TECHNICAL SPECIFICATION

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1 TENDER DOCUMENT NIT No.: DLI/C&E/WI-665/292 FOR Tender for Design, Engineering, Supply, installation, testing & commissioning of HOIST PACKAGE AND ASSOCIATED WORKS for the project of Augmentation of Raw Material Handling Receipt and Handling facilities with new OHP Part B (Package- 061) of Bhilai Steel Plant, (SAIL). VOLUME 2B TECHNICAL SPECIFICATION ENGINEERING PROJECTS (INDIA) LIMITED (A GOVT. OF INDIA ENTERPRISE) Core-3, Scope Complex, 7, Lodhi Road, New Delhi TEL NO: FAX NO

2 VOLUME - 2B CONTENTS Sl. No. DESCRIPTION 1. General, Documents/Information to be furnished alongwith offer 2. Scope of Supply 3 Technical Specifications Electric Hoist 4. Technical Specifications Manual Hoist 5. List of drawings / documents required 6. List of Hoist 7. Spares 8. Technical data sheet (to be filled by the vendor)

3 GENERAL The following Technical Specification shall be read in conjunction with General Technical Specification (GTS) of Bhilai Steel Plant, SAIL and General Specification. If there are any provisions in this Technical Specification, which are at variance with the provisions of General Technical Specification (GTS) of Bhilai Steel Plant, SAIL and General Specification, the provisions in this Technical Specification shall take precedence. 1.0 DOCUMENTS / INFORMATION TO BE FURNISHED ALONGWITH OFFER. (i) Clear Scope of supply. (ii) List of Commissioning spares and start-up spares with unit rates. (iii) List with unit rates of special tools and tackles, if any required. (iv) Price Schedule for supply & erection work as per the format enclosed. (v) List of recommended spare parts for 3 (Three) years trouble free operation and maintenance alongwith unit rates as per the format enclosed in price schedule. (vi) Technical data sheets duly filled by the vendor (blank data sheets enclosed). (vii) Catalogues/ Leaflets and O&M Manuals. (viii) Reference list of your Customers for the similar supply of items. (ix) Un-priced Copy. (Furnish un-priced copy of Price Schedule alongwith the Technical Bid.)

4 2.0 SCOPE OF SUPPLY The scope of the supply includes Design, engineering, manufacture, shop fabrication. assembly, testing and inspection at manufacturer s works, packing, dispatch, transportation, delivery to site, receipt, required fabrication at site, installation, testing & commissioning completion of facilities, performance guarantee testing, final painting at site and handing over to Bhilai Steel Plant, SAIL/EPI of HOISTS AND ASSOCIATED WORKS as per specifications and scope defined in tender documents complete with all accessories and drive, which are not mentioned specifically but are required for the efficient and trouble free operation of the equipment/system. a) Following items are also included in bidder s scope. (i) Complete Hoist including all the mechanical, electrical & Instrumentation items as per the details given in the specifications. (ii) Consumables like first fill of lubricating oils etc. for the initial operation of the equipment till handing over. (iii) Commissioning spares and start-up spare parts. (iv) Special tools & tackles, if any required. (v) Recommended spare parts for (3) three years trouble free O&M. (vi) Painting of complete equipment (including final painting before handing over to the Employer). (vii) Installation, testing & commissioning at site. (viii) All drawings / documents along with operation and maintenance manuals as per requirement mentioned elsewhere in the tender document. (ix) Getting approval of design/drawings and any other design calculation related to the equipment from BSP/MECON. (x) 3 Ph, 415V, +10% & -15%, 50 Hz +4% & -6%, power supply shall be provided at Diverter gate terminal at one point through power cable. (xi) Carrying out any modifications/ deletions /additions / alteration in design / drawings/ documents as required by client & Client s consultant and EPI for proper execution of works at site till completion and handing over of the project to the client. (xii) Trailing / Flexible Cables as required for hoist shall be in bidder s scope. Festoon cable trolley system for hoists shall be in bidder s scope. (xiii) Size of the monorail shall be furnished by successful bidder. (i) (ii) Exclusions: Civil works including grouting. Monorail supply & fixing.

5 b) Tenderer to note the following: (i) Makes of gear box shall be Elecon/ NAW/ Flender/ Premium energy transmission/ Shanthi gears. (ii) All LT AC / DC motors, actuators, brakes etc. as per technological and process requirement. (iii) Generally Squirrel Cage Induction Motor with DOL starter / VFD / Soft Starter will be provided. Use of Slip ring motor in general will be avoided. Suitable Rotor contactor panels and SS-grid Resistance Boxes will be provided for slip ring motors if inevitable (iv) Soft starter will be provided for LT motors of rating more than 75kW. (v) All LT motors for conveyors will be S6 duty and will have class F insulation with temperature rise limited to class B. Inverter duty motors (used for VFD application) will have class H insulation with temperature rise limited to class F. (vi) Equipment selection and dating will generally be based on ambient temperature of + 50 Deg.C. For specific areas and shops, the ambient temperature conditions indicated above will be taken into consideration and equipment suitably derated wherever necessary. (vii) The equipment should be suitable for smooth, efficient and trouble free service in the tropical humid climate prevailing at plant site and under the ambient temperature conditions indicated elsewhere. (viii) Roller bearings will be provided at DE end for motor of rating 30KW and above

6 3.0 TECHNICAL SPECIFICATION OF ELECTRIC HOIST 3.1 The hoist shall be designed in accordance with IS: For outdoor hoists, motors, brakes & other equipment shall be covered to suit to outdoor operation. 3.3 All trailing cables shall be clamped with PVC or non-metallic clamps. 3.4 Defects in the materials like fractures, cracks, blowholes, or laminations are not allowed. 3.5 No cast iron parts shall be used except for electrical equipments and no wood or combustible material shall be used unless specifically mentioned otherwise 3.6 All working parts requiring replacements or inspection or lubrication shall be easily accessible without the need for dismantling of other equipment or structure. 3.7 All bolts except those with nyloc nuts shall be provided with grip lock nuts or spring washer. 3.8 All parts of the hoist shall be thoroughly cleaned of all loose mill scales, rust or foreign matter & then painted as specified. All parts inaccessible after assembly shall be painted before assembly & assembled while paint is still wet. 3.9 All parts except motors, resistors, gears, thrustors, solenoids, etc. shall be derusted manually & painted as follows MECHANICAL DETAILS Wheel & drive The electric hoist shall run on two pairs of wheels, a pair of which shall be driven by motor through reduction gear. The wheels shall be of cast steel/forged steel, single flanged with taper / parallel treads to suit to monorail. The wheels shall be mounted on anti-friction bearings & shall be easily removable for repair & replacement. The wheel diameter shall be selected such that skidding does not take place even under unloaded condition Hoist mechanism The hoist mechanism shall consist of a bottom block fitted with a standard forged swivel hook of the specified capacity, supported on 2 or 4 falls of wire rope. However, non-spinning type of wire rope shall be used for 2 falls rope arrangement. The wire rope shall be wound on a grooved drum which shall be sufficiently long to accommodate in one layer the length of rope requisite for the specified lift & in addition not fewer than two turns at each anchored end & one spare groove at the opposite end. The hoist drum shall be motor driven through gears enclosed in oil filled reduction gearbox.

7 Gearing Straight & helical spur gearing shall be used for all motions. Worm & bevel gears shall not be used with specific permission from purchaser. Preferably all first reduction gears shall have single helical teeth. All gears shall be hardened & tempered alloy or carbon steel with machine out teeth. Surface hardening of teeth is not acceptable. All gears shall be enclosed in oil filled gear box except when not possible Couplings Each motor shall be connected to its gear drive by a flexible coupling Lubrication All gears & bearings shall be lubricated either by splash lubrication or by grease. If possible, all the lubricating points shall be grouped together in easily accessible positions Bearings Ball & roller antifriction bearings of reputed make shall only be used, with minimum bearing life as per IS: Brakes D.C. Electromagnetic brake shall be provided for each motion, however in case of conical rotor motors manufacturer's standard brake can be used The Electric hoists shall be inspected as per IS: and as specified in tender document 4.0 TECHNICAL SPECIFICATION OF MANUAL HOIST 4.1 Ball and roller anti frictional bearing only shall be used. 4.2 Swiveling type standard shank hook mounted on grease lubricated anti-friction thrust bearing shall be used. 4.3 The Chain Pulley Block shall conform to class-i duty as per IS: Load chain & operating chain shall be of calibrated type. 4.5 Pulley used for the operating mechanism shall have suitable guards to prevent the operating chain from coming out 4.6 All the open gearing shall have suitable cover.

8 5.0 LIST OF DRAWINGS / DOCUMENTS REQUIRED 5.1 List of Drawing/ Documents to be furnished by the Successful Tenderer for approval / reference. a) General arrangement drawing of equipment showing full details in plan and sections. b) Engineering and design calculations. c) Quality assurance plan for inspection. d) Specification of oils and lubricants and other consumables and their quantity and frequency of change (reference). e) Detailed layout plan and sections for power supply system. f) Other drawings & documents required as BSP/MECON/EPI. 5.2 List of Drawing/ Documents to be furnished alongwith equipment by the Successful Tenderer. a) GA drawings, complete assembly and sub assembly drawings of the equipment. b) Engineering and design calculations. c) Test and warranty certificate for each item of equipment. d) Test reports and inspection reports. e) Instruction manuals for testing and commissioning. f) Operation, maintenance and safety manuals. g) Requirement of special tools and tackles, if any, for subsequent maintenance. h) All other drawings & documents as stipulated in Tender document.

9 LIST OF HOIST S.No ITEM DESCRIPTION QTY 1 Electric Hoist - Capacity : 15 T & Lift : 17 Mtr 1 No. 2 Electric Hoist - Capacity : 15 T & Lift : 15 Mtr 1 No. 3 Electric Hoist - Capacity : 7.5 T & Lift : 16 Mtr 4 Nos. 4 Electric Hoist - Capacity : 7.5 T & Lift : 9 Mtr 2 Nos. 5 Electric Hoist - Capacity : 7.5 T & Lift : 4.5 Mtr 1 No. 6 Electric Hoist - Capacity : 5 T & Lift : 4.5 Mtr 1 No. 7 Electric Hoist - Capacity : 5 T & Lift : 9 Mtr 1 No. 8 Electric Hoist - Capacity : 5 T & Lift : 12 Mtr 4 Nos. 9 Electric Hoist - Capacity : 5 T & Lift : 14 Mtr 4 Nos. 10 Electric Hoist - Capacity : 5 T & Lift : 15 Mtr 3 Nos. 11 Electric Hoist - Capacity : 5 T & Lift : 17 Mtr 2 Nos. 12 Electric Hoist - Capacity : 5 T & Lift : 18 Mtr 3 Nos. 13 Electric Hoist - Capacity : 5 T & Lift : 20 Mtr 2 Nos. 14 Electric Hoist - Capacity : 5 T & Lift : 22 Mtr 3 Nos. 15 Electric Hoist - Capacity : 5 T & Lift : 23 Mtr 1 No. 16 Electric Hoist - Capacity : 5 T & Lift : 24 Mtr 2 Nos. 17 Electric Hoist - Capacity : 5 T & Lift : 25 Mtr 1 No. 18 Electric Hoist - Capacity : 5 T & Lift : 28 Mtr 1 No. 19 Electric Hoist - Capacity : 3 T & Lift : 4 Mtr 1 No. 20 Electric Hoist - Capacity : 3 T & Lift : 9 Mtr 2 Nos. 21 Electric Hoist - Capacity : 3 T & Lift : 10 Mtr 1 No. 22 Electric Hoist - Capacity : 3 T & Lift : 12 Mtr 2 Nos. 23 Electric Hoist - Capacity : 3 T & Lift : 13 Mtr 1 No. 24 Electric Hoist - Capacity : 3 T & Lift : 15 Mtr 1 No. 25 Electric Hoist - Capacity : 3 T & Lift : 16 Mtr 3 Nos. 26 Electric Hoist - Capacity : 3 T & Lift : 28 Mtr 1 No. 27 Electric Hoist - Capacity : 3 T & Lift : 49 Mtr 1 No. 28 Manual Hoist - Capacity : 3 T & Lift : 4.5 Mtr 3 Nos. 29 Manual Hoist - Capacity : 2 T & Lift : 3 Mtr 6 Nos. 30 Manual Hoist - Capacity : 3 T & Lift : 4 Mtr 12 Nos. 31 Manual Hoist - Capacity : 3 T & Lift : 9 Mtr 2 Nos.

10 7.0 SPARES (A) Commissioning Spares and Insurance Spares Supply of commissioning spares and insurance spares as required shall be in scope of supply of the Bidder alongwith the equipment. The list of commissioning spares and the insurance spares as per the format as given in SBD shall be furnished alongwith the tender. It shall cover requirements of erection, cold tests, startup and initial operation of the plant till integrated testing & successful commissioning and commencement of commercial production up to a period of six months. Any leftover commissioning spares shall be the property of the Purchaser. Any commissioning spares required over and above the list given by the Bidder shall have to be provided by the Bidder free of cost up to the successful commissioning & commencement of commercial production of the plant and equipment. The Bidder shall supply adequate insurance spares to ensure smooth operation and maintenance of the plant. (B) Consumables The Bidder shall supply all consumables such as initial fill of lubricants, oils, grease, chemicals, refractories, resins etc. as required to complete the plant till commissioning and shall have a shelf life of minimum one year. The scope of consumables shall include electrodes, shims, packings, bolts, nuts, gaskets, rivets, washers etc. The Bidder shall fulfill the requirement given in SBD. The Bidder shall also furnish Indian equivalent of oils, lubricants, refractories and other consumables along with necessary specifications, drawings, catalogues etc. to enable the Purchaser to procure them from indigenous sources. The Bidder shall indicate the annual requirement of all such consumables. (C) Operating, Maintenance and Two Years Spares: (1) The Bidder shall ensure the interchangeability of the parts wherever possible. The Bidder shall furnish an itemized list of interchangeable spares as given in SBD. (2) The list of spares as necessary and recommended by the respective manufacturer for two years of reliable and trouble free operation and maintenance of all equipment under this package shall be in the scope of the Bidder. The same shall be quoted separately. In the event of order the successful Bidder shall furnish complete specification of the same.

11 (3) Spares list giving complete list of the replaceable parts, fully illustrated, shall be supplied. The list shall include the following information. Item designation Reference drawings Quantity installed Quantity recommended for two years normal operation including the insurance spares Weight of each spare part Supplier or sub-supplier s catalogue number Recommended minimum stock Expected replacement time Installation instruction in detail shall be supplied both for original installation and future, for replacement of major electrical equipment, circuit wiring diagram shall be provided. (D) Special Erection / Maintenance Tools and Tackles: (1) The Bidder shall supply a complete and unused wet of all the special tools and tackles including required number of tool boxes as required for erection, maintenance, overhaul or complete replacement of the equipment and components required for the plant. The Bidder shall submit a list of such special erection and maintenance tools and tackles. (2) All the tools shall be supplied in separate containers clearly marked with the name of the equipment for which they are intended. (3) The Successful Bidder shall indicate list of construction machineries, handling equipment and other facilities including tower crane or equivalent for erection at high elevation required for the execution of work based on their previous experience, considering site conditions and other considerations of work and furnish resource deployment plan. The successful Bidder shall mobilize these equipment at site for the execution of work and this is an important requirement of the project. The availability of required facilities shall be ensured for completeness of the project in time. (4) For any fabrication / control assembly (necessary for erection) work to be done in the plant premises the plan shall be indicated by the Bidder. The necessary equipment such as plate bending machines, special purpose welding machines, fixtures, tools & tackles and other equipment required for fabrication shall be arranged by the successful Bidder. (5) The successful Bidder shall carry out the testing of welded joints by radiographic and ultrasonic methods. They must have only qualified / certified welders with them for completing all the welding jobs. (6) All the measuring instruments shall be calibrated having reference to NPL (National Physics Laboratory).

12 (7) All tools and tackles, apparatus, special instruments required for erection, testing, commissioning and establishment of the Performance Guarantee Test, measurements required for establishing the pollution control norms and such other instruments, as required, shall be arranged by the successful Bidder. After commissioning, the successful Bidder shall handover all the special tools & tackles to the Purchaser as per the requirement given in SBD. (8) The successful Bidder shall supply all required consumables, initial fill, oil, lubricants, construction and erection materials including but not limited to shims, packing plates, joining compounds, kerosene, solvents, sealing compounds, tapes, connectors, brazing and soldering materials, welding and brazing gases and rods, electrodes and wires, erection bolts, nuts, rivets, piano wire, packing sheet and packing compounds, temporary supports, spacer templates, jute and cotton waste cloth, sand and emery paper etc. for the commissioning of the plant. (9) For load testing of handling equipment, loads shall have to be arranged by the successful Bidder. Electrical/ operation tests, as per standard practice, shall also be arranged and completed by them. (10) All materials, equipment, tools, tackles etc. brought at site by the successful Bidder within the plant area shall not be removed without the written permission of the Purchaser. Similarly, all enabling works built/erected and/or acquired by them within the plant premises shall not be dismantled and removed without the written permission of the Purchaser. (E) Information/ Data on Spares and Consumables The list of Spares & consumables shall be furnished by the successful Bidder as required in SBD. However, the successful Bidder shall furnish various information regarding spares, consumables, tools & tackles etc. as per the schedules indicated in chapter 12 of this Technical Specification.

13 8.0 TECHNICAL DATA SHEET (To be filled by the vendor) 8.1 ELECTRIC HOIST 1. Make 2. Capacity 3. Duty Classification 4. Total weight of the Hoist 5. HOIST 5A. Speeds with safe working load lifting Height a) above floor level b) below floor level 5B. WIRE ROPES a) Type of construction b) size c) No of falls d) Factor of safety 5C. ROPE DRUM a) Materials b) Drum 5D DRIVES a) Type & material of gear box b) Gear & pinion c) Material & hardness 5E MOTORS a) Type & number b) Kw rating c) Synchronous speed d) Class of insulation e) Pull out torque f) Frame size 5F BRAKES a) Type b) Size c) Torque rating

14 5G. LIFTING HOOK 5H 5I 5J 5K a) Type b) Material Type & details of limit switches Type of couplings Type of bearings Type & details of controls 6 TROLLEY Speed with safe working load 6A WHEELS 6B 6C 6D 6E 6F 6G a) Numbers b) Diameter c) Material & hardness d) Max. wheel load e) Wheel base DRIVES a) Type & material of gear box b) Gears & pinions c) Material & hardness d) Kw rating e) Synchronous speed f) Class of insulation g) Pull out torque i) Frame size BRAKES a) Type b) Size c) Torque rating Type & details of limit switches Type of coupling Type of bearings Type & details of controls 7 Clearance diagram indicating the basic dimensions. 8 Type & lubrication provided

15 9 Type & size of cables 10 Location & control details of hoist block power feeding arrangement 8.2 MANUAL HOIST 1. Make 2. Capacity 3. Class of Duty 4. Minimum radius of curvature of track beam size 5 Maximum tractive effort (Kgs) Hoist Travel 6 Movement in M corresponding to operating chain movement of 30M Hoist Travel

TECHNICAL SPECIFICATIONS

TECHNICAL SPECIFICATIONS TENDER DOCUMENT TENDER NO.: DLI/C&E/WI-675/275 FOR Tender for Design, Engineering, Supply and Supervision of installation, testing & commissioning of Cable Reeling Drum with Composite Flexible Trailing