Mfr’s TC ( if not IS:1570 / BS 970 drawing/ IS2048 Supplier's IR
keys, spacers
Hardness value / UT / test materials) / IS:2048 Specification/
3,2 - 1 114 and A388.
IS:1570 / BS 970 2) DPT or MPT shall be performed as
MPT/ DPT of materials
per ASTM A 275, E709
Machined components Key ways shall be inspected by TPIA
5.1.1 Dimensional conformity Major Measurement/ 100% Component Component Supplier's IR
for Gear boxes like input before assembly of gearboxes.
Hardness of gear teeth/ Visual drawing/ drawing/ IS4460/
shafts, gears, pinions, Measured Dimensions shall be marked
Bearing s/ Oil seals/ keys examination for IS4460/ AGMA/DIN/ Heat 2 - 1
keys, spacers etc., on component drawings.
and key ways. finishing AGMA/DIN treatment chart
IS:2048

Legend
1 Third Party Inspection Agency (TPIA) Place: Signature of Crane Vendor
2 Vendor (Suppliers) Date: with Designation
3 Sub Vendor / Item Supplier
 Annexure - 3
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Agency
Type / Extent

Performed

Witnessed
Sl. Components/ Characteristic Ref. Acceptance Format of
Category Method of of Remarks

Verified
No Operations to be checked Document Norm record
check check

A B C D E F G H I J K
Measured Dimensions shall be marked
5.1.2 Gear box Assembly Dimensional Major Measurement/ 100% Gearbox GA Gearbox GA Supplier's IR
on Gearbox GA drawings with
H conformity/ Inspection Visual check of drawing Drawing.
allowed dimensional variations.
of machined surfaces Internal 2 - 1
(HOLD)
like gearbox base, painting
bearing mounts etc.,.
Contact ratio of No Load Test shall be witnessed
Gear box assembly Major Measurement & 100% Gearbox GA Gearbox GA Supplier's IR
surfaces/ Backlash/ by TPIA. Noise level of gearboxes
no load running drawing / drawing / IS4460/
testing Noise level & Bearing shall be ≤ 80dBA. Temperature rise
5.1.3 IS4460/ AGMA Specification / 2 1 - shall be as per gearbox manufacture
(No load run test for temperature/ Breather/ / Specification Noise level of standards.
minimum of 4 hours ) Oil level gauge gear box ≤ 80dBA

5.2 MECHANICAL COMPONENTS – LT AND CT DRIVE SHAFTS

5.2.1
Materials of LT & CT
Material composition/ Major Correlation with 100% Approved Approved Mfr's TC/ Test 53
Shafts, and Keyways & UT of wrought and forged materials as
Mechanical properties Mfr’s TC ( if not drawing/ IS2048/ drawing/ IS2048 reports/
Keys
Hardness of material / test materials) Specification Supplier's IR
3, 2 - 1 per ASTM
Specification/
UT / DPT IS:1570/BS970/ IS:1570 / BS 970
Machining of LT & CT Keys & keyways shall be inspected
5.2.2 Straightness & Major Dimensional 100% Approved Approved Supplier's IR
Shafts, and Keyways & by
Dimensional conformity Measurement/ drawing/ drawing/ IS2048
Keys ( Dimensional TPIA before assembly.
Checks & Inspection of Visual Specification Specification/ 2 - 1
measurement)
Key way milling examination IS:1570 / IS:1570 / BS 970
BS 970/IS2048 /IS 2048
COUPLINGS Keys & keyways shall be inspected by
5.3 Coupling s Size/ Major Correlation with 100% Approved Approved Mfr's TC/
a) Materials TPIA before assembly.
Material composition/ Mfr’s TC drawing/ drawing/ IS2048 Supplier's IR
b) Torque capacity Mechanical properties / Specification Specification/ 3, 2 - 1 UT of wrought and forged materials
as per ASTM
c) Key ways Hardness value / UT / IS:1570 / BS 970 IS:1570 / BS 970
DPT

Legend
1 Third Party Inspection Agency (TPIA) Place: Signature of Crane Vendor
2 Vendor (Suppliers) Date: with Designation
3 Sub Vendor / Item Supplier
 Annexure - 3
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Agency
Type / Extent

Performed

Witnessed
Sl. Components/ Characteristic Ref. Acceptance Format of
Category Method of of Remarks

Verified
No Operations to be checked Document Norm record
check check

A B C D E F G H I J K
5.4 Plummer blocks & PB & bearing sizes/ Major Correlation with 100% Approved Approved Mfr's TC/ Review of Test certificates by TPIA and
bases Material composition/ Mfr’s TC drawing/ drawing/ Supplier's IR issue Compliance certificate.
Mechanical properties Specification Specification/ 2 - 1 Measured Dimensions shall be marked
on Component drawings with allowed
dimensional variations.
5.5 LT & CT Wheels
5.5.1 Material composition/ Major Correlation with 100% Approved Approved Mfr's TC/ Test Review of Test certificates by TPIA and
Mechanical properties Mfr’s TC drawing / Tech. drawing / Tech. reports/ issue Compliance certificate.
a) Material Forged steel Specification Specification
3, 2 - 1
Hardness of material / Supplier's IR
C55Mn75 IS:1570/BS970 IS:1570/BS970

UT of forged blanks Major UT checking 100% ASTM A-388 ASM A-388 Mfr's TC Review of Test certificates by TPIA and
3, 2 - 1
Supplier's IR issue Compliance certificate. 54
b) Wheels after
5.5.2 Dimensional Conformity Major Measurement 100% Approved Approved Supplier's IR Measured Dimensions shall be marked
machining with Keys &
for Bore, wheel tread, Component Component on each Component drawings with
key ways 2 - 1
taper of flange / drawing drawing allowed dimensional variations.
Hardness/depth

5.6 WHEEL AXLES with key Material composition/ Major Correlation with 100% Approved Approved Mfr's TC/ Test Measured Dimensions shall be marked
ways & keys Mechanical properties Mfr’s TC / drawing / Tech. drawing / Tech. reports/ 3,2 on each Component drawings with
Dimensional inspection Measurement Specification Specification Supplier's IR
- 1
allowed dimensional variations.
IS:1570/BS970 IS:1570/BS970
UT & DPT /MPT

5.7 Pulleys with Roller Bearings

a) Material (Forged Steel )
5.7.1 Material composition/ Major Correlation with 100% Approved Approved Mfr's TC/ Test Review of Test certificates by TPIA and
Mechanical properties Mfr’s TC drawing / Tech. drawing / Tech. reports/ issue Compliance certificate.
Hardness of material / Specification Specification Supplier's IR
3, 2 - 1
UT & DPT / MPT IS:1570/BS970 IS:1570/BS970

Legend
1 Third Party Inspection Agency (TPIA) Place: Signature of Crane Vendor
2 Vendor (Suppliers) Date: with Designation
3 Sub Vendor / Item Supplier
 Annexure - 3
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Agency
Type / Extent

Performed

Witnessed
Sl. Components/ Characteristic Ref. Acceptance Format of
Category Method of of Remarks

Verified
No Operations to be checked Document Norm record
check check

A B C D E F G H I J K
b) Visual Inspection Measured Dimensions shall be marked
5.7.2 Overall visual inspection Major Measurement 100% Component Component Mfr's TC
c) Dimensional Inspection on each Component drawings with
/ All dimensions as per with vernier / drawing / drawing /
allowed dimensional variations.
drawing like bore, Micrometer Specification Specification 3 - 1,2
width, groove, Noise level of
etc.,/hardness of gear box < 80db

5.8 Snatch block Cross Material composition/ Major Correlation with 100% Approved Approved Mfr's TC/ Test Measured Dimensions shall be marked
head Mechanical properties Mfr’s TC / drawing / Tech. drawing / Tech. reports/ 3, on each Component drawings with
- 1
Dimensional Measurement Specification Specification Supplier's IR 2 allowed dimensional variations.
inspection, 100% UT & IS:1570/BS970 IS:1570/BS970
MPT
5.9 Snatch block assembly Dimensional Conformity Major Measurement 100% Approved Assembly Supplier's IR Review of reports by TPIA
2 - 1
Assembly dwg . Drawing
Material composition/ 55
Major Correlation 100% Component Component Mfr's TC Proof load test from Govt. approved
Mechanical properties/ 3 - 2, 1
with TC. drawing / IS1875 drawing /IS 1875 test house.
and 100% UT& DPT /
MPT
5.10 Hook
Proof Load Test Major Testing 100% IS5749/IS3815 IS5749/IS3815 Mfr's TC 3 - 2, 1

Stress relieving Major Verification 100% Component Component Vendor TC

3 - 2,1
drawing/ IS3815 drawing /IS3815

Material composition/ Major Correlation with 100% Approved comp. Approved comp. Mfr's TC/ Test Measured Dimensions shall be marked
5.11 Mechanical properties Mfr’s TC / drawing / Tech. drawing / Tech. reports/ 3, on each Component drawings with
- 1
Specification Specification Supplier's IR 2 allowed dimensional variations.
Brake Drums with key IS:1570/IS1030 IS:1570/IS1030
and Key ways 1. Dynamic balance report shall be
Dimensions/ Dynamic Major Balancing test/ 100% Component Component Mfr's TC
reviewed by TPIA.
balancing/ Key way and Measurement drawing / drawing /
key inspection. with Specification Specification 2. Measured Dimensions shall be
5.12 2 - 1 marked on each Component drawings
with allowed dimensional variations.

Legend
1 Third Party Inspection Agency (TPIA) Place: Signature of Crane Vendor
2 Vendor (Suppliers) Date: with Designation
3 Sub Vendor / Item Supplier
 Annexure - 3
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Agency
Type / Extent

Performed

Witnessed
Sl. Components/ Characteristic Ref. Acceptance Format of
Category Method of of Remarks

Verified
No Operations to be checked Document Norm record
check check

A B C D E F G H I J K
6 BOUGHT-OUT & Other items

Dimensional, Genuine Major Mfr's TC 100% Component Component Mfr's TC Review of Mfr's TC by TPIA.
of make, Lay, core and drawing/ BOOM drawing / BOOM 3,2 - 1 Visual examination of wire rope for any
6.1 Wire Rope stands, Tensile grade defects by 2 & 1.

Breaking Load test Major Mfr's TC 100% IS2266 IS2266 Mfr's TC 3 - 1

Bearing No./ Genuine

6.2 Bearings Major Mfr's TC/ 100% Approved make SKF/FAG/TIMKEN Mfg TC/
make conformity 2 - 1
Invoice and type Supplier IR

6.3 Machined Fit Bolts & Material composition/ Major Correlation with 100% Approved comp. Approved comp. Mfr's TC/ Test Measured Dimensions shall be marked
Nuts Mechanical properties / Mfr’s TC / drawing / Tech. drawing / Tech. reports/ 3, on each Component drawings with
Measure dimensions Measurement Specification /IS Supplier's IR
- 1
Specification 2 allowed dimensional variations. 56
IS:1570/IS1030
Type / Genuine make
6.4 FASTENERS (Bolts, nuts, Major Mfr's TC/ 100% Approved make TVS/UNBRAKO Mfg TC/
conformity 2 - 1
washers, lock nuts) Invoice and type Supplier IR

7 ELECTRICAL EQUIPMENT
7.1 Electrical Control Dimensional, Visual Major Electrical test 100% Electrical Circuit Approved Supplier's IR Review of test certificates of all bought
Panels ( VVVF drive Sequence / Functional diagram/ drawing/ out items by IA
panels) and high voltage Test Approved Specification. 3 1
drawing/
Specifications

7.2 Motor Visual/ Name Plate Major Name Plate 100% IS 325/ Spec IS 325/spec Mfr's TC 2 - 1

7.2.1 Routine / No load test Major Elec. test 100% IS 325 IS 325 Mfr's TC 3 - 2, 1 Review of TC & Flameproof
certificates by TPIA
7.2.2 Flameproof test cert. Major Gap measure 100% IS2148/ CMRI IS2148/ CMRI Type test cert. 3 - 2,1

Legend
1 Third Party Inspection Agency (TPIA) Place: Signature of Crane Vendor
2 Vendor (Suppliers) Date: with Designation
3 Sub Vendor / Item Supplier
 Annexure - 3
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Agency
Type / Extent

Performed

Witnessed
Sl. Components/ Characteristic Ref.Acceptance Format of
Category Method of of Remarks

Verified
No Operations to be checked Document Norm record
check check

A B C D E F G H I J K
7.3 Brakes and Visual/ Name plate/ Major Name plate 100% Approved Approved Mfr's TC/ Type Review of TC & Ex-proof certificates
Make Torque & Thrust / details, make Drawing/ Make/ Drawing/ Make/ test cert for by
Thrusters, Material TC verify / Test Verification of BOM/Spec BOM/Spec/ Flameproof / TPIA
3 - 1
certificate/ Ex proof TC ATEX- PTB/ Supplier IR
Brake Coil certificate Verification of IS2148 -CMRI
Accessibility of parts. Ex-proof TC

7.4 Resistance box Megger test, Resistance Major Electrical test 100% BOM/ drawing BOM/ drawing / Mfr's TC Review by TPIA.
3 - 1
value / Specifications. Specifications.

7.5 Master controller / Sequence, Number Major Visual 100% BOM/ drawing / BOM/ drawing / Mfr's TC Review of TC by I.A.
Limit switches / Switch of cams, Idle Specifications. Specifications. 3 - 1
Gear operational test
57
7.6 Cables Routine test Major Test One per BOM/spec. BOM/spec. Mfr's TC Review of TC by I.A.
3 - 1

8H ASSEMBLY OF CRANE (Before assembly of EOT crane all parts shall be inspected by TPIA/Purchaser. Supplier shall inform readiness of all parts) (HOLD)

8.1 Bridge Girder & Overall Dimension s Major Measurement/ 100% Approved Approved Supplier's IR Measured Dimensions /
End carriage Structural Alignment & visual General General alignment values shall be
assembly. LT Wheel alignment. inspection Arrangement Arrangement 2 1 - marked on GA
Span measurement drawing / drawing / /component drawings with allowed
Diagonal Checks Specifications Specifications dimensional variations.

8.2
Crab assembly with Dimensional & CT Major Measurement 100% Approved Approved Supplier's IR Measured Dimensions /
Main Wheel alignment drawing / drawing / alignment values shall be
Hoist & CT machinery Couplings’ alignment Specifications Specifications marked on GA
2 1 -
/component drawings with
allowed dimensional variations.

Legend
1 Third Party Inspection Agency (TPIA) Place: Signature of Crane Vendor
2 Vendor (Suppliers) Date: with Designation
3 Sub Vendor / Item Supplier
 Annexure - 3
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Agency
Type / Extent

Performed

Witnessed
Sl. Components/ Characteristic Ref.Acceptance Format of
Category Method of of Remark

Verified
No Operations to be checked Document Norm record
check check s

A B C D E F G H I J K
9 H LOAD TESTING AT WORKS (HOLD)
NO LOAD TEST
9.1 NO Load test/ Major NO Load test/ 100% Approved dwg / Approved dwg / Supplier's IR & Measure Gear Box Noise. (Noise
(MH ,AH , CT & LT Performance & Safety Measurement IS807/ IS 3177 IS807/ IS 3177 Load test Level should be <80dBA).
mechanisms) 2 1 -
systems verification of parameters /Specification /Specification Format
speed, Current etc.,

9.2 FULL LOAD (SWL) TEST AT WORKS FOR HOIST & CT MOTIONS
DEFLECTION TEST
9.2.1 Deflection Major Measurement 100% Specifications/ Specifications/ Supplier's IR & Deflection < Span/1000 . Record
With Safe Working Load as per approved IS807/ IS 3177 IS807/ IS 3177 Load test 2 1 - procedure of test & measurement
procedure. Format with sketch.
Main Hoist and Auxiliary
9.2.2 Performance, duty cycle, Major Full Load test/ 100% Approved dwg / Approved dwg / Load test Measure Gear Box Noise. (Noise
Hoist With Safe Working 58
Speeds, Current, , Safety Measurement IS807/ IS 3177 IS807/ IS 3177 report 2 1 - Level should be <85dBA) .
Load
systems etc., of parameters /Specification /Specification /Supplier's IR
CT Mechanism With Safe
9.2.3 Performance, duty cycle, Major Full Load test/ 100% Approved dwg / Approved dwg / Load test Measure Gear Box Noise. (Noise
Working Load
Speeds, Current, , Safety Measurement IS807/ IS 3177 IS807/ IS 3177 report 2 1 - Level should be <85dBA) .
systems etc., of parameters /Specification /Specification /Supplier's IR

9.2.4 OVER LOAD (125% SWL) Static test/ Capability of Major Capability of CT 100% Approved dwg / Approved dwg / Supplier's IR & Record procedure followed for test
TEST all motions/ Permanent &Hoist motion/ IS807/ IS 3177 IS807/ IS 3177 Load test & measurement with sketch. After
2 1 -
(MH, AH & CT) set Measurement /Specification /Specification report testing check for any damage,
cracks/paint flaking in load bearing
members.
10 PAINTING
10.1 Sand/ Grit Blasting & Surface Cleanliness/ Major Visual Random Specification / Specification / Supplier's IR
Surface Cleaning 2 - 1
texture visual inspection SSPC SA2 1/2 SSPC SA2 1/2

10.2 Primer Coat Painting DFT Thickness/ visual Major Measurement Random Specification / Specification / Supplier's IR Paint thickness shall be measured
2 - 1
inspection in µm / Visual DFT ≥75µm DFT ≥75 µm with paint thickness gauge/
elcometer.

Legend
1 Third Party Inspection Agency (TPIA) Place: Signature of Crane Vendor
2 Vendor (Suppliers) Date: with Designation
3 Sub Vendor / Item Supplier
 Annexure - 3
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Agency
Type / Extent

Performed

Witnessed
Sl. Components/ Characteristic Ref.Acceptance Format of
Category Method of of Remarks

Verified
No Operations to be checked Document Norm record
check check

A B C D E F G H I J K
10.3 Epoxy paint Painting DFT Thickness/ visual Major Measurement/ Random Specification / Specification / Supplier's IR Paint thickness shall be measured with
(Two coats of 80 µm & inspection Visual DFT ≥195 µm DFT ≥195 µm 2 - 1 paint thickness gauge/ elcometer . Final
40 µm) DFT measured in presence of TPIA.

11 ERECTION AT SITE
Gantry rail Span, Level, Major Measurement 100% Approved Approved Supplier's IR Tolerances:
11.1 GANTRY GIRDER RAIL
straightness, rail Joints of parameters drawing / IS 807 drawing / IS 807 Rail span : ±5mm; Slope of rail : 1/1000
ALIGNMENT
and Rail clamp distance. Specification / Specification / 2 - 1 at 2m interval; Height diff : ±10mm
IS3177 IS3177 between LH & RH rails; Rail Gap :2mm;
Straightness of rails: ±5mm

12 LOAD TESTING AFTER ERECTION AT SITE.

12.1
NO LOAD TEST
NO Load test/ Major NO Load test/ 100% Approved dwg / Approved dwg / Supplier's IR & Measure Gear Box Noise. (Noise Level 59
(MH ,AH , CT & LT Performance & Safety Measurement IS807/ IS 3177 IS807/ IS 3177 Load test should be <80dBA).
mechanisms) 2 1 -
systems verification of parameters /Specification /Specification Format
speed, Current etc.,
DEFLECTION TEST
12.2 Deflection Major Measurement 100% Specifications/ Specifications/ Supplier's IR & Deflection < Span/1000 . Record
With Safe Working Load as per approved IS807/ IS 3177 IS807/ IS 3177 Load test 2 1 - procedure of test & measurement with
procedure. Format sketch.
Main Hoist and Auxiliary
12.3 Performance, duty cycle, Major Full Load test/ 100% Approved dwg / Approved dwg / Load test Measure Gear Box Noise. (Noise Level
Hoist With Safe Working
Speeds, Current, , Safety Measurement IS807/ IS 3177 IS807/ IS 3177 report 2 1 - should be <85dBA) .
Load
systems etc., of parameters /Specification /Specification /Supplier's IR
CT Mechanism With Safe
12.4 Performance, duty cycle, Major Full Load test/ 100% Approved dwg / Approved dwg / Load test Measure Gear Box Noise. (Noise Level
Working Load
Speeds, Current, , Safety Measurement IS807/ IS 3177 IS807/ IS 3177 report 2 1 - should be <85dBA) .
systems etc., of parameters /Specification /Specification /Supplier's IR

Legend
1 Third Party Inspection Agency (TPIA) Place: Signature of Crane Vendor
2 Vendor (Suppliers) Date: with Designation
3 Sub Vendor / Item Supplier
 Annexure - 3
QUALITY ASSURANCE, INSPECTION AND TESTING PLAN FOR EOT CRANE
Agency
Type / Extent

Performed

Witnessed
Sl. Components/ Characteristic Ref. Acceptance Format of
Category Method of of Remarks

Verified
No Operations to be checked Document Norm record
check check

A B C D E F G H I J K
12.5 LT Mechanism With Performance, duty cycle, Major Full Load test/ 100% Approved dwg / Approved dwg / Load test Measure Gear Box Noise. (Noise Level
Safe Working Load Speeds, Current, , Safety Measurement IS807/ IS 3177 IS807/ IS 3177 report should be <85dBA) .
systems etc., of parameters 2 1 -
/Specification /Specification /Supplier's IR

12.6 Brake Path Test/ Each Brake holding Major Measurement 100% Specifications/ Specifications/ Load test
Brakes Effectiveness Brake path / Delay of path & Brake path Brake path report
testing for all motions between two brakes Brake currents ≤17mm for Hoist ≤17mm for Hoist /Supplier's IR 2 1 -

12.7 Static test/ Capability of Major Capability of CT 100% Approved dwg / Approved dwg / Supplier's IR & Record procedure followed for test &
OVER LOAD (125%
all motions/ Permanent &Hoist motion/ IS807/ IS 3177 IS807/ IS 3177 Load test measurement with sketch. After testing
SWL) set Measurement report check for any damage, cracks/paint
/Specification /Specification 2 1 -
TEST (MH, AH , CT and flaking in load bearing members.
LT motions) 60
Final Painting & touch up Aesthetic look of crane/ Thickness Tech . Tech . Final DFT measured in presence of
13. Major Random Supplier's IR 2 1 -
DFT measurement measurement Specifications. Specifications. TPIA.

Safety features like limit Tech . Tech .

14 switches, overload relays, Performance, interlocks Minor Performance 100% Specifications./ Specifications./ Supplier’s IR 2 1 -
buffers, stoppers etc., IS3177 IS3177
As per
15 As per Load test
Spool limit switch Specifications
Specifications report
Performance Major No Load test 100% 2 1 -
/Supplier's IR

Decoupling of main As per As per

16 Ensuring the Major Ensuring the 100% Load test
hoist output shaft specifications specifications
decoupling of drive removal and report
coupling to rope drum system fixing of drive /Supplier's IR 2 1 -
system

Legend
1 Third Party Inspection Agency (TPIA) Place: Signature of Crane Vendor
2 Vendor (Suppliers) Date: with Designation
3 Sub Vendor / Item Supplier
 Annexure - 4
LIST OF OPTIONAL SPARE PARTS (LUMPSUM PRICE)

S.No Item Description Unit Qty

I Electrical
1 Main Hoist - CUVC card No 1
2 Semi conductor fuse (for each type) Nos. 3

3 Indication lamps Red, Yellow, Blue (Each) Nos. 2

4 Push buttons Nos. 6

5 Emergency push button with lock and key Nos. 1

6 Encoder for main hoist No. 1

II Mechanical

7 Brake liner for main hoist Set 2

8 Thruster assembly for Imported Main hoist Brake (flame proof) No. 1

9 Bearings for input shaft of MH gearbox. Nos. 2

10 Bearings for CT Wheel. Nos. 2

11 Bearings for LT wheel. Nos. 2
12 Oil seals for input shaft of MH gearbox. Nos. 2
13 Oil seals for input shaft of AH gearbox. Nos. 2

14 Sealing rings for geared coupling (each type - 1no.) Set 2

15 Main hoist thruster brake springs Nos. 2

16 LT rail clamps Sets 5
17 CT rail clamps Sets 5
18 Special grease nipples of different sizes (Each) No 10
TOTAL COST OF SPARE PARTS OPTIONAL TO BE MENTIONED IN THE
PRICE BID (Rs.)

61