1. Design, Fabrication, Supply, Installation, Commissioning, Warranty of Control Panel for 30/5 Te Outdoor Goliath Crane in adherence to attached specifications, dismantling & removal of the existing pedestal mounted control panel. (A brief detailing on the 30/5 Te Outdoor Goliath Crane is provided at the end of this document) Detailed Specifications: a. Design: i. Supplier may visit to the site and get familiarized with the exact requirements prior to design. The visit to site shall be planned at least with advance information of 2 days. Interim visits are also envisaged. ii. The panel will be located on outdoor sea face corrosive atmosphere. Panel material shall not be affected by sunlight or rains or temperatures. iii. The panel shall be designed to cater the protections, crane controls including radio remote, power supplies and controls for crane auxiliaries/accessories. The components required for Protective Panel, Main and Auxiliary Hoist Panel, Long Travel Panel, Cross Travel Panel, etc. shall be accommodated in the panel. iv. Supplier shall provide New Base platform on Girder which can be welded on the Long travel Support Platform of the crane so as to support & take the load of the Power, control panels and at least additional weight of about 200 Kg. v. The panel power supplies will be 415Vac, 3- phase, 50 Hz. Single source. The panel shall derive its control power supplies from this power source as well as the supplies for various drives, brake, etc. It shall be equipped with internal space heater and illumination circuits. vi. The panel shall be designed for minimum IP-56 protection class. vii. The design drawings shall be submitted to NPCIL for approval prior to fabrication of the panel. The design/engineering drawings shall consist of the following. i. General Arrangement (GA) Drawings ii. Design Drawings(DD) Drawings iii. Terminal Lists (TL) iv. Electrical Wiring Diagrams v. Electrical Drawings vi. Bill of Material viii. The material/components selected for the crane panel fabrication shall be approved prior to fabrication from NPCIL with detailed catalogues. The supplier shall also provide critical spares list with required quantity for a period of 5 years of trouble free operation.
b. Fabrication: i. All the components required for functioning of Protective Power Panel & control panels should have been installed & wired as per drawing submitted and approved from NPCIL. Also, the control & power cables should have ferrules as per drawing indicating the cross terminations of all the wires. ii. The material of the panel and the base platform shall be Sheet Steel of 1.6mm ±0.2mm thickness, pre-treated and Hot dipped Galvanized as per IS- 4759 with average mass of Galvanization not less then 610 gm/m 2. Supplier shall provide self certification in this context. iii. Mounting screws, nuts, handle for door must be cadmium plated. iv. The Variable Voltage Variable Frequency Drives should be provided for Main Hoist, Cross Travel, Auxiliary Hoist & Long Travel. v. Dynamic Braking resistors for each motion i.e. Main Hoist & Auxiliary Hoist, Cross travel & Long Travel suitable with VFD drives shall be rustproof unbreakable grid type suitable for starting and regulating duty, intermittent rated. vi. Automatic reset type of Rotary Geared, Safety Switches & Lever type limit switches shall be provided to prevent over travel for each of the following notions: (a) Right and Left travels of the bridge. (b) To and Fro travel of the trolley. (c) For Up and Down motions of the main hook and auxiliary hook. The limit switches & safety switches should be as per existing arrangements. Four (4) 15 Amp Non-fusible air break isolating switches will be fitted at the four corners of the crane so as to be accessible while standing on the crane platform. vii. Radio remote control suitable for all operations as specified in the drawing. The details of remote control to be provided along with the channel number for proper identification. The radio remote transmitter & receiver shall be having designed such that the IP classification is not less than IP65. viii. Supply of Control Cable & power cables between Panel & Components: i. Supply of Lighting Cables: Lighting cables for all provisions of Lighting given in the drawing is to be provided as per existing drawing. ii. Supply of Control Cables: The cable and wires shall be 1100V grade PVC insulated and PVC sheathed Aluminium conductors for power wiring and with standard cropper conducts for control circuit wiring. iii. Supply of Power Cables: Wiring adjacent to resistors and control panel wiring shall be of standard 1100V grade flame heat and moisture resistance, insulation suitable for operation a high
temperature. Wires for motor primary and secondary circuits shall have adequate current carrying capacity to carry maximum plugging current of the motors. All wires shall terminate in approved lugs or other approved devices which will maintain good connection under rough usage. ix. Power cable for Warning Horns & Crane Under bridge Lighting should be Provided. x. Non-corrosive Cable trays/conduits shall be used for routing of the power and control cables. c. Supply, Installation & Commissioning: i. Complete panel, with all internal wiring, after NPCIL QA checks shall be shipped to TAPS # 3&4. The approved critical spares for a period of 5 years of trouble free operation also shall be supplied along with the panel. ii. Trained Manpower adequate to install the panel and commission the same within a period of 4 working days shall be deputed to Tarapur Maharashtra Site. iii. Supplier will have to arrange for lodging, boarding, transport, insurance, safety training, protective gear, etc. of deputed personnel. iv. The supplier also will have to provide tools and equipment required for installation & commissioning at Tarapur Maharashtra Site on returnable basis. v. The panel shall be shifted from TMS stores to the installation area by the supplier under his own arrangements. Vehicles can be provided subject to availability. vi. Supplier shall demonstrate all tests and safety operations on the commissioned new panel with all existing features working. Commissioning shall be considered completed only after crane is load tested. vii. Load testing will be carried out by NPCIL in presence of Party representative executing the job. viii. The existing panel shall be dismantled without any damage to the crane structure and deposited to the TMS stores. d. Warranty: The supplier shall provide 12 monthly preventive maintenance visits and all breakdown maintenance calls in lieu of One Year warranty.
Pictures depicting existing Crane
Details of Existing Crane: GOLIATH CRANE 1 AREA/CRANE CCW PUP HOUSE DESIGNATION 2 LOCATION -DO- 3 TYPE OF INSTALLATION OUTDOOR 4 NUMBER REQUIRED ONE FOR EACH UNIT 5 TYPE OF CRANE GIRDER DOUBLE BOX GIRDER 6 CLASS OF CRANE CLASS.II FOR MECHANICAL & STRUCTURAL COMPONENTS AND CLASS.III ELECTRICAL COMPONENTS 7 MAIN HOIST CAPACITY TONNES 30.0 8 AUX:HOIST CAPAXITY TONNES 5.0 9 MAIN HOIST LIFT METRES 10.5 10 AX HOIST LIFT METRES 27.8 11 GRANE SPAN METRES 22.4 12 LENGTH OF RUNWAY METRES 95.6 13 MAIN HOIST HOOK TYPE SWIVELLING SHANK TYPE 14 AUX HOIST HOOK TYPE SWIVELLING SHANK TYPE 15 MAIN SPEEDS METERS/MINUTE 15:1: MAIN HOIST 2.0 TO 3.0 15:2: AUX HOIST 2.0 TO 3.0 15:3: CROSS TRAVEL 8.0 TO 10.0 15:4: LONG TRAVEL 14.0 TO 15.0 16 MICRO SPPEDS METERS/MINUTE 16:5: MAIN HOIST 16:6: AUX HOIST 10% OF MAIN SPEEDS 16:7: LONG TRAVEL 16:8: CROSS TRAVEL 17 METHOD OF ACHIEVING PLANTARY GEAR BOX MICRO SPPED 18 OPERATION OF CRANE BY PENDANT, COUNTER WEIGHT TYPE PENDANT UP BUTTON PUSH BUTTON STATION 19 TYPE OF CABIN: NOT APPLICABLE 20 TYPE OF DOWNSHOP LEADS BARE COPPER CONDUCTOR/PVC ENCLOSED COPPER CONDUCTORS 21 CRANE RUNWAY GIRDERS STEEL/STEEL CONCRETE 22 DESIGN SESMIC AS PER IS:1893 COEFFICIENT 23 TYPE OF BRAKES 23:1: MAIN HOIST ELECTRO-MAGNETIC & HYDRAULIC THRUSTOR (ONE EACH) 23:2: AUX HOIST -------------DO------------- 23:3: CROSS TRAVEL HYDRAULIC THRUSTOR (TWO NOS) 23:4: LONG TRAVEL HYDRAULIC THRUSTOR (FOUR NOS) 24 HOLDING TORQUE 24:1: FOR HOISTING 1.5 TIMES FULL LOAD TORQUE BRAKES 24:2: FOR LONG AND CROSS TRAVEL BRAKES 1.25 TIMES FULL LOAD TORQUE
25 WALKWAY NOT APPLICABLE 26 GALVANISING OF HOIST NOT REQUIRED ROPE 27 PARKING BRAKES REQUIRED Cables Used in two Gantry Cranes: 1) FIXED CABLES (PVC-AL-ARM) a) 3 ½ C x 50 mm 2 = 27 METERS b) 3 C x 25 mm 2 = 10 METERS c) 3 C x 10 mm 2 = 63 METERS d) 3 C x 6 mm 2 = 100 METERS 2) CONTROL CABLES (PVC-CU-ARM) a) 20 x 2.5 mm2 = 110 METERS b) 20 x 2.5 mm2 = 250 METERS c) 10 x 2.5 mm2 = 70 METERS d) 12 C x 2.5 mm2 = 62 METERS 3) FESTOONED CABLES (PVC-CU-FLEXIBLE) a) 3 ½ C x 50 mm2 = 40 METERS (FOR C R0) b) 3 C x 10 mm2 = 26 METERS (1 x 28 Mrs) c) 3 C x 4 mm2 = 145 METERS (5 x 26 Mrs.) d) 3 C x 2.5 mm2 = 153 METERS (3 x 26 Mrs.) e) 19 C x 2.5 mm2 = 32 METERS (2 x 10 Mrs.) f) 8 C x 1.5 mm2 = 73 METERS (PVC-CU-FLEXIBLE SCREENED PROTECTED TYPE) FOR PLUSE ENCODER COMPONENT DETAIL CHART FOR 30/5T X 18.45M GOLIATH CRANE A) MOTORS MOTION FRAME SIZE KW 1. MH ND-180L 17.0 2. AH ND-112M 3.9 3. CT ND-112M 3.9 4. LT ND-160M 8.0 B) BRAKES : ELECTRO HYDRAULIC THUSTOR (EHT) MOTION TYPE SIZE 1. MH EHT 200 Ø 2. AH EHT 160 Ø 3. CT EHT 160 Ø 4. LTI EHT 200 Ø 5. LT EHT 200 Ø C) LIMIT SWITCHES
MOTI ON TYPE 1. MH ROTORAY GEARED 2. MH COUNTER WT. GRAVITY 3. AH ROTARY GEARED 4. AH COUNTER WT. GRAVITY 5. CT TWO WAY LEVER 6. LT TWO WAY LEVER D) CONTROL PANELS WITH VVVF DRIVE (UIH MAKE) TYPE VOLTS AMPS E) DBR 1. PROTECTIVE PANEL 415 80 2. MAIN HOIST PANEL 415 50 3. AUX. HOIST PANEL 415 16 4. CROSS TRAVEL PANEL 415 16 5. LONG TRAVEL PANEL 415 50 TYPE Ohms Watts 1. MAIN HOIST DBR 14.0 23.5 KW 2. AUX. HOIST DBR 60.0 7.0 KW 3. CROSS TRAVEL DBR 57.0 890 Watts 4. LONG TRAVEL DBR 14.0 4.2 KW F) TRANSFORMERS TYPE Watts 1. LIGHTING TRANSFORMER 1 KVA/150VA 2. CONTROL TRANSFERMER 1 KVA